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1954 RHD Barndoor Samba - Back To Stock Restoration
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Air Kraft
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PostPosted: Fri Apr 29, 2016 8:59 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

More little tricky areas...

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Air Kraft
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PostPosted: Fri Apr 29, 2016 9:08 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

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Air Kraft
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PostPosted: Fri Apr 29, 2016 9:16 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

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PostPosted: Fri Apr 29, 2016 9:25 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Beautiful, quality work and craftsmanship. This bus is lucky to have found both an owner to invest in repairing it right and a shop with this talent.

My question for you is this. What are you doing to treat the rust inside the frame rails and other boxed in sections? Obviously the welds are bare metal inside after they are closed up. In many of your photo's of the frame rails opened up, you can see the corrosion/rust inside them.

Keep up the great work and updates!
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Air Kraft
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PostPosted: Fri Apr 29, 2016 10:33 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Hi Bill. Thank you for the kind words. We are treating any bad rust as a cancer and cutting it out completely. The light surface stuff is being treated with soda blasting, then phosphoric acid and then finally a heavy zinc coating. I'll probably upload some pictures of this process when time allows. I have a million photos of the work done, but I'm adding only a fraction to keep the thread from being overly boring.

In future updates there'll be lots of Pullmax, Eckold and English Wheel action!

Have a good weekend folks!
Matt
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Air Kraft
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PostPosted: Fri Apr 29, 2016 11:48 pm    Post subject: Re: Barndoor Samba - Back To Stock Restoration Reply with quote

[quote="RockStock"]
Scotty wrote:


good detail

why are they there?
is it bracing/strengthening for the receptive threads of the beam bolts?


Yes, they are exactly that. On our bus the arc welds were extremely rusty and porous. They needed to be completely repaired and redone. The reason they aren't finished yet is I'm having to borrow an arc welder to replicate the authenticity with 100% accuracy. Not many shops use arc any more including us, so tricky to find! Very Happy
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PostPosted: Tue May 03, 2016 6:12 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

It's really interesting to see photos inside places you can't normally see.

Great fab skills Mr K as always
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Air Kraft
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PostPosted: Tue May 03, 2016 9:34 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Thanks Scotty 👍
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PostPosted: Mon May 09, 2016 11:21 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Another tricky task: the inner window skins had perforated, so needed replacing. As no commercial panels are readily available, we decided to make our own; to exact original spec. The panels have a tricky radius return, which is impossible to make on a folding break...
To do the job with 100% accuracy, we cut a small section out from a corner and side window, and then cast two pairs of Pullmax dies:

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Last edited by Air Kraft on Mon May 09, 2016 11:45 pm; edited 1 time in total
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Air Kraft
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PostPosted: Mon May 09, 2016 11:26 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

The panels were then radiused with the special dies (corner windows) and then welded in and planished/hand finished:

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andre b
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PostPosted: Tue May 10, 2016 6:22 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Nice to someone pay attention to detail.amazing work!! Very Happy keep the pics flowing
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PostPosted: Tue May 10, 2016 6:22 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Beautiful work!

Did you have the dies made or? Love the attention to detail.
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Air Kraft
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PostPosted: Tue May 10, 2016 8:53 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Thanks guys!

Bill: we make the dies ourselves at Airkraft. We cast them specifically for any forming job necessary.

Thanks, Matt
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PostPosted: Tue May 10, 2016 8:53 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Air Kraft wrote:
Thanks guys!

Bill: we make the dies ourselves at Airkraft. We cast them specifically for any forming job necessary.

Thanks, Matt



Nice...I'd love to see some pictures of that process if you're will to share. Very Happy
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Decades of VW and VW parts restoration experience.
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**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**
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vwhelmot
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PostPosted: Tue May 10, 2016 11:54 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Yeah, get sharing ! lol :D
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Air Kraft
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PostPosted: Thu May 12, 2016 1:11 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Well, I have to say that Sam excelled himself today! Since joining Airkraft he has taken to every challenge thrown his way with gusto. Today's task was to make a lower door skin for the Barndoor Samba. Now you may ask why didn't we just buy one? The simple answer is that there aren't any out there that fit as well as a custom wheeled item. We take pride in being 100% as good as we can be. We just love hand crafting panels whenever we can! Now the lower section of the cab door is a very difficult panel with a varying compound curve in both directions, requiring some tricky English Wheel work...

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kilgore
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PostPosted: Fri May 13, 2016 3:58 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

absolutely incredible workmanship Matt! love seeing all the fabrication photos keep them coming!!
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Air Kraft
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PostPosted: Fri May 13, 2016 11:31 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Thank you Kilgore 👍
Don't worry, there's plenty more pictures to follow Wink
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PostPosted: Sun May 29, 2016 4:34 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Great work.. PM sent, could use some metal you made dies for.
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Air Kraft
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PostPosted: Wed Jun 01, 2016 11:31 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Hi Empi. Yes, we can make and supply you the necessary rear corner and side window inner sheet metal. Where are you based?
Regards, Matt
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