I think you are right Mark about any flex possibly cracking the filler line. I was hoping 2 rows of spot tacks spaced apart (plus some edge seam tacks) would help.
One thing I did find though, when the Express bubble panel was stamped, the arch shape still remains more as a flange:you need to trim it back and dress it into the conventional arch shape with a lip.
I'd marked it all out on the car ready to cut, then decided to do the dressing, but in turning the edge in, it also pulled both sides of the wheel lip in closer, ending up with a 'tighter' wheel radius.
Luckily it wasnt all cut before this stage.
 
Good question on the seam sealer:I have some bought from the local paint supplier when I grabbed filler and etch prime, some german brand and about $30+ from memory.
 
Great link Marty about using Sika, many thanks.
I reckon the Darwin Ebay guy is going to find his sales suddenly spike up, and not know why. :) 
With all my patches, I' think I'll need abox of the stuff.
I saw somewhere the go is to mask up each side of the seam, spread it out then pull the tape off leaves it neat?
 
Also what color is that Blue you did the van in Marty?
 

I just order 3 tubes from our Darwin mate, hopefully that gets me at least 1/2 way.
They have some good gear actually, including tapes. I was thinking of maybe flush mounting the rear perspex door windows with VHB tape and Silka.
 
Marty I tried my handheld joggler a few times, but it only makes a short flange, 10mm maybe? so its not as universal as I hoped.
It looks like there is a new Ford Performance Blue out in the Mustangs. I like blue, but have the Capri and my wifes car coming in blue, I think I need another color to wash.
 
Any thoughts on how useful these might be for spotwelding? I didnt know they existed with copper face just for this exact thing.My current wide clamps are just a bit too short to reach enough over the bubbles.
https://www.ebay.com.au/itm/252106078180?chn=ps&norover=1&mkevt=1&mkrid=705-139619-5960-0&mkcid=2&itemid=252106078180&targetid=1280421173959&device=c&mktype=pla&googleloc=9071205&poi=&campaignid=10101784952&mkgroupid=124139257673&rlsatarget=pla-1280421173959&abcId=9300367&merchantid=115585497&gclid=CjwKCAjwkvWKBhB4EiwA-GHjFlY5wBqDuWjVELwl7t2hoeWepwbI_xbhaYORQmHmtPxHz60pieGP_RoCYcYQAvD_BwE 

what would be good is a wide, long arm version, with the copper heat sink, and spaced top jaw bit so you can weld in between the jaws.

Deano, what fuel tank are you using in the van, keeping it stock or going custom ?
As for my blue van, I sold the tank during the resto cause I had the plan to run it on LPG only, but ... Finding a gas tank that'll fit in the space under the tray behind the axle got frusto so gave up that plan, now(9yrs on) I'm thinking about using one of those alloy $140 race type tanks with sender and EFI pump all in one , just need to know the dimensions it'll fit in , I can make bkts to suit etc , just don't want to chop the car in any way ..

That'll be cool, depending if yours is the late mk2 tank or early pre 77 square barrel type, I'm more for the barrel type as it bolts to the ribs not by straps..

The rear valance is two panels, inner n outer, if you have the drop tank there's no way to have a centre zorst outlet as it'll be hitting the tank.. a sedan zorst will fit the std van but the rear hangers differ slightly and it'll not reach to the back, needs about 200mm extra at the back . I installed a hotdog muffler on my yellow van to make up the length and keep it quiet

also, do I use these front struts which came on the car and  possibly are reco'd or swap over the 2lt ones?
I dont think its worth putting adjustable ones on a road car, provided the overall height is sorted ok first.
 
 

Struts look 2.0 veriety , if you want to cheap it by lowering, you can carefully grind the welds( with inserts out obviously) that holds the lower spring platform and then slide it down about 1in, be careful tho as the tyre height regulates how low you can move it down . True about not going coilovers for a roader , just set it where you like. I can't remember if I did this to my yellow van but did do this to the blue mk1 van

Hey Robbie those top mounts are proper tuff, I've a set in my blue van and orange mk2, mine are the original cortina mk2 towers I scammed from a wreckers when wreckers were worth going to, I scabbed 4x sets back then! I know their tuff cause I used to fly my Escort a lot and landing from 3 to 4ft at high speeds nothing broke except very very light reshape if the door gaps lol .
Deano gas large towers do they're going to fit just nice. Handy hint for dust covers is use mits magna /sigma dust covers, they fit exactly ... Should put this in the trivia blog lol

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