What strategies have people employed in fitting these? The existing lip/flange is OK, so no real need to cut it out *unless* the rubber and glass wont fit correctly due to the extra mm or 2 of metal. JK replacement panel clamped into place ->
I'd just graft what you need into the rotten bits, if you've got to do the whole length then make the join along where the side cover backets weld on if every thing below is fine if you need to go further down to get rid of rot, then make the join in the recess (about half way up) where the door roller/guide channel would be if it was a slider side. Not sure what you meant by being 2mm too thick on the lip, are you saying you will chop it all out except for the bit that the seal goes over? If thats what you mean, then personally Id take the seal lip off also, no point in leaving just a little strip of original metal - better to replace the lot IMHO, that way you only have to weld the bottom of the repair panel to the body (rather than having to do a seam at the top as well) if that makes sense ;D
I hadn't seen the panel before, if it wasn't for the original post I don't think I wouldn't have ever. But here is the link: http://www.justkampers.com/search2?location=shop&method=match_all&keywords=J12971 Just ordered one!
You haven't shown us the rot, but I'd cut the rot out at each side, the everything in between and like diddy suggests, unpick the old from the window lip and use the panel. Ideal if you have access to a spot welder, but plug welds will do it - just more work. If you find yourself doing the sliding door side, below the face the cover channel fits to some of these panels angle in and downwards, rather than head in at 90 degs. Be aware that the slding door hinge will foul it and possibly it will prevent you even getting the door back on. Just thought I'd mention that. Also on both sides there is a safety belt bracket inside. You can see some big spot welds on the recessed face.
Ta for the tips diddy, a bit more work done today so I took the original lip off. Hate drilling spot welds. Glad to be of assistance & possibly a guinea pig Dicky & 73Johnathan. Zed, here's what I started with rot wise -> http://moblog.net/view/962491/window-cleaning bearing in mind all the advice offered here I cut more of the original metal and cut the panel smaller too. Ta for the heads up about the panel. This one does not go 90, but at an angle, so will source a different panel to do that side, when or if I ever get there.
Good pics. (looks familiar) Must be ever so tempting to graft the new panel onto the existing window lip! More pics if you get the chance!!
