Removing windows in my van

Hey all, I have got to the stage on my van where I need to make a decision on my windows in my van.
What is your opinion on how to do it, Weld in a sheet of steel using a Mig or Tig or Oxy or glue a panel in using the 3M product?.
I have cut all my rust out and I'm starting on the body now as all hang off panels are in guide coat as I have been putting this job off, I have even toyed with the idea of putting another set in the front of the rear ones or Bubble windows but do prefer the windowless look, I have had a quote in Perth of $4000 to remove the two windows but that's just way to much to pay.
I am after a neat job as I'm not having anything to hide welds on the inside as I'm want to paint it in the factory colour in the back and have it as per factory look, Any help or ideas would be appreciated, Cheers Andrew

sounds like you answered your own question

but do prefer the windowless look

if it was me i would tig them in

from my experience and this depends on the operator and the materials and processes used

mig welds are very hard and prone to cracking if worked by hammer or wheel once cold so for me mig is out

oxy will give you a much softer weld something that you can work with a hammer and dolly but it normally leaves grater distortion because of a larger heat affected area

tig gives you most of the benefits of oxy as far as a softer weld that can be worked with a wheel or hammer and dolly but it gives you less heat affected material = warping and generally requires less skill then oxy to operate as well as a slightly cleaner weld

but just remember you can never have to many tacks i would not even bother welding a continuous bead i would draw out where and how many tacks i would need starting with one every 15 mm then work my way randomly around until i have enough i fell that working in a row wont cause excessive distortion

also figment is key because the closer the infill panel is to the surrounding material the less shrinkage = warping can occur because the tack can only shrink until the infill and the surrounding materials meet

hope this helps

Leave the windows ,there is nothing worse than see a good job
turn sour 12-18 months down the track.
I personally don't know what the fuss is about everyone wanting a window less van .
We all know that they where made that way;sure, but can't help how many have bee fitted with windows.
In one way you have luck on your side or a rare avan with only one set .
Leave the windows .....  

Thanks buddy for your help, a few people have suggested glue to stick them in as no warping but never used the stuff but imagine all panel shops use it now, Tig sounds like the best option, I thought about a grand would be the price but odviously I was way out, I will keep exploring and see how I go.......

after having to but join tig weld sand and polish some stainless piller covers for work there will be hours and hours and hours of work to get them to look right

neil might be right about the windowed vans i know if i had the choice i wouldn't cut windows into a van but after owning and driving mine i cant imagine not having windows and im not filling them in

and if your worried about privacy theres nothing some mirrored window tint cant fix   

VANDIL wrote:
What is your opinion on how to do it, Weld in a sheet of steel using a Mig or Tig or Oxy or glue a panel in using the 3M product?.

I am after a neat job as I'm not having anything to hide welds on the inside as I'm want to paint it in the factory colour in the back and have it as per factory look

Think you answered your own question regarding the panel glue.

I to this day have not seen a van that has had windows filled and not be able to pick that the windows have been filled once told that they have been done.... If they get it wrong you will hate looking at the car each time you walk past it.

Cut two more in and job done, on with paint.

Jenny's Madeira coloured Sandman originally had windows, a good friend of there's Adam removed and filled the windows and you'd never pick it, inside or out. The job is the neatest job I've ever seen or should I say haven't seen. Anyone who's seen it up close will vouch for the quality of the job.
Ask Jenny (Sandmum) how Adam did it but the results are great.

The Zodiac wrote:Jenny's Madeira coloured Sandman originally had windows, a good friend of there's Adam removed and filled the windows and you'd never pick it, inside or out.

I have seen the van recently Rob.... You can most certainly pick it now.

As time goes on, like all panel work. Different medias expand and contract differently to one and another.

I have windows in my escort,i was going to get rid of them.But after driving it with windows its a lot safer when you can do a quick head check over you left shoulder when changing lanes. I still use my mirrors, but they don't show the whole picture.   

send troy, majestic xx7 a pm he has done them before

Hi mate. I had bubble windows in my last van. Loved them. Two down each side. Made it easier for reversing out and lane merging. I tinted them with spray tint and was very happy the results. I almost wished my new one had windows in the side. I think nice bubbles would look better then a bad fill job.

Hey guys thanks for your feedback, going great on the body and will be in guide coat in two weeks and then back on the chassis, decisions decisions on the windows, I think bubbles would look cool but its not really the look i'm after.
I have to make a decision soon, I remember how straight I had Vandal after the body was done and after two years it started to get ripply due to panel vibration and wouldn't want to see the windows or where they had been after a few years....

Just to put it out there.. A van I will be doing for my wife has the two windows per side and the idea we have for it is to cut the two into one large hole, but instead of glass i'm going to make a 'sheet steel over ply board' panel then have a vinyl print graphic stuck on. this idea came from the Black Sandman that most will know of and was at the 2014 Van nats  If this works out we can then either change image's easily or even go for an Air brush job.

Vanning is about being individual & different .
How many vans do you see with only one window in them ..
I'm sure a man of your talents Andrew will come to the right decision for your van and the look you want...