Deformation panel and inner front valance replacement help please

Discussion in 'Restorations' started by mjones1969, Jan 28, 2015.

  1. Hi, I am in need of some help!
    my rust free Aussie bus 1975/76 is looking a bit rusty:( I took off the front bumper and found this.
    IMG_1929.JPG IMG_1934.JPG
    looking into the deformation panel.
    Its been plated from behind.
    Do I need to remove the lower part of the front panel to weld ? what is the best way of replacing and in what order?
    The cab floor has been patched and chassis rails are all looking in good condition
    Any help much appreciated
     
  2. Depends, are you just repairing the inner and fitting a new outer panel or doing both at the same time? Either way you don't need to remove any of the front panel unless that's rotten too.
     
  3. Both are rotten, so will be replacing both at the same time. The front panel is ok I just cannot get into my head how it all fits together with the inner floor and front panel with the join.
    It maybe that because it has been plated from behind it does not look clear
    Is there a good diagram some ware of how it all fits together ?
     
  4. The cab floor is attached to the inner valance panel, this is the panel that your washer bottle bolts to. That sits on top of your inner deformation panel, the lip at the bottom of your front panel is spot welded to the top of that inner panel and then the outer deformation panel just welds onto the inner. There are the two closing panels either end which are welded to the outer, front step and the lip of your front panel, as well as folding over the A pillar. Schofields are pretty good for exploded diagrams, try their website, it'll make more sense with a diagram to back it up!
     
    Poptop2 likes this.
  5. davidoft

    davidoft Sponsor

    To replace the inner you need to cut a few inches of the bottom of the front panel off. the lip that sticks out of the bottom of the front panels is welded to the inner, it looks like your inner is repairable either way you're gonna need to pull the deformation off, though you could repair both
     
    Last edited: Jan 28, 2015
  6. Just done this recently on my resto, if you take a look you will see all the separate pieces and how they fit together.

    Chances are you will find lots more rust when you cut that off, my valence, inner kick panel and A posts were rotten too.

    I cut a small amount of my lower panel away just to get everything in that area rust free.
     
    paradox likes this.
  7. Thanks all its all becoming clearer!
    can you buy a lower front patch panel about 2" high? or do you have to buy a full lower one and cut it?
     
  8. Poptop2

    Poptop2 Administrator

  9. Zed

    Zed Gradually getting grumpier

    Looking at your pic inside, the inner folds up then outwards. The deformation panel welds onto the "up" bit and the front panel to the "outwards" bit.
    The deformation panel is toast so cut that off for starters. :)
     
  10. Thanks @zed, had another good look tonight and the inside reminds me of a very large bag of crisps!
    surprising really as the chassis legs and A pillars really are ok strange how these buses rot, must have been a mini climate in there!
     
  11. Drill out the spot welds on the deformation panel and take it from there


    Ive always said there is no such thing as a rot free bus:(
     
  12. I had mine done a couple of years ago and had real problems sourcing an inner panel .
    Think i ended up buying a JK inner as they were the only folks in the UK with one in stock and they knew it . cost me the best part of £200 .
    Think it had Westfalia written on it in felt tip ...

    :hattip:
     
  13. Inner panels are now about £150ish from Heritage. I have some "issues" with my inner front behind the deformation panel but it's going to be a real ballache if it all has to come off. Unlike the OP, my deformation panel appears to be intact.
     
    Poptop2 likes this.
  14. A full lower one and cut it which is about £40, you can do the job without removing any front panel, i just did it to make sure everything behind was sound, which it wasn't!

    I just cut enough away to be able to repair the panel behind, which was probably filled with water for a few years due to a leaking windscreen / washer bottle.
     
  15. :)my rust free Aussie bus 1975/76 is looking a bit rusty:(
     
  16. Thanks all, new cutting disks and deformation panel now arrived :) will be busy me thinks
     
  17. Hi Where did you get your panel for £40 from? thanks
     
  18. ^^^
    Hi Where did you get your front panel for £40 from? thanks
     
  19. Just checked and it's listed online for £45 from Alan H Schofield, if you are buying quite a few bits in one go they tend to give a decent discount.

    I try to order most things needed in one go rather than dribs and drabs for this reason, not friendly on the wallet at the time but cheaper overall as a total project cost.
     

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