How To MIG Spot Weld on Replacement Panels Boogie Van Fender Install

[@theusualsudspects]

Thanks for the mention, Karl - it was my pleasure. Keen to see the whole van come together!

[@grumpymadvanner]

Your name is perfect! I had a G20 Shorty in Langley that had "master blaster pressure washing&detail" plastered all over. Was probly defunct in the years before I had the Van in 2000ish. There's a great market to be had down there. Take care Grumpy

[@MakeItKustom]

You’re so welcome man! I really appreciate the work you did and happy to see you and your girlfriend the other night!

[@davidsnyder2000]

Have been doing bodywork for 30yrs…..Your plug welds look REALLY nice to me Karl👍 You do a real good job at everything you do It’s great to see your passion for metal fabrication👌🙂

[@SkaterStimm]

seriously those are beautiful mig plug welds.

[@MakeItKustom]

Thanks a lot David I appreciate it especially from someone with your experience!

[@lawncuttingplusdelta]

And it’s great to see real world 🌍 honesty …. Not perfect but 100% good enough !!! …. Great statement , I ll use that myself forward 💪🏻

[@mikel3419]

You are a special teacher. First you admit you don't know everything and are still learning, seeking answers from those who went before you. Second, as you learn from others you are quick to become a very effective teacher. You are a an artisan, making sure to do the job right as you learn. And IMHO you are at least a little bit of an artist. In my day (old) these skills were taught as Industrial Arts in the US from junior high through college. These avenues have died out. Your passion will keep these skills alive. Thanks for all you do.

[@MakeItKustom]

Thanks a lot Mike! I love to learn and I’m not afraid to make mistakes haha 😂

[@kennyvelez8060]

@@MakeItKustom just wondering what the inside looks like and or what you plan to do on the interior? I may have a few things for it, if your interested contact me,,,

[@lazyhoundracing9621]

I agree the body doesn't need to be perfect. In the 80's what we needed to be perfect was the shag carpet. Thank you for your time.

[@MakeItKustom]

Hahah that shag tho! I drove 14 hours to get the perfect shag for this van from a very old lady who renovated her house in the 80s lol

[@jasonbose3507]

Looks Awesome Carl!!! Back in the day the full size van was about freedom and style. The prize was the interior, it would have a party and camping theme. Plush, plush, plush with a wet bar was the norm back then in the 70's & 80's. Shag so thick you could swim in it and wood paneling so polished you could see your face in it. It was cool when you'd see someone wire up a 45 record player to the stereo system with the 8 track. I could spend all day at the beach hanging out in the van with my friends. Also, it was a cool place to hang with your friends to get away from the parents. Thanks Carl for the video.

[@MakeItKustom]

Yeah I’m thinking it definitely needs a belt interior

[@jaredm450]

I appreciate how Karl shows off ALL the work and doesn't just edit the video to make things look simple and easy (which they never are for me). Karl - you might consider a pair of the Knipex pliers wrench - gives you vise-grip level gripping power, but doesn't mar the surface. I think you would find it handy for bending small areas. You can also use them to flatten crinkled edges, or for extreme grip on rusted fasteners, etc. At least for me, it was a tool that didn't seem like it would work well until I tried one. I suggest the 10" for a first pair.

[@MakeItKustom]

I’ll definitely check out those players! Thanks a lot Jared I appreciate your support!

[@owcooling]

I agree those Knipex pliers are very handy. Use my 180mm ones all the time: sheet metal on my truck, general car and building maintenance, snapping small cuts when tiling.

[@Andrewlone174]

It's cool to see how peoples restoring this vans, not finished project.

[@christianmccollum1028]

Another great lesson, Karl. ...especially the part about the importance of coating the hidden areas with weld thru primer. Thinking those areas are out of sight, so out of mind is a big mistake. Ignoring that step can (and will) come back to haunt you. Keep the videos coming, man. Respect from Texas.

[@MakeItKustom]

Thanks a lot Christian! Yeah it’s definitely important to do those inner coatings

[@inmyopinion6836]

Hey Carl, digging the van. I'm a 70s guy, I know the joys of the home away from home high school bedroom. Enjoy brother!

[@peterrobins3708]

Whoever designed that respirator is a clever dude...Maybe they're common as, but I've never seen one. Oh, enjoyable video all round. Nice looking van

[@CAROLDDISCOVER-2025]

1970s through early 1980s called and said they wanted thier van back. What an awesome job!

[@jeanlawson9133]

I Love the content you bring too Your videos... I use to do and try everything Auto , motorcycles. I guess you would say Jack of all trades master of none...This past Christmas Covid put me the Hospital for three months....Had to learn to walk and talk and even eat... didn't know who I was, Everyone thought I was done. God brought me back.... I am still healing lost my drive my motivation....But want to Thank you for sparking old thoughts....😎 Never Quit.... Brother....

[@MakeItKustom]

Wow Jean Sorry to hear about your hospitalization! You must be a strong sore keep on keeping on! Cheers thank you

[@gregsmith3366]

I love it when body dude’s do paint 😅. Could be wrong but I’ve been watching this channel from the start and that’s the first painting I’ve seen👌

[@larryreece1403]

That mini bike is PERFECT! Spent thirty years working on Commercial aircraft, Still surprised how many people know about Cleco's. Everybody should be using them.

[@MakeItKustom]

Yes everybody should know about them! They are the best!

[@jeffo881]

Is it the patience or the skill that's more important???? good stuff. enjoy the channel, keep it up.

[@aantlipp]

The van is awesome. You motivated me to rig up something on the front of my 72' 1/2 ton GMC for one of my Rupps!! Thanks for the inspiration!! Canada Proud!!!!

[@johnmcclain3887]

I've got an 89 Van almost exactly the same, watching you set this all up motivates me to get my old van back together. Great work, really enjoy watching. Thanks!

[@bradleybatt1401]

Came from the channel Dirty Garage Guy. Going to be watching loads of your videos, glad Matt mentioned your channel. I'm doing custom Turbo Mk3 MX-5/Miata stuff and your videos will help loads.

[@bunning63]

There's always something fun about paintpainting with spray cans! Being me I would have taken their suggestion and added an extra can, I have a suspicious mind. Looks the bomb bro.

[@David_11111]

the mini bike on the front lol gona be crazy lol

[@gregorycatren3442]

For someone who is not a painter Karl you did real good...thumbs up..from California...be safe

[@MakeItKustom]

Thanks Gregory!!

[@gregorycatren3442]

I calls em as I sees em...you are welcome ...

[@maranatha.media.c...]

Great job Karl! Has any one ever herd of matching the primer color when matching the original paint?

[@steelmill]

Nice to see the van getting some attention.I bet it has seen some crazy stuff over the years.

[@stevekirksey9293]

Karl your right those 3M purple disc are the only way to go, your work looks great 👍 keep them coming thanks from Michigan

[@MakeItKustom]

Right!? They are so good

[@jeanlawson9133]

I remember those days back in the 70's at the skating rink where I worked as skating rink guard.... Many of those Vans with stickers and tag's even painting's don't Come knocking if the Van is Rocking.... lols 😎 Ain't it just ain't it.

[@davidhyson9910]

Carl, I love you man. Hoping I'm wrong and the jack stands are hidden. Safety first buddy.

[@12DGJB21]

I've done an awful lot to stick welding on the farm when I was in high school (in the 70s) but it only needed to be strong and functional. It didn't usually need to look good. I'm just starting to learn about MIG welding and am amazed at how clean and accurate it can be in the right hands. I am hoping to purchase my own hobby level (or better) multipurpose welder in 2023. One thing I have learned is that a 220vac welder will provide a better welding and learning experience for the beginner MIG welder. Thank you for outstanding content!

[@MakeItKustom]

Yes, absolutely having a powerful enough welder definitely helps make nicer welds, especially on thick material

[@markchirillo5083]

rootbeer brown,man that buff out real nice

[@jamesmcnamara7484]

I thought I needed a “plug/spot welder “to do this. Now I know how I can do this with what I have! Excellent video brother! Thank you for everything you do.

[@ogt92fromthe1step9]

Man the amount of pride that goes into your builds is awesome. You don't just slap shit together just a kick out of video like so many others do. Your videos are meticulously thought out and the skill level is on point. 💪

[@MakeItKustom]

Thanks man! Anything worth doing is worth doing well!

[@ogt92fromthe1step9]

@@MakeItKustom nailed it 👌

[@mohawk2416]

Were do u get the new fenders from . I see alot of people ask but no reply. Can u pass tht info so we can also buy new fenders

[@brunocoutant4204]

Crazy brawn... Love it. Specialy of the 70'. Bruno from France

[@javman03]

Damn Karl! That Rupp looks soooo good mounted on the front of your Boogie Van! They are a match made in Kustom heaven my friend. Nice work as always.

[@imaginenonn37]

Put an A-Team Van stripe going down the sides from the from grill, in yellow, to match the bike. itll help take your eye of the paint blend and match the bike.

[@MakeItKustom]

Such a great idea too. I ordered up some plexiglass for in the Bubble windows in yellow

[@John_D75]

This is perfect timing Karl! Thank you for this!

[@MakeItKustom]

You’re welcome John! 🙏 cheers!

[@mopar4656]

VAN-tastic! [and all those other 70s superlatives, that include the word, van] Looks great!

[@jamiw9906]

❤❤❤❤ another throwback beauty

[@harmlesscreationsofthegree1248]

That thing looks feckin’ sweet, especially with the bike in front 👌🏽

[@philhubert5505]

I totally love your van. my first vehicle was a 78 Check Van 10, shorty. I bought that when I was 15. It was dubbed "Magic Carpet Ride" due to the custom van trend

[@benjaminmergele333]

Love the Terror rip shirt your detail guys rocking! Sick

[@theusualsudspects]

Ayyy, I’m glad someone picked up on that. Cheers, man.

[@jakefromstatefarm9721]

Hey man, you should pick up some draw clecos. They do the same job but no pliers needed. They use a wing nut and allow you to tighten it as much as you want allowing you to “draw” the two pieces of metal together, eliminating any gap between them.

[@richsmith6952]

Drilling the holes in that RF fender wheel well without safety glasses was scaring me a bit brother. ❤ 🤓

[@jacklioyd8571]

It is called a cowl or a spacer in between windshield and hood. Enjoy your series. Thank You, Karl. Jack.

[@flyingmachinecustomparts8227]

Much respect for doing a amazing quality job !!! 👏 really enjoy your work because it's top shelf.

[@bkgaragerestorations]

I didn't know the fenders were welded to the vans, what a pain to change them. When you're painting multiple panels like that it is a lot easier if you take the hood off and paint it separately. It's hard to keep a wet edge with it all in one piece like that. Keep up the good work, that looks awesome with the mini bike on the front of the van!

[@caseytrainor8300]

Your fly was down, your welcome lol love you bro, keep up the good work! ❤

[@MakeItKustom]

Ha ha ha I edited the video and I didn’t notice

[@fredblair8694]

Just let you know I'm old guy from England I used to build Marcos cars as a young man did some fabrication on exhaust systems for original mini Coopers love your channel

[@Bigskyguy56]

Karl, A nice job & well documented & explained. Rick

[@MakeItKustom]

Thanks a lot Rick! Hope you’re doing well

[@lawncuttingplusdelta]

I always like 👍🏻 to see you do the work !!! ….. it’s motivating and inspiring !!!…. Your friend paul from delta bc Canada 🇨🇦, right around the corner 💪🏻

[@ricklaporte9930]

I have body hammer handle envy, another great video. Keep up the great work!

[@MakeItKustom]

That was a very old body hammer I made the handle for and gave to my friend Cam (the guy that made the baby buick body)

[@rescuedandrestoredgarage]

Sweet video brother this van is looking awesome. It's great watching what you do, to give me idears for our own projects. Looking forward to seeing how far you go with this project 😀.

[@jeremyhanna3852]

The one thing you got to realize is Karl is professional. So on your project after you clamp and line up fenders before you weld double check the door opens properly. Some vechile there is a lip on the door past the hinge that has to pivot inside the fender as you open the door. So make sure it operates properly before you weld it in place.

[@n1352-m1i]

Dude, pretty good job with the rattle can !

[@alsearle]

“I’m looking for 100% good enough” excellent comment, I shall be borrowing that with your permission lol!

[@MakeItKustom]

Do you have my permission lol it’s kind of my favourite phrase

[@damittcars7172]

Awesome work, my only concern was the lack of axle stands you were working under that van on just a Jack! I have been working on cars for 24 years now and the first thing I ever teach an apprentice is to put an axle stand under anything! Please do this, I have seen first hand the result of not using stands! Stay safe dude! Other than this you have inspired me to pick up the restoration work again after a few years just doing general repairs. Love your work and your videos are excellent.

[@philbrown2878]

Picked up a few of the purple disks the other day to give them a try, like you said worth every penny. Great product, thanks for the tip 👍

[@terryeustice5399]

The van is really looking sharp. Thank you for sharing this excellent work! Thanks for sharing!

[@williamstidham2163]

Another fix that will stay fixed, Fantastic skills that takes it to a different level, aftermarket parts will fit if the right man puts them on right. We all can learn from these videos that took years to master from his hard work of learning doing it right the first time. 👍

[@grayzbildz]

Karl, another great video, but please put jack stands under the vehicle and not rely on a hydraulic jack, ESPECIALLY when getting under it, in the wheel wells! Cheers, Andy

[@comingtofull-ageinchrist6736]

love those double pronged vice grip pliers! Great body work on the front and paint restoration!

[@123gonow]

I think you may be wrong on perfect is not achievable here sir ! You are probably the best person to make it perfect just not worth the time doing so lol ! You are the man sir ! Learning a lot here every video thanks for sharing Karl !

[@MakeItKustom]

Thanks a lot man! I appreciate it cheers!

[@ImprobableGarage]

I have a '95 G20 van that I bought with 91k original miles. Never hit, always babied. And your panel gaps are *massively* better than the factory ones. Love following this build as Ive been documenting my own Boogie van build. Gotta keep these vans alive.

[@MakeItKustom]

Good to know man! They probably built entire vehicles at the factory in the time I put that front clip on lol

[@glennmiller9031]

Van looks pretty sharp.

[@darrelkinney9856]

Hey CARL like the video.reminds me of a special friend he was killer on the rattle can paint. He painted a picture of YosimiteSam on the trunk of his car. Very detailed.

[@comingtofull-ageinchrist6736]

Karl, I recently learned that calling your lead a ground is incorrect! It's not a ground; it is actually the lead that allows current to have a full circuit back to the source.

[@theoriginalDirtybill]

a spot weld cutter would give you a good result using the 1/8" cleco holes for the pilot..... the HF ones are smaller in diameter than the more expensive ones from Lisle and other brands like Eastwood etc...

[@mikepelelo5657]

Needed to wait a couple days to make the time to watch this longer video. It was worth the wait. The van has come out really really nice so far. Good job and thanks!

[@gregsmith3366]

A trick when using self tapers pre drill the outside steel slightly bigger than the screw that way the back pulls up to the front. Best content by far 👌🇦🇺

[@gjponsford4892]

Love the van! I feel it needs some bad ass side pipes. She would be ready for a trip to the nostalgia drags

[@MakeItKustom]

I got some cool side pipes! They will be going on soon

[@lancemclean9273]

Gotta get me some klikos. Don’t even know how to spell it , but I could use them. Some big projects coming up for me

[@MakeItKustom]

Aircraft tool places or eastwood.com you will never go back lol they are amazing

[@Triceranuts]

thanks for constantly providing entertainment / inspiration!

[@MakeItKustom]

Absolutely Ted! Thanks for watching it as always!

[@Samuel_el_toro]

When those GM vans and trucks were new the panel fitment was laughable. I think you have it looking damn good

[@jparker785]

Ya eased in to my old wheelhouse! You can definitely tell difference between builder and collision tech. We use screws for the tightest fitment. I use panhead phillips with 1/8" pilot and 3/16 outer panel hole. Grab some Zebra clamps from wurth for flange clamps. Aftermarket parts have been an issue for a long time. Glad to see you fit hood! Many forget that until it's too late! Great work as always 😊✌️

[@vinni8276]

a've done chevy van front fenders and can attest to the difficulty removing and reinsatallin them. kodos lad!

[@timr.3108]

Again, Great content Karl. That paint matched very good, considering the age of the old paint.

[@MakeItKustom]

Thanks Tim it’s definitely close enough!

[@SchysCraftCo.]

Karl always awesome videos man. It's always great to see and learning from your videos. Can't wait to see more videos soon. Keep up the great craftsmanship and hard work my friend. Fab On. Weld On. Keep making. God Bless.

[@MakeItKustom]

Thanks a lot Jared I appreciate your support!

[@azspeedbuggy]

vans are cool...great work, you are the man...

[@Richard56er]

That panel you pointed out at about 28:57 behind the hood is called the Skuttle Panel in the UK.

[@ryanmorton6851]

It’s called a cowl in Canada

[@peterpowell4821]

Wow - best rattle-can paint job I've ever seen. Spot wellds not bad either 😉. Great video Karl, look forward to the next one 👍

[@MakeItKustom]

Thanks a lot Peter!

[@davidwood1923]

You are going Above and Beyond... Thanks for Sharing. Keep Up the Great Work... Brother

[@MakeItKustom]

Thanks David!

[@JaimeDstx]

Super rad series. Cant' wait for more.

[@bigdaddy741098]

The van looks great, and like you said, the paint is good enough. It might all blend together even better once everything is all together with a final detail. Oh and I'm really jealous... I wish I was there for that party. Beers, bikes, V8's, And live music by fire light?... I bet it can't get much better than that.

[@MakeItKustom]

Man it was so good. Couldn’t believe the experience after the power went out

[@bigdaddy741098]

@@MakeItKustom yeah man, I believe that. Even that quick clip you showed managed to capture that feeling.

[@jamiw9906]

Finishing touches are everything ❤

[@peterhertel7089]

You line your hood first with the hood latch making sure it catches and releases, then you line up your fenders with the hood. Sometimes using a length of 2X4 and c club hammer.

[@anthonykinrade8642]

Thoroughly enjoyed every minute of this one, great stuff...!

[@herbiederby3394]

It is what it is karl i dig it like the motor bike rack bookie van its coming together great work as always...✌🙂🙏

[@PlinkyPlonkyDonky420]

love all the work man, please use jack stands though

[@allensnook7760]

Happy turkey weekend karl n clan looks well from here.hope u survive the pie coma.ha,ha,snookie pa.💥🤟💥

[@ScheunenTecCNC]

Nice Work thanks for Showing 👍

[@MidnightCustoms-C20]

Where did you find reproduction van fenders ?

[@tjakr3869]

Mortske repair mentioned your channel and your van. I enjoy both of your channels, very entertaining and educational.

[@MakeItKustom]

Right on! I saw he just picked up a cool van too!

[@TheDistur]

We've got a 70s club wagon that's basically a storage shed. Making me wish it wasn't so rusty.

[@drivewayshop]

Looks great! That mini bike is a perfect extension of the van. You should do yellow accents on the van to match... Maybe even do them slightly aged

[@MakeItKustom]

Love that idea! Definitely on the list

[@TrashcanGarage]

Been fun to watch the transformation on the van. Turned out great! 🤘😎

[@MakeItKustom]

Thanks man it’s a pretty fun project!

[@badijks]

It is pretty much the same method that I have used on fenders from old tractors welding the support structure on backside. Used this because we didn't own a spot welder

[@laurikennedy6344]

Love your videos! What respirator did you use? I'd like to find it 💕

[@scottiehunnybunnywoowoo462]

Just a comment on using tex screws we call then in the UK The self drilling screws you mentioned. I prefer a drill over an impact driver. So much more controllable. But hey man loving your work you have skillz I can only dream of.

[@lawncuttingplusdelta]

A heck of a good days work ! … I had a 72 chevelle I think was sane Color ?? Is it Navajo gold ?? ….. 👍🏻 great job saving another cool vehicle

[@randysoong6129]

Killer spot welding!!

[@MakeItKustom]

Thanks Randy!

[@Jason78400M]

The klinkos are a very cool Never seen them used before. Very nice job on the van. As usual your eye for detail brings together another fine job.

[@MakeItKustom]

Yeah they definitely work well! You can get them from Eastwood

[@briandrake9467]

I have to keep my freak E, truck led sleads are cool, but a altered wheel base mid engine Gasser. I need a lift in the front. And Volkswagen style sliding sunroof, my roof is cut.