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jpeters
Samba Member
Joined: May 06, 2005
Posts: 1025
Location: Woodsfield, Ohio
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 Posted: Mon Oct 10, 2011 11:46 am Post subject: My new 68 Westy "Budget Bus" Project |
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I recently picked up a 68 Westy for cheap. I figured it is time to start a rebuild thread. I'm going to be calling this the "Budget Bus." I hope to do the majority of work myself and the goal is to keep as much money in my pocket as possible, but to have a decent looking, reliable driver upon conclusion.
Lower nose (and behind the lower nose) is really bad, front floors need replaced, inner dog legs also shot.
Before (looks worse in person):
You can also see pics here: http://68vwbusphotos.shutterfly.com/
Got started today with some paint removal on the driver rocker:
Any suggestions on fixing up these rockers short of a complete replacement? As I said, this is going to be a budget bus. However, I'm buying a new mig welder and plan on doing the best I can do in an attempt to repair the rust. I'm just hoping to avoid what I fear will be my largest expense...body panels.
It is hard to tell in those pictures, but there are a lot of pinholes and also about a 6 inch section in the middle along the seam that is rusted through. Also found some bondo and some bodywork. The work wasn't horrible, but the bondo was probably about 1/4 inch thick in one spot.
_________________
'73 Westy (dual stock carbs, SVDA w/ compufire)
'68 Westy http://www.thesamba.com/vw/forum/viewtopic.php?t=484180
'65 Westy SO-42 http://www.thesamba.com/vw/forum/viewtopic.php?t=435614
'65 Bug
'63 Bug
neverdnf on Instagram
Last edited by jpeters on Mon Oct 10, 2011 11:49 am; edited 1 time in total |
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Skoolieman
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Joined: January 31, 2011
Posts: 573
Location: Chattanooga TN
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| Posted: Mon Oct 10, 2011 11:49 am Post subject: |
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Congrats on your 68 Westy! I just bought a 69 Westy, I think it is the same model. Mine as well needs a new front floor and some patches in the cargo area. I am looking forward to following your thread. I am also on a pretty tight budget.
Good luck! |
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Islero
Samba Member
Joined: August 11, 2011
Posts: 89
Location: Spain
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| Posted: Mon Oct 10, 2011 11:57 am Post subject: Re: My new 68 Westy "Budget Bus" Project |
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| jpeters wrote: |
Any suggestions on fixing up these rockers short of a complete replacement? As I said, this is going to be a budget bus. However, I'm buying a new mig welder and plan on doing the best I can do in an attempt to repair the rust. I'm just hoping to avoid what I fear will be my largest expense...body panels.
It is hard to tell in those pictures, but there are a lot of pinholes and also about a 6 inch section in the middle along the seam that is rusted through. Also found some bondo and some bodywork. The work wasn't horrible, but the bondo was probably about 1/4 inch thick in one spot. |
If you want to keep it in budget you can patch with new metal those areas, if you do it well you should not have any problem for a long time, just use some good quality wire for the mig and don't miss any rust spot before next step.
Good luck! |
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WestyMan1971
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Joined: March 27, 2008
Posts: 682
Location: The Granite State
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superman73
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Joined: December 21, 2006
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Location: Crystal Springs, Mississippi
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jpeters
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Joined: May 06, 2005
Posts: 1025
Location: Woodsfield, Ohio
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WestyMan1971
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Joined: March 27, 2008
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Location: The Granite State
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jpeters
Samba Member
Joined: May 06, 2005
Posts: 1025
Location: Woodsfield, Ohio
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| Posted: Tue Oct 18, 2011 6:31 am Post subject: |
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I was able to get everything stripped out of the bus. The wood underneath the rear floor was all wet and rotted, but suprisingly the floor is very solid but for some surface rust.
I also continued to sand down the driver side panel. At first I planned on going down to bare metal, but I bought an orbital sander and some 120 grit and got down to the original paint. It appears to be super hard and I'm thinking it will act as a nice primer, so I doubt I sand much further except for more prep. The white is the original. Yellow must have been a repaint somewhere along the way. I'll probably sand down the yellow but it is pretty tough as well.
And I finally found the PO's hack job. The lower nose is full of bondo and fiberglass. Good news is that there appears to be little rust above the lower lip, so I could just buy the lower repleacement piece. Though, there is also a little damage around the passenger turn signal, so the lower nose from gerson that replaces the turns signals will probably be my best option.
Also found a ton of bondo above the passenger headlight. Not sure what I'll do there yet. Maybe weld in a new piece of sheet metal.
Lots more sanding/grinding to go.
_________________
'73 Westy (dual stock carbs, SVDA w/ compufire)
'68 Westy http://www.thesamba.com/vw/forum/viewtopic.php?t=484180
'65 Westy SO-42 http://www.thesamba.com/vw/forum/viewtopic.php?t=435614
'65 Bug
'63 Bug
neverdnf on Instagram |
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VAVWFAN
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Joined: January 16, 2010
Posts: 758
Location: Middletown, Virginia
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| Posted: Tue Oct 18, 2011 2:02 pm Post subject: |
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Bondo -vs- metal??? IF, you're trying to restore to original; by all means, replace the metal. If you're trying to get a useable bus, that looks good after repair, and the bondo is in good shape; no rust arount it etc, why not just protect it and leave it alone?!?
If you're a purest, you know what ya gotta do! If you're trying to make a good, but not perfect bus, with a sense of maintaining throughout it's life; you know what you gotta do!
POR-15 or Rust Bullet, and a "little" bondo, and/or fiberglass works wonders for old vehicles in select locations.
Once again; "what's your plan for it?!?"
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If it weren't for "last minutes;" -- nothing would ever get done! |
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brookmp
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Joined: February 05, 2010
Posts: 347
Location: San Diego, CA
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| Posted: Tue Oct 18, 2011 3:30 pm Post subject: |
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Hey, welcome to the '68 Westy club. Long live the earliest of the Bays! What is its "birth" date (on your m-code plate)? My Bus was produced in October '67. Have fun with this one and enjoy...
Brook
_________________
1968 Westfalia Campmobile
1971 Double Cab Pick-up
1974 Standard Beetle |
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jpeters
Samba Member
Joined: May 06, 2005
Posts: 1025
Location: Woodsfield, Ohio
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| Posted: Tue Oct 18, 2011 6:29 pm Post subject: |
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| VAVWFAN wrote: |
| Bondo -vs- metal??? IF, you're trying to restore to original; by all means, replace the metal. If you're trying to get a useable bus, that looks good after repair, and the bondo is in good shape; no rust arount it etc, why not just protect it and leave it alone?!? |
I was actually debating replacing that section with new metal or pounding out the dent the best I can and then using some filler. What I didn't want to do was to use 3/4 of an inch of bondo like someone else did. This spot is just dented really bad. It doesn't have any rust.
Don't worry, there will be plenty of POR15 used. I've used it before with really good results. My hope for the bus is to have a mechanically sound, decent looking, rust free bus, that could be a daily driver. I also want to do whatever I can to keep rust from coming back.
_________________
'73 Westy (dual stock carbs, SVDA w/ compufire)
'68 Westy http://www.thesamba.com/vw/forum/viewtopic.php?t=484180
'65 Westy SO-42 http://www.thesamba.com/vw/forum/viewtopic.php?t=435614
'65 Bug
'63 Bug
neverdnf on Instagram |
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jpeters
Samba Member
Joined: May 06, 2005
Posts: 1025
Location: Woodsfield, Ohio
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| Posted: Tue Oct 18, 2011 6:36 pm Post subject: |
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| brookmp wrote: |
Hey, welcome to the '68 Westy club. Long live the earliest of the Bays! What is its "birth" date (on your m-code plate)? My Bus was produced in October '67. Have fun with this one and enjoy...
Brook |
Production date was April 30, 1968. Yours must be one of the earliest ones.
_________________
'73 Westy (dual stock carbs, SVDA w/ compufire)
'68 Westy http://www.thesamba.com/vw/forum/viewtopic.php?t=484180
'65 Westy SO-42 http://www.thesamba.com/vw/forum/viewtopic.php?t=435614
'65 Bug
'63 Bug
neverdnf on Instagram |
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jpeters
Samba Member
Joined: May 06, 2005
Posts: 1025
Location: Woodsfield, Ohio
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| Posted: Mon Oct 24, 2011 12:34 pm Post subject: |
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I'm getting ready to place an order with Gerson. I'm quickly getting to the point were I'll need to start cutting and welding. I plan on picking these up, in addition to other pieces.
Do I have to replace inner and outers or can I just replace the outer rockers?
_________________
'73 Westy (dual stock carbs, SVDA w/ compufire)
'68 Westy http://www.thesamba.com/vw/forum/viewtopic.php?t=484180
'65 Westy SO-42 http://www.thesamba.com/vw/forum/viewtopic.php?t=435614
'65 Bug
'63 Bug
neverdnf on Instagram |
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914guy
Samba Member
Joined: September 08, 2008
Posts: 167
Location: Cincinnati, Ohio
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| Posted: Mon Oct 24, 2011 7:27 pm Post subject: |
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It depends whether the inner or middle rockers are rusty.
Look under the bus at the cross members' ends. Is there a panel attached to the ends of the cross members? This is the inner rocker. If this piece has holes when looking toward the outer rocker (the piece in your picture of the Gerson part), you may need more than just the outer rocker.
Good luck. |
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jpeters
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Joined: May 06, 2005
Posts: 1025
Location: Woodsfield, Ohio
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jpeters
Samba Member
Joined: May 06, 2005
Posts: 1025
Location: Woodsfield, Ohio
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| Posted: Mon Nov 07, 2011 7:06 am Post subject: |
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Did a little more sanding this weekend. The process is painfully slow, but I'm hoping it will be rewarding in the end.
Check out this beautiful front floor  :
Looks like Gerson is going to be making out on this deal. The far passenger side of the floor is a little rusty, but I was hoping to get away with only replacing half the front floor. May be easier to just do the whole thing.
I also found where the PO had cut an access hole for the fuel tank in the hatch area. Looks like I'll need a piece of sheet metal to weld in here too.
My parents also picked up this welder for me for xmas:
http://www.northerntool.com/shop/tools/product_200332691_200332691
I'm hoping to have all of the sanding done by xmas, so that I can start cutting/welding.
Any tips on essential electric cutting/grinding tools that I should be looking for? I don't have a large enough air supply to run air tools yet.
_________________
'73 Westy (dual stock carbs, SVDA w/ compufire)
'68 Westy http://www.thesamba.com/vw/forum/viewtopic.php?t=484180
'65 Westy SO-42 http://www.thesamba.com/vw/forum/viewtopic.php?t=435614
'65 Bug
'63 Bug
neverdnf on Instagram |
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Greg Knister
Samba Member
Joined: July 30, 2011
Posts: 47
Location: Alberta Canada
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| Posted: Mon Nov 07, 2011 8:22 pm Post subject: I have the same van only 1969 |
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| Thats A cool welder should do what ever you want body wise. Have a lincon that looks the same with the same out put. Just make sure that you have both wires for it thicker metals take more heat . flux and fluxless wire both have there uses. |
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jpeters
Samba Member
Joined: May 06, 2005
Posts: 1025
Location: Woodsfield, Ohio
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| Posted: Tue Dec 06, 2011 10:47 am Post subject: |
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I was able to get some more work done on the Westy this weekend. The weather here was unusually warm, so I figured I better make the most of it.
Here is a pic of the PO fuel tank access hack that I mentioned before:
*IF ANYONE HAS PANEL FROM A PARTS BUS THAT I COULD USE TO WELD IN THIS AREA, PLEASE PM ME. THANKS.
I was also able to get the cargo area sanded down and hit with POR-15:
Hard to see in the last pic, but the rear hatch sill at the bottom is pretty rusted from water laying around the seal. Not sure what I'm going to do here as a replacement panel would be hard to source. I'm hoping to just clean it up and smooth it out a bit. I'm debating using one of POR's epoxy putty products, molding a new sill and hitting it again with por-15.
So much for the title "budget bus." I'm afraid the budget has already been blown. To buy a new front floor, outer long rockers, short rockers and lower nose section from Gerson is $565.00. Also need an inner front valance and inner and outer front steps from BusDepot, so add another $150ish. Kind of scary spending that kind of money when I have no experience yet with body work. However, after reading the body panels thread, I just can't justify spending the cash on anything but Gerson where available.
I'm hoping to get familiar with my new welder and start replacing some panels over the Christmas holidays.
_________________
'73 Westy (dual stock carbs, SVDA w/ compufire)
'68 Westy http://www.thesamba.com/vw/forum/viewtopic.php?t=484180
'65 Westy SO-42 http://www.thesamba.com/vw/forum/viewtopic.php?t=435614
'65 Bug
'63 Bug
neverdnf on Instagram
Last edited by jpeters on Tue Dec 06, 2011 11:28 am; edited 1 time in total |
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aguynamedloren
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Joined: December 04, 2011
Posts: 91
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| Posted: Tue Dec 06, 2011 11:11 am Post subject: |
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Great build! I'll definitely be following this one. I just purchased a '69 bay and started a build thread, also called 'budget build' (coincidentally) as I'll be doing most of the work myself and keeping costs low.
Regarding the metal-vs-bondo statement, I agree that you should go with bondo wherever possible if you're on a budget. Dents? Dings? Pick up the proper metal working tools and pound them out as much as possible, using filler to finish them off. It's amazing what you can accomplish with a bit of elbow grease. The pinholes from rust can also be taken care of with bondo (and proper rust prevention). Obviously there's no way getting around the major rust like the floorpans. I've just found myself in the same situation (albiet my rust holes are only baseball sized, not basketball sized  ).
Anyway, good luck with the restoration! |
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jpeters
Samba Member
Joined: May 06, 2005
Posts: 1025
Location: Woodsfield, Ohio
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| Posted: Tue Dec 06, 2011 12:04 pm Post subject: |
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Thanks. This bus is really weird. The floor, inner dog legs and front lower nose are completely rusted out. However, with the exception of what I would consider below average rust on the rockers for this area, the bus is extremely solid. I'm not sure what happened to the lower front area. I would have guessed a leaking windshield, but I haven't found any evidence to support that yet. Maybe I'm yet to find it though.
_________________
'73 Westy (dual stock carbs, SVDA w/ compufire)
'68 Westy http://www.thesamba.com/vw/forum/viewtopic.php?t=484180
'65 Westy SO-42 http://www.thesamba.com/vw/forum/viewtopic.php?t=435614
'65 Bug
'63 Bug
neverdnf on Instagram |
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