Velvet Green Single in MD

Schwing · Posted: Mon Sep 28, 2015 6:52 am Post subject:

Ok I managed to finish up lower frame repair and start on the Treasure Chester Floor installation. I had to mark, punch and drill 233 holes on each half, so that's over 500 plug welds. I had my friend stand on the floor while I welded the driver side and I may have my son be the weight for the passenger side.

Lessons learned:
1)Install passenger side first, then driver (they overlap)
2)Pay very close attention to how the treasure chest doors latch since that is defined by floor placement and rocker position, in some cases you may need to trim the catch or adjust the outer rocker.
3)Don't set a deadline, this takes longer than you think, but its not difficult. I still have to weld the driver side, but all in all this is only a 10-12 hour job if your lower frame is good. If I was a shop I'd quote 12-15hours Smile

The frame repair, this is 2mm steal on the ][ frame:

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

That's 233 holes, took about 2+ hours to do one side. Others might be able to do it quicker.

Here is the driver welded in, and the passenger in place ready to weld.
I will no longer drop tools "through" my truck haha.

Door shuts really well:

Also knocked out some patches on the driver side:

The corner-

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73sports · Posted: Mon Sep 28, 2015 11:15 am Post subject:

A little late at this point to do, but it would be interesting to see how much the truck weighed at the start, and then at the end of all the metal work! I bet it feels a lot different now.
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kevsplitty · Posted: Mon Sep 28, 2015 12:36 pm Post subject:

Good work

I have a velvet green 65 uk rhd,love using mine for work

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j.pickens · Posted: Wed Sep 30, 2015 7:23 pm Post subject:

You did all those welds "Great Escape" style lying on your stomach?
I can see why crukab Tom wanted a rotisserie. He put it on its side and stood up inside the treasure chest to do these welds.
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Schwing · Posted: Thu Oct 01, 2015 6:02 pm Post subject:

kevsplitty · Posted: Thu Oct 01, 2015 10:54 pm Post subject:

Thanks bud, it was found bout 8 years ago in a barn,where it had sat 23years!! only 58k from new,one owner, old farmer used it for only light duties. Had some work but basically is as it was found,just needed brakes overhaul, engine rebuilt & a dam good wash/polish up. Was covered underneath in thick clay/mud which seemed to have protected it,just a couple of jacking points,small section in an outrigger but rest was ok.
When i got it home after a wash

seat had seen better days but managed to find some material to match & my mum done it

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Schwing · Posted: Fri Oct 02, 2015 4:05 am Post subject:

Wow beautiful truck! I love the original paint, wood slats, and your mom did an excellent job on those seats! Unfortunately mine was a respray with too much rot to retain original paint. Thanks for sharing. Do you have the Blazecut fire Suppression system?
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esde · Posted: Fri Oct 02, 2015 9:29 am Post subject:

kevsplitty · Posted: Fri Oct 02, 2015 4:00 pm Post subject:

Schwing · Posted: Fri Nov 06, 2015 7:43 am Post subject:

Still plugging along if anyone is following.
I finished welding all of the verticals for the treasure chest floor and ground down the welds. I got to a point where I could almost guess the amount of time it took to grind each one and I could grind some without looking. I also re-welded some of the previous repairs to B, C Pillars and verticals since my new Lincoln seems to do a better job than my Eastwood welder

This door is from a Deluxe so I had to weld up the trim. My 6 year old son was dead against this decision. "Dad these doors are rare". haha

Next obstacle was something I wasn't sure how to handle, the pipes for the heat. On a bus you have a heat log under the rear seat and on a single cab you don't have a back seat, you simply have a Y that protrudes the plane of the treasure chest floor. Mine was rotten, and I bought the heater kit from Alan Schofield. What's interesting is that the kit does not include the two pipes, just the small "Y" intersection. I think they do this so the kit is not specific to truck or bus.
So I had the local shop bend me some pipes using the original as a reference. They did an excellent job.

Oops it looks like these pipes were installed before the floor, so I had to cut away temporary access.

I decided to weld parts of the floor seam to make it stronger. These will get ground down and seam sealed so you won't notice.

Next up is the rear parcel tray. Thanks to our friend Glideking I know how to do this, I just need to buy the steel. Also I need to order the separation panel frame and trapezoid from Gerson. KF754 before I lose my sticky note.
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kevsplitty · Posted: Sat Nov 07, 2015 12:53 am Post subject:

Top work fella,looking great Cool

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0nebadbug · Posted: Tue Nov 24, 2015 9:06 am Post subject: Re: Velvet Green Single in MD

Truckbus is lookin great!
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54bugn · Posted: Mon Dec 07, 2015 1:40 pm Post subject: Re: Velvet Green Single in MD

Hello Schwing. Unbelievable welding work on this single cab! I was following your awesome work on your oval build, and am finally welding on my 54 bug so now am watching your welding job and learning, thank you.

Hope you don't mind, but I am stealing a comment you made as my new welding mantra:

"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

Again great work,
Mike
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65Bugsmasher · Samba Member Joined: August 12, 2012 Posts: 183

What size/ type of tubing did you use or get to use from that Y section to the back? I have the same problem with my 65 standard and think I just found a solution reading this thread. Great work by the way!!

Schwing · Posted: Tue Dec 08, 2015 7:01 am Post subject: Re: Velvet Green Single in MD

Thanks kevsplitty, onebadbug (Gene), and 54 bug'n (Mike) I really appreciate the nudge.

Mike what a blast from the past! Hope you are well these days. What can I say you found my abomination. Glad to hear that early oval is getting some love, I will watch for updates.

65bugsmashin - The pipe measures 2 1/4" which is pretty standard for exhaust on most vehicles. I just measured my original and its also 2 1/4". The shop charged me $50 to do the bends and I left my original with them for reference. It was the only way I knew how to overcome the problem. It might not be a perfect replica but it beats PVC!
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Schwing · Posted: Wed Dec 09, 2015 11:23 am Post subject: Re: Velvet Green Single in MD

To get away from the monotony of repairing the area behind the gas tank I took a break to strip the nose and apply Oshpo and mount the new door I picked up from Shane Morgan. I know it seems like I bounce around a lot but this is how I stay motivated on a project that might be out of my league.

The kids keep asking if they can help so I give them 80 grit paper and tell them to go to town. They love it.

And here is the piece I fabricated for the gas tank area where the parcel tray meets the treasure chest floor. It will be a butt joint at the top and I drilled holes on the flange for the treasure chest floor. Once the butt weld is done I will get the truck up on ramps and plug weld the two together from the bottom just like factory.

I started with a big piece. I've learned when bending metal its way easier to start big and then cut to size.

Just laying in place before it got trimmed to size.

Started to tack it in. You will see I have a small rectangle to weld.

Last but not least, huge news for my project! First, I finally have the title in my name and all cleared up. Second, I was about to take the engine lid to the blaster when something caught my eye, I could see the faint remains of a dealer sticker under 2 layers of paint. I carefully dry sanded with 800 grit until words started to appear! This was really exciting, as I have had very little history on this truck. Roland Willis Jr. & Son, Burlington, NJ Wow, no way!!! This is 41 miles away from my childhood home in PA.

Through the power of the interwebs and a bunch of phone calls I was able to locate the son of the man who was the general manager there for many years. He has boxes of memorabillia and I hope to get the opportunity to buy some things for him for this truck. I bet this truck was purchased there new.

I know, its a shame to blast away history but I took a bunch of pics. Pin holes all over this engine lid. I also blasted my dash tray.

Also finished up all repairs on the upper frame, pending the arrival of some Gerson for the tophat/separation panel frame.

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caseydenise · Posted: Wed Dec 09, 2015 8:14 pm Post subject: Re: Velvet Green Single in MD

You are a machine! Shocked

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Who.Me? · Posted: Thu Dec 10, 2015 6:31 am Post subject: Re: Velvet Green Single in MD

What are your plans for the fuel tank outlet hole? Are you cutting it in-situ?

The original hole has a flange to hold the tank-to-floor seal in position.
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Schwing · Posted: Thu Dec 10, 2015 6:46 am Post subject: Re: Velvet Green Single in MD

Schwing · Posted: Mon Jan 04, 2016 10:44 am Post subject: Re: Velvet Green Single in MD

Small update, still plugging along in the gas tank area. I received my frame from Gerson (KF754) in case anyone needs the same thing. The vertical trapezoid was wrong so I will fabricate my own patch and keep my original. I also cleaned the welds that I did in another session and applied Ospho.

The rest of my winter break was spent building what I call the "Wagen Haus". My son and I made the sign together, I still need him to outline the lettering.

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