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Tue Nov 18, 2008 8:38 am

I thought I was just replacing some of the floor and rocker

it turns out I need the inner rocker support and the jackpoint and c pillar going down as well as crossmember under jackpoint area.

It even rusted the inner area near bottom of wheel well. I need to fabricate that to supprt the rear rocker area and wheel well lip

I need to fill in the rusted out pieces in here as well on the pillar coming down this is in the front part of cargo door area. always more then you figure

ok time to grind now and clean it up before fabricating and welding begins.

i removed the jackpoint and cross member as well now :p

cleaned up the front so can see what all i need to fabricate now up there.

here is a straight on view of rear pillar i need to fix

took some advice from Santa as my kids call him aka Gilbert :0 I bought some weld through primer. also bought a gallon of por 15 so I have enough to do a few projects.

Started to sand blast that gross green emblem i bought off thesamba.

Started cleaning up the metal used sand blaster. Since it's the floor it doesnt need to be perfect.
I Know how people frown on sandblasting but its just the floor :p I dont want it behind the panels. I figure sand blasting it will make the por 15 stick better and wont have a layer of rust encapsulated under neath. the weldable primer will coat the parts first that I need to weld.

I decided that i cant sand blast at night due to my compressor is the loudest thing in the world and dont want to upset neighbors.

I need my new garage built.

So I did not get very far before having to quit. Needless to say it will be an ongoing project :p learn as I go .

Tips appreciated And flames as always

Ps i know gerson makes that little part for the pillar going down. I might just order it rather then me trying to make one.

Tue Nov 18, 2008 8:56 am

Good Job. Keep the pics coming!

Tue Nov 18, 2008 9:07 am

I have done that job your about to do over 20 times..

First salvage the cargo door striker plate if you can it will be better that the panel one.

I cant quite see it but if that outer cargo rocker is the wolfberg west red one through it in the trash, Its a travesty to go to all the trouble of doing a good job and weld on such a terrible panel.
You will have a horrible cargo door gap at the bottom, look at you panel and see how bad that pressing is.

:cry:

Tue Nov 18, 2008 1:03 pm

Blasting the cargo floor area with sand is a bad idea. I did it to my 1958 bus, years ago, then I decided to replace the cargo floor halves and everything underneath them: sand came puring out of the cross members, outriggers, and rockers when I was removing them. After that, all that I needed were sunglasses, a lounge chair, and a Pale Ale: the beach was already there.
I would recommend that you remove the cargo floor halves and replace everything beneath them that looks bad: U-shaped cargo floor supports, cross members, rockers, outriggers, and jack supports. You have at least one cargo floor support that needs replacing and it is easy to remove everything once the floors are out. I'm doing it to my 1957 bus. Two of the cargo floor supports are shot.
For the few people who may not know this, always remove the enamel or packing primer from the aftermarket panels, and condition the bare metal before painting (Gerson now conditions the metal on his panels).

Wed Nov 19, 2008 8:47 am

Sheesh. That's an undertaking. At least you have access for fitting the c-pillar, in-out-mid rocker, rear patch, and whatnots. Weld the floor last but keep fitting with it for perfect alignment.

Wed Nov 19, 2008 9:57 am

is this the right kind of outrigger i need for under that jackpoint says right middle

or this one for rear . Not sure if jack point is considered rear or middle

i take this is correct c pillar piece.

Just want to order the right parts from bustoration. might as well get some good stuff to mix with the crap :)

Ill definately treAT ALL THE METAL FIRST AND SAND DOWN TO BARE METAL. Caps lock is bad

I dont want to try explain over the phone :) i am sure easier for you guys to tell by pics.

Thanks again.

Apreciate all the input. live and learn as I go

Wed Nov 19, 2008 12:57 pm

For the simpler panels such as the heater pipe supports, U-shaped cargo floor supports, outriggers, and inner rockers, I have had good luck using the ruddy-colored panels. I just made sure that I conditioned the bare metal and coated it.
The more complex ruddy-colored panels, such as the "grinning" corner panel that I bought, were a different story, though, and it would be worth spending the extra money for the higher priced ones.
The three black cargo floor halves that I bought from C.I.P., some years ago, were good. I couldn't get a fourth one so I was forced to buy a ruddy-colored one, and the sheet metal was thinner.
I would think that you are going to replace one or more of the U-shaped cargo floor supports in your bus, which would mean that the cargo floor halves would have to be removed. After the floors, engine, transaxle, and shifting shaft are out, you would remove the jack support and outrigger with the support (cut through the support by the frame rail to remove the unit on each end, then remove the middle section of the support with the heater pipe panel). When the unit is out, you can then fashion a piece of sheet metal to replace the rusted out sheet metal at the rear of the front wheel well.
The pieces fit together like a puzzle so if there is any doubt about the condition of the panels and supports in the bus, the time to replace them is now.