Hi Pete,
Sent you a PM :)
Cheers
Ron

How did you go this weekend?

Update?

Thanks Pete! you are super awesome

A quick YouTube search.
I found this for you

https://m.youtube.com/watch?v=A3Cw58U0I4Q

Similar to what I do, i don't do the 1/8 drill hole that's all.

I just sharpen the drill a little different to do both.

Looks like that guy "Restolad" he calls himself, has many videos.

Awesome demo videos by him I say. (even if he is over from over the ditch)
Some smart Kiwis over there

See what you think?

Hey, that's a start

I had heard those spot weld bits didn't last long.

I forgot to say, I made my own, using just a regular steel twist drill bit.

Use a 5/16 or 8mm which ever you prefer.

You sharpen it a different way to normal.
Removing the the steep angle, usually 118degrees for a regular twist drill and making it flat.
While still keeping the point in the centre to align the drill

I'll try take a picture of one for you.

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Made some progress 2day :)
Used the spot weld drill bit for the first time and it was going all good until the little spring in the middle gave up :(. Had a hard time explaining people from Bunnings what spot weld bit was lol. I bought it from PEPs but unfortunately they are out of stock atm. Anyone knows where i can get one in Sydney?
Tried to use grinder but I prefer the drill bit (I am probably not doing it right).

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Thanks mate!!

In my opinion, the panels are cheap. So worth having a go.

Once you get the replacement panels, you will be able to see where to look for spot welds.
They run right around the entire edge of panel.

The new panel is just an outer skin, it will fit upto the inner panel.
Then needs spot welding to fuse the two pieces back together.

YES, you will see the line where new panel sits against inner panel.
That original photo is below the ute rail and tie down points I think?
So yes it will fit the same way.

I put seam sealer on after I finished spot welding.
Below the ute rail and down the door frame too.
Seals it up and looks almost factory.
Any auto parts place or bunnings hardware even sell it


I also decided to smooth the line joining rear quarter to tail light section.
It only needed a skim of body filler to tidy up.

I use GAS MIG,

I can't see why gasless wouldn't work.
For working outside, gasless is better.
You wouldnt have to worry about the wind blowing your shielding gas away.

Good luck with the spot weld drill bit.
I hope this helps you

Cheers

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wow!! thats an awesome job DatPilot!
Only wish I could do this to mine lol. Will start ripping pot the panels this weekend and will keep you guys posted.
So does the new panel sits on top of the old one? Is the line still visible?(like the ones on my original pic). And did you use gas or gassless MIG?

Thanks DD for the photo help
I'm using an iPad. So I think I've got an app now that will reduce the size of my pictures
See how we go?

This is my progress so far with fitting the reproduction panels.

Cheers

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Nice work bailz

more photos: bailz 1200 ute