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Easy's '58 walk through panel build
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easy e
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Joined: May 28, 2008
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Location: 1 hr north of Santa Barbara
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PostPosted: Wed Oct 29, 2014 6:15 pm    Post subject: Reply with quote

I appreciate the suggestions... I'll use my current lengths as baseline, get
sorted on fittings & get something along these lines:
http://www.anplumbing.com/Extras/PreMade-8+Hose-61.html
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volksfahrer.nl
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PostPosted: Thu Oct 30, 2014 11:55 am    Post subject: Reply with quote

That is gonna be a cool and good looking bus!
Brave to go with those two colors. I think i't gonna look real good!
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66 panel
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easy e
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PostPosted: Sun Nov 02, 2014 8:26 pm    Post subject: Reply with quote

Thanks!

I took one of Clara's panels into Home Depot & they used their color matching machine to whip up a quart of satin. I primered some speaker pods I got here:
http://www.thesamba.com/vw/classifieds/detail.php?id=1410686

After primer, I used a foam weenie roller & happy with the results.
Key trick for the grilles... if you get bridging... just blow on the holes.
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Basically how they'll look / where they'll go:
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Rear amps in... power supply is from a deep cell dedicated 2nd battery. When metalwork was being done... I added a driver's side battery tray (KF). Battery is separated by the slick Yandina C100. It will run sound system, dome lights & an inverter. I wanted to be able to toss a little LED TV & DVD player under the rear seat, to drag out occasionally when camping. In substitute of tar board strips for the luggage area... I used a Fat Mat product that's ~1/4" thick. Looks pretty good & will help quiet down the engine noise. Ground strap is attached to CB Performance fuel pump mounting bolt. RCA cable is run from head unit down driver's side frame rail & to the rear.. Inverter will be fed from a spot on the junction block:
Image may have been reduced in size. Click image to view fullscreen.

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easy e
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PostPosted: Mon Jan 19, 2015 8:10 pm    Post subject: Reply with quote

Door seals have been giving me a pain. I've about got the cargo doors squared away.

Front doors have been a royal pain. Not looking close enough at the cab door hinges during prep has come back to bite me. Both uppers were too tired. My buddy Eric was came through with some upper (body side) hinges with standard dia. holes. A real relief to find. I also found some door side hinges with standard dia. hinge pin holes. Lower hinges seem good. I'll post more on the fix later.

I installed Clara's luggage panel & it fit great.
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I slapped up a good sized piece of Rattle Trap (tar/aluminum sound deadener stuff) on the ceiling above each seat & put up two layers of the aluminized bubble wrap. Ceiling cards just need a few taps from the rear to find home.
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Pretty much all aftermarket bumper bolts I've seen are too flat.
They don't have the look of an old fashioned structural steel rivet, as original.
The short bolts I used are NOS beetle bumper bolts.
Long beetle bumper bolts will work for the rear bracket, but you can only use a wave washer & not the flat washer + split lock washer... not enough threads. I used some NOS long bolts for brackets too, but the beetle ones are 31mm long & orig. calls for 35mm. Three of the four long bolts I cut & lengthened. I cut nearer the head... so the threads required to be beyond the thick rectangular washer would be available.
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When I was putting on my rear brackets... the diagram below helped (no. 2 is correct).
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A fresh set of StaceyZ glass is in now & I just put the rear hatch seal in yesterday. For the windows... parachute cord & some soapy water.

I was stoked a local guy offered me a pair of NOS dealership plate frames from my hometown. They went out of business in the early 90's. Clark & Larsson picked up the Audi brand sometime after Audi became a subsidiary of VW in the mid-60's. Later, Clark & Larsson plate frames also carried Audi cars & logo.... in addition to the VW logo. Double VW logo'd frames from them are super hard to find.
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easy e
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PostPosted: Sun Feb 01, 2015 2:10 pm    Post subject: Reply with quote

Vent widow & window frame work...

I was having a hard time getting the steel rivets flat... so I used some short countersunk slotted screws. The slots oriented horizontal let the slots be hidden behind the vent window seal. When I was installing the whole frame into the door... the round edge bead wanted to be tucked under the frame & wouldn't let the frame go all the way down. After getting the frame to door bolts in... I got them snugged & used a small pick to jab into the seal's inner bead & it let me work along the bead & pull it out from under the window frame. I grabbed a "trial size" of baby powder & it definitely helped all the rubber parts / painted parts slip past each other for installation.

Here's an original latch plate / rivet
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Pain in the ass steel rivets I abandoned before I screwed up the paint & would have probably looked like ass & jiggled around anyway.
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The screws I picked had heads a fuzz larger than I would have liked... but had a thicker shank than the next smaller size... which would have provided a sloppy overall fit. There's the little pick I used to pull the edge bead. At the angle in the door... I still need to trim the ends of the cut bead flush & join ends with black weatherstripping adhesive. The rubber bead ends will probably end up shrinking & separating later, oh well (see 1st pic above).
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


The Brazilian vent window seals fit great (needed a little relieving here & there) & installed surprisingly easy. Locating the place to cut a slot for the upper vent window tab took a couple rounds of verification. The seals had a lot of casting slag at all the mold joints & it took about an hour per seal to get them looking tidy with a razor blade. An exacto knife is a good tool to cut the round hole at the lower pivot pin... it unfortunately comes filled with rubber.
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Spreadsheet for Bus RPM, based on gearing & tire size (Excel format)
Searchable, click-navigable 1958 Bus Parts List


Last edited by easy e on Wed Feb 11, 2015 12:06 am; edited 2 times in total
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easy e
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PostPosted: Fri Feb 06, 2015 6:06 pm    Post subject: Reply with quote

I finally got all doors to shut... wheeew!

This electric knife was a life saver. $6.96 at the thrift store. Cargo doors wouldn't close. I closed each door separately for a day each. This let an impression line make itself shown where pressure was greatest... and needed to be made a fuzz thinner.

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Image may have been reduced in size. Click image to view fullscreen.

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Big Bill
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PostPosted: Sat Feb 07, 2015 7:51 am    Post subject: Reply with quote

The panel is coming along nicely, great attention to detail. Love your license plate. Smile
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easy e
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PostPosted: Sat Feb 07, 2015 11:29 am    Post subject: Reply with quote

Thanks Bill!

Went out for the maiden voyage last night! I was a little nervous... but the test drive went fine & I relaxed towards the end. No steering box, bumper or exhaust scrapes. First through third gear were good. I want to get an alignment before I get into fourth. Cyl head temp got to 260.

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It was fun to finally pull into the gas station again. I should have snagged a photo.... as most of my photos are from 10' away. It's raining now so I'll have to wait.
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busworks
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PostPosted: Sat Feb 07, 2015 11:52 am    Post subject: Reply with quote

Bus turned out great Evan!
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srfndoc
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PostPosted: Sat Feb 07, 2015 12:00 pm    Post subject: Reply with quote

Really nice job. Enjoy it!
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Bendango
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PostPosted: Sat Feb 07, 2015 7:29 pm    Post subject: Reply with quote

Nice bold paint - I would certainly go for a white pin stripe to tie it in with the bumper insert.

Nice
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Getting Used - SWR 60 westy copy built by vw ( apparently Rolling Eyes )
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brettsvw
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PostPosted: Sun Feb 08, 2015 6:10 am    Post subject: Reply with quote

Thoroughly enjoyed. Smile
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My 59 kombi build.
http://www.thesamba.com/vw/forum/viewtopic.php?t=635003&highlight=

My buggy build.
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http://www.thesamba.com/vw/forum/viewtopic.php?t=289807
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zuggbug
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PostPosted: Sun Feb 08, 2015 5:57 pm    Post subject: Reply with quote

Applause Applause
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vwtrey
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PostPosted: Sun Feb 08, 2015 6:33 pm    Post subject: Reply with quote

Looks good. I really like that color combo!
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easy e
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PostPosted: Tue Feb 10, 2015 7:44 pm    Post subject: Reply with quote

Thanks guys... I love watching other's builds!

From my readings in the barndoor & split bus sections...post barndoor ('55-1958) had fat base mirror arms & mirrors with wide flat area at perimeter & no part number or logo on the stanchion base. Barndoor has bigger balls on the stanchion. I think I recall the tighter arc on the driver's side arm didn't appear until '57 & before that, mirrors weren't obligatory & would have been the passenger side style (if the bus had side mirrors). Supposedly mirror w/part number & thin base arm appeared right around late 58-early '59. (Maybe somebody say if they know specifics)

It seems these mirrors are very hard to find, even in crappy condition. I feel very fortunate to have found one good used & one NOS. I paired them with some NOS clamps, which were weren't too bad to source. I bought around ten from Jaime in Manilla & picked the best of the bunch for install. I bought a grip of BeaterBarndoor's fiber washer's for safari sliders, vent window pivots & mirror arms.

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Image may have been reduced in size. Click image to view fullscreen.


I had a few early westy coat hooks & put one on one both sides of the bus.
I located position per reviewing a few other examples of early coat hooks in the "campers" section of the Gallery. I had them chromed wile I was doing the batch of exterior handles, escutcheons & grab bar stanchions.

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Spreadsheet for Bus RPM, based on gearing & tire size (Excel format)
Searchable, click-navigable 1958 Bus Parts List


Last edited by easy e on Wed Feb 11, 2015 12:08 am; edited 4 times in total
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campingbox Premium Member
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PostPosted: Tue Feb 10, 2015 7:49 pm    Post subject: Reply with quote

easy e wrote:

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This is a beetle vent wing latch - not sure if you care. Seems like you're trying to be fairly detail oriented so I figured I would mention it incase you didn't notice the difference. Easy enough to swap out.
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easy e
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PostPosted: Tue Feb 10, 2015 8:06 pm    Post subject: Reply with quote

I know Sad ... you're an eagle-eye... and I appreciate your taking the time to offer help. I've seen black ones posted in the bus classifieds... but were actually bug ones. I haven't seen any correct black ones ... so I went with the WW option. I wanted them to be black more than I wanted them to be 'bus'... they'll be swapped sooner or later.

IIRC, the bus ones have a little less meat at the plate to latch friction point (than the bug ones). Before new paint, I rolled with crappy seals. With new seals... I'm wondering if there is any advantage to having the bug latches... if that little bit if extra meat will help keep the wing window be closed tighter (maybe not whistle?...might be an optical illusion?).

Nobody makes bus latches. I'll put it on the 'to-do' list... find some bus ones & powder coat black (it's all WW does with their chrome bug latches, from what I gather).

Just found a pic... bug left... bus right (correct?):

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Spreadsheet for Bus RPM, based on gearing & tire size (Excel format)
Searchable, click-navigable 1958 Bus Parts List


Last edited by easy e on Wed Feb 11, 2015 12:25 am; edited 2 times in total
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CaLiBus
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PostPosted: Tue Feb 10, 2015 8:28 pm    Post subject: Reply with quote

Here's a few of my collection. The green and red one are the very early style of arms for post Barndoor buses 55-56 with driver and passenger being the same with a soft curve to them. The dove blue is 57-58 driver side only.

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easy e
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PostPosted: Tue Feb 10, 2015 8:31 pm    Post subject: Reply with quote

Thx for posting pics of OG ones. My arms are repro (JOGR)... I got my heater tube wrap set from him too... nice stuff.

Hinge pin hole dia. needs to be orig. spec (or veeery close) for JOGR's arms. JOGR doesn't make oversize pins on his arms (as far as I know). I ended up replacing both cab door body-side hinges & passenger side door hinge. Seemed weird the driver's side was nice & passenger was sloppy... I thought it should have been the other way around. Maybe this delivery was with a dedicated driver that sat on his ass all day & had a passenger that frequently got in & out for deliveries.
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Spreadsheet for Bus RPM, based on gearing & tire size (Excel format)
Searchable, click-navigable 1958 Bus Parts List


Last edited by easy e on Wed Feb 11, 2015 12:18 am; edited 2 times in total
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CaLiBus
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PostPosted: Tue Feb 10, 2015 8:52 pm    Post subject: Reply with quote

Original... Those reprose out there make my eyes water Crying or Very sad

just kidding.. looks Good Easy!
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