Meet Schultz the 1963 Double Cab

[nlorntson]

We picked up this 1963 Double Cab 18 months ago from a guy in WI that had it since the late 70's. He had bought it from a local marina and drove it for a while before parking it to do a full restoration.

Move ahead 25 years later and there it sat in his barn taking up space and still no time or money to restore it. He advertised it on the local Craig's list and I went over to see it, and struck a deal to buy.

We knew it likely had a bunch of previous repairs and the sculpted bondo was thick so we planned for the usual 8" all the way around the bottom to need replacement. Sitting inside a dry storage all those years saved the majority of the truck from further decay, but the mice did have a wonderful home for some time.

Pictures as found and when we got it home. From 20 feet away and with the doors closed, it didn't look too bad. But I knew better once I saw missing vertical panel seams, drain holes in doglegs and gates, etc. I knew "the bondo was thick with this one"

First order of business was to pressure wash it inside and out to rid it of the mouse nests, acorns, seeds and droppings. Next was to peel off the bondo and see what was hiding under it. I used a propane torch to soften the bondo and a putty knife to peel it off. Some of the thinner areas I used a stripper wheel on a angle grinder. Below is a look at the carnage.

We also removed what was left of the cargo floor

[nlorntson]

We did the initial outer body sheet metal repairs using a combination of sheet metal from the usual vendors. We've found that no one vendor makes all the best pieces so we get what we believe to be the best pieces for a particular area from who ever makes them.

The original decklid had issues along the bottom and one hinge mount was broken so it came apart to fix.

Same with the gates, they were awful and full of bondo on the entire bottom rib and a few of the vertical and end ribs. We used the KF replacement pieces to make them solid again.

Had to add holes and other small details to the KF pieces.

We'll use a rust encapsulator and internal chassis sealer product from Eastwood to try and halt the rust we know is inside the other ribs. There is just no way to get that removed unless the gates are completely taken apart.

All three doors had rust at the bottom. Only the cargo door needed inner and outer pieces replaced. Front doors were in good enough shape to mostly patch. The bottom inner structure of one needed to be replaced.

The process was similar to the decklid and gates; peel back the lip, release the spot welds, cut out the rust and fit and weld the new piece. Finally, hammer and dolly the lop back over.

Once the bulk of the body panels were replaced, we sent the whole truck, doors and gates off to get stripped of all paint. We supplied them with the tipping arms so they can flip the truck on either side and get the entire bottom and chassis too. The company we use does a lot of cars and has a very gentle touch. We've never had a panel come back warped.

Once it arrived back to the workshop, the remaining metalwork and rust repair was completed. This included the usual base of the windshield, bottom of the nose, inner and outer valence, front floor halves and other miscellaneous pin holes and cheesey areas that were not revealed.

The cargo floor was welded in. This was very tough since it was such a cramped space under the rear where the fuel tank sits. The fuel tank bases and the piece for the base of the block off doors was added.

The heater system pieces were repaired and reinstalled. We know of only one place that even reproduces these pieces but have no idea of the quality so we repaired the pieces we had,

The insulation for a Double cab has a hole for the paper tube

Amazingly the load bed was in wonderful condition with just some minor dents and pitting. The m-code plate indicates it was delivered with a tilt and bows so maybe this helped some.

We used a series of metal bucks formed to the corrugations, to hammer and dolly those out. We also removed the remaining wood slat rivets and welded up the holes. We'll drill new holes when we trial fit the wood slats before heading to final body work.

Once the nose was buttoned up, it was time to final trial fit the front doors and ensure they will fit with good gaps. We did the same for the cargo door, decklid and gates.

Finally, the bumpers were trial fit and adjusted as needed so as to avoid any serious tweaking when we're dealing with freshly painted parts.

With all the underside parts cleaned, straightened and repaired, we are finally ready for some paint on the chassis. We opted for actual paint rather than the primer put on from the factory, but we stayed with the primer gray color. Hopefully this will protect our hard work for years to come.

And finally off to the body shop.

Hubby and I do this restoration work together. He does the metal repairs and I do the mechanical/electrical/interior and reassembly. While all this metal work has been going on, I've rebuilt the front axle, transmission and rear axle, 1500cc engine. I'm a fan of stock everything so this will stay 6V. My only concession was to put in 1600cc P/C. and I'm going with a 50A generator/regulator for a little extra juice for possibly adding some fog lights since we do drive our cars.

I've also gone through and restored or repaired all the electrical systems and lights (http://www.thesamba.com/vw/forum/viewtopic.php?t=646495)

We have a few more details to complete while it's at the paint shop, like painting the bumpers and wheels, finishing the upholstery, and cleaning up remaining nuts, bolts, etc. Ideally when it returns from the paint shop, it will be an reasonably fast reassembly since all the pieces that can bolt on should be ready to go. Fingers crossed!

I'll update things when Schultz returns from the paint shop.

[OB Bus]

Wow! Very impressive work!
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Larry in OB
Stop dead photo links! Post your photos to The Samba Gallery!
69 Westfalia and 2002 Eurovan Camper.

[Pinetops]

Beautiful work so far on this truck! I love the last pic of the mechanicals on the rack.
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"A rolling bus gathers no rust."

[srfndoc]

Really nice work. How many hours do you think you have in it at this point (metal work/body/paint)?
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RPM=(MPH*336* (R&P*4th*1.26))/Tire Diameter in inches

[Stocknazi]

Nice front axle/trans/motor storage rack.
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WANTED:
58 Westfalia cabinet knobs (3 needed), roof rack, and (7) privy tent poles (silver painted).

"When the people are afraid of the government, that's tyranny. But when the government is afraid of the people, that's liberty."
"Resistance to tyrants is obedience to God."

Thomas Jefferson

[crukab]

[mandraks]

good work on Schultz, glad Schultze did not get the blues. (obscure movie reference, IMDB it. love the movie)

this is a pretty perfect example of what double cabs look like underneath. Always more places to fix than expected
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regards

Uli

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'53 3-Fold Oval, L35 Metallic Blue, looking for a narrow hatch panel

[nlorntson]

[wcfvw69]

I love these threads where people fix these well deserving VW's the correct way. I figured it was going to be media blasted when I started at the top of the thread. I "cringed" a bit thinking about what happened to my convertible bug body at the blasters. They managed to warp about every panel on the bug. I was NOT happy. I'm glad you found a good blaster.

What's the plan on it? Are you keeping it or?
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Contact me at [email protected]
Follow me on instagram @sparxwerksllc

Decades of VW and VW parts restoration experience.
The Samba member since 2004.

**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours**

[dietermkII]

Great work on the dc Nancy!

Will be as new when you get it ready!

Grts Dieter

[nlorntson]

[nlorntson]

[scottvw]

Nice job...looking forward to seeing it on all 4 wheels again.

[dietermkII]

We will defenitly be there in 2017!!!

The bus is doing great, we did an offroad trip about a month ago.

[KombiMadness]

Wow! Impressive work and a husband and wife team, no less.....

Your '63 DC, Schultz was asked by Colonel Klink - " Schultz, tell me about the bondo"

Schultz - "Bondo, Herr Kommandant? I know nothing.... nothing"




I love it when people get stuck right in to a resto. You have both done amazing work!
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My brother & I on the roof of Dad's Splitty circa 1967 - I'm the half pint with the skinny legs!

[nlorntson]

[nlorntson]

More progress on the DC. We're hoping to have it back in a couple of weeks to begin assembly and hopefully finish for the local Twin Cities VW show on the 5th. We're supposed to have the window pieces and doors first so we can hopefully get them assembled before the body arrives.

Paint shop has all of it in final primer. There are so many bits and pieces that get paint! I have to source 15 more large phillips head screws for the door and gate hinges to finish all the painted parts.

I know WW and others sell ones that will work, but the head profile and diameter is just a bit off so I'd like to find originals if possible.

Anyone with extras please PM me.

[Red Fau Veh]

Golly that's some awesome stuff, just rad.
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1971 Deluxe Sunroof Bay 1905 stroker, dual idf40's, 74mm Scat forged crank, engle 110 cam. CB 044 heads, AutoCraft rockers, chromoly push rods
1973 Orange transporter stock type 4 with dual 40 Dellortos and Empi single quiet pack
1969 Adventurewagen blue whale Gene Berg 1776 built by Dave Kawell dual 36 DRLA's, Vintage Speed exhaust, Bosch 019 screamer
1961 Swivel Seat camper, L345 grey

[EverettB]