has anybody done this before?...maybe pissed off the walk-through set-up or replaced one that has been hacked at, like mine.
where do I start? how (drill..5mm??)
Rob King,Andrew or anybody who has done this before
Rob

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its the bottom seam I'm worried about :jesus

so Roy is that what the bit is call...spot weld bit?

The only way to do it is grind the replacement on down and drill out the spot welds on the one that is in the bus.

Cheers
Dave

if its only the wheel arch that is hacked, then why not jsut cut and replace that section? jsut wondering.

thanks Wes, maybe this is a better idea, was talking to "dub" & he said that this way is on the money too.

How far is the panel in the car cut down to? The divider panel from what I can see in my bus goes all the way down to the lower edge of the top hat and it is welded to the top hat. If you dont need to replace the top hats I would be trimming your replacement panel to meet the remaining top edge of the existing panel and then getting a welder who knows what they are doing to butt weld the join. When you are drilling the spot welds out try not to drill through any parts that you want to retain. This will allow you to use a hand held spot welding gun to redo the welds particularly on the visible areas. Most panel beaters have this type of welder but I reckon you should talk to one before you start cutting.
Cheers Nicko