Ben's '59 Panel Project

[ernstben]

[Pinetops]

I don't blame you, that's some rough work for sure. They came out nice. Luckily my front blade is mostly straight. The rear will take some convincing, and the guards are all dented.
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"A rolling bus gathers no rust."

[ernstben]

Would anyone do me a huge favor and measure the distance the dogleg extends forward from the B pillar on the very bottom? A PO cut mine and I'd like to return it to stock.

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Ben

'63 Ghia Coupe Project
'59 Panel Project
'56 Ragtop Project

[Eric&Barb]

[ernstben]

[Eric&Barb]

[Eric&Barb]

Here you can see in this close up the bottom line of that area is angled upwards, then hits a radius about 3/4" and that ends in the forward curve that goes up and over the tire.

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In Stereo, Where Available!

[Eric&Barb]

So, could trace out a template if you need. Will mark it for where the forward lip/flange starts out.
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In Stereo, Where Available!

[ernstben]

Oh! More complicated than I thought. Ok... will have to noodle on that one for a while. As you say, best would be to make a cardboard copy of that from a good bus. The rest of the doglegs are in good shape, so I can't bring myself to order new ones or even patch panels from the classifieds for such a small area...

Thanks for the picture, that helps a bunch!
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Ben

'63 Ghia Coupe Project
'59 Panel Project
'56 Ragtop Project

[ernstben]

[Eric&Barb]

Pmail us your address so we can send the tracing to you.
_________________
In Stereo, Where Available!

[ernstben]

Started doing a little exploratory cutting around the rocker and had to stop when it started to get a little overwhelming:

I was hoping to get by without having to tear into the B pillar and the top hat sections, but I think that's inevitable now that I've seen the extent of the rust.

Oh well... to recover from that, I've started re-paneling her sides:

Welded up some pinholes and cracks on the bottom of a cargo door:

Started de-crustifying the parcel tray:

And repaired the cut-out radio section:

_________________
Ben

'63 Ghia Coupe Project
'59 Panel Project
'56 Ragtop Project

[69vwcarl]

Ive replaced cut windows in a panel before.. major work. But can be done nice looks good on what you have done already.. keep in mind there is a slight bend to that panel. I made a template of the curve and had my pre cut panels rolled in a large slip roll at a local HVAC shop that way the panel was relaxed in the same shape of the curve of the body. Really helped to get a nice result when finished.
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LOVE splits more than Jean-Claude Van Damme

[ernstben]

[ernstben]

It's hard to get outside with winter still hanging around, but I was able to get a couple things done today. I added some 3-point seat belt mounting points in the cab area:

and repaired this weird rust-through area in the rear:

I also finished up cleaning up the headlight buckets. They were a fun indoor, stay warm, activity this winter. I'm going to run the original chrome rings for the time being and then more than likely upgrade at some point in the future to some new ones from WW:

_________________
Ben

'63 Ghia Coupe Project
'59 Panel Project
'56 Ragtop Project

[BarryL]

[ernstben]

She's a panel again! Well, half of her:

Also, I picked up a rebuilt 40hp today as well. Out with the old, in with the new:

Cutting out rust from this area was intimidating and sort of overwhelming. Now that I'm back to solid metal, I think I'm ready to build things up again:

_________________
Ben

'63 Ghia Coupe Project
'59 Panel Project
'56 Ragtop Project

[ernstben]

I had to drill out the screws holding the engine lid hinges on, so I had to do some surgery to replace the plates:

Post-op:

Cut out the swiss cheese where something scraped along the passenger's side door:

On a way more interesting note, I think I've kind of settled on some colors. I was going to go for a stock grey look, but I think I'm starting to drift toward something a little darker. I sprayed the vent wing swooshes what would be the body color and the nose emblem the accent color:

_________________
Ben

'63 Ghia Coupe Project
'59 Panel Project
'56 Ragtop Project

[ernstben]

Completed some rust repair on the rocker area. First some stuff to cut out:

And then skipping ahead a couple days:

I'm slowly making it to the end of my list of broken off fasteners to repair:

Hand brushed some paint on the bumpers to give myself some thickness to sand:

And started paneling up the other side:

_________________
Ben

'63 Ghia Coupe Project
'59 Panel Project
'56 Ragtop Project

[ernstben]

While I have the beam out of the bus, I decided to replace the center pin bushings:

Post-reaming, but pre-cleaning:

Also, behold! A cargo floor and rocker:

_________________
Ben

'63 Ghia Coupe Project
'59 Panel Project
'56 Ragtop Project