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Sun May 24, 2020 6:21 pm

Bet you haven't been pulled in as many directions as you were when installing the headliner! Only those who have installed one will get that.
Keep up the great work. So much detail you're doing on that bus,

Thu May 28, 2020 6:40 pm

See the bead on Clara's post photo?
Clara wrote:
Are you going to have that on yours?
flemcadiddlehopper wrote: I wanted to continue on with the cargo area, so I completed the left side upper and lower install.

Fri May 29, 2020 6:47 am

BarryL wrote: See the bead on Clara's post photo?

Are you going to have that on yours?

I have seen that before, and it does finish the lower cargo piece nicely. I don't have any of the pea green welting for that. Plus I opted for trying to hide as many screws as possible. The 2 screws in the centre of it will be behind the spare and the other 2 at the front edge will be hidden by the seat back, leaving a clean look.

I had thought of running the headliner bead from the B-pillar all the way back to the hinge cover. Just have to investigate if it can be done the same on both sides. I'm not a fan of asymmetry.

Gordo.

Sun Jun 28, 2020 6:49 pm

So, it's time for another quick update on the Bus project.

I just had to go through a covid-19 test due to an eye infection (one of the lower level symptoms of Covid-19). Test results were received in 48hrs...negative for the corona virus. Not sure if anyone has had to have a test yet? But, as it seems that the test is conducted different ways in different places, even across Canada. In B.C. the test is a rather unpleasant one. A swab, about 7" long is shoved into your nose directly at your brain stem and then wriggled about for half a second. Words can't really begin to describe the sensation, but it'll make you wash your hands a little more thoroughly from then on.

Now onto the Bus, as I missed a couple days at work I was able to dig into the door panels a bit more.

I found an issue with the interior trim that I purchased from Wolfsburg West. The front door lower trim bits are about an inch longer than my original ones. If I was to us them, it would move the colour break on the lower section up 2". Not a big deal....unless I want those lines to line up with the cargo doors. I know what your thinking....just move that line up too. Not a problem, unless I want the cargo doors trim to line up with the walk-thru seat backs. The trim for the lower rubber kick drops down to where the trim should be if I used my original front door trim.

Now looking at the gallery I see many door panels that have the lower trim where my original is, and many that have it where the Wolfsburg West piece would sit. With little rhyme or reason based on year or trim package.

In my case, as I am not strictly conforming to the M-code, or any sort of stock conformity, I will be able to place the lower trim in a position to align all panels with the rubber wrap around trim. The front door speaker pods will be forcing me to cut the trim to fit, so the length of the lower pieces is a moot point, thankfully.

I have all panels cut to shape and mounted (accept the driver's seat back) and I'll begin the process of marking where the previous trim will go. Then the trim will be mounted and then dis-mounted before the upholstery goes on the panels.
This whole thing is a much longer process than I had anticipated. Bully to all those who do this, or have done it in the past.

Just have to install some nut-serts for the walk-thru seat backs rather than using rivets as done originally.

Gordo.

Tue Jun 30, 2020 7:45 am

The last panel is now fitted. The Alpine PXE-0850S Audio Processor mounted in it's location with holes for all the cables punched through. I will still need to fabricate a cover for 10 RCAs to keep it tidy looking. I know that is not the correct location for the ash tray, but the back of the middle seat looks so clean without it. I think it looks alright there. The other little stainless pieces are small fold down hooks. Thought they would be handy for hanging towels, beach bags, or shopping bags.

Now I can mark out where the division of each of the panels so it all lines up. Once lines are drawn I will begin the task of drilling all the mounting holes for the trim.
I should be getting on with the upholstery pretty quick. Maybe that's how I'll spend my Canada Day.

Tue Jun 30, 2020 1:58 pm

The lower trim lines on the door panels alignment reference point starts at the trim line for the lower rubber wrap around kicks on the walk through.
The upper trim line aligns with the centre of the door handles on both the front doors and the cargo doors.

The trick, in my case, is using those references to align all of the trim lines. Using careful measurement and the application of masking tape to eyeball verify the alignment.

I then rechecked that I had enough of the Silver Beige material by marking out a rough cut line for each panel. One bonus to the Silver Beige material is that my centre panel measures 15.5" , which just happens to fall directly on the more solid lines in the pattern, making for easier precise cutting.

Gordo.

Tue Jun 30, 2020 6:30 pm

flemcadiddlehopper wrote: The trick, in my case, is using those references to align all of the trim lines. Using careful measurement and the application of masking tape to eyeball verify the alignment.
.

Marvelous just marvelous.

Wed Jul 01, 2020 10:53 am

One last alignment check before I start drilling holes for the trim.

Notice the front door line looking through the walk-thru.

Think I nailed it, hopefully I can drill that straight.

Gordo.

Wed Jul 01, 2020 5:58 pm

Well, all holes are drilled so there's nothing holding me back from laying on the upholstery.

One done...

Gordo.

Thu Jul 02, 2020 5:15 pm

Just a quick question to any of you who have made your own door panels. Have any of you used wax paper to keep the two contact cemented pieces apart while aligning?

Just asking because I completed what would most likely be the easiest door panel to upholster. This was not as simple a task as I had imagined. (much like almost everything I have attempted on this bus. Ignorance is bliss...it's the awakening that's a real bitch) Now I am trying to imagine how I am going to be able to work the long panel pieces. I have had the opportunity to work with a cabinet maker before, and he used the wax paper technique when installing countertops. Worked great. He just slid the paper out one end as he aligned it and stuck it down.

So....?

Gordo.

Fri Jul 03, 2020 6:50 am

I've never heard of the wax paper technique, but that's a really good deal!

Mon Jul 06, 2020 6:25 pm

So the wax paper idea would be great, however, I can't seem to find wax paper in rolls wide enough for this purpose. Still looking.

I have managed to put together another cargo door panel and mount them on the doors. All trim lines still line up nicely.

Quick question regarding the front upper edge of the rear cargo door. I temporarily placed a piece of headliner welt, but it looks odd. There is a groove there , with a metal tab that was obviously pried up during my hasty disassembly. So... what goes in that groove with the tab folded down on it? Is there another door seal that bridges that gap or something to that effect? And please post pictures if you have them.

Gordo.

Tue Jul 07, 2020 2:30 pm

flemcadiddlehopper wrote: So the wax paper idea would be great, however, I can't seem to find wax paper in rolls wide enough for this purpose. Still looking.
Restaurant/Bakers supply?

flemcadiddlehopper wrote: Quick question regarding the front upper edge of the rear cargo door. I temporarily placed a piece of headliner welt, but it looks odd. There is a groove there , with a metal tab that was obviously pried up during my hasty disassembly. So... what goes in that groove with the tab folded down on it? Is there another door seal that bridges that gap or something to that effect? And please post pictures if you have them.
All it is is a flap/tab that holds and finishes off the painted dot fabric from having a loosie-goosie edge that could peel back with time. I don't know how many rebends you can get out of the tab. I'm betting it was a few degrees sticking out at the factory then tapped lightly flat...not being meant to do many more than once. It was painted before being bent, I believe.

Do I really have to post a photo?

Tue Jul 07, 2020 6:58 pm

Thanks Barry.

and no, you don't have to post a pic as the answer was not too technical for me.

Gordo.

Wed Jul 08, 2020 9:48 am

There's a similar holding flap on the B-pillar only that one the material is pushed into the opening and then ends up doing a wrap-around to hide the flap. Capiche?

Thu Jul 09, 2020 6:25 am

BarryL wrote: There's a similar holding flap on the B-pillar only that one the material is pushed into the opening and then ends up doing a wrap-around to hide the flap. Capiche?

Thanks. I figured out the passenger side B-pillar wrap. The front edge of the rear door has already been cut and glued at this point. I think I will have to figure something else out for it. I would like to somehow cover the gap in that area to minimize the amount of black painted metal seen between the windows of the cargo doors. That will have to wait until i begin to dig into all of the door seals.

Gordo.

Thu Jul 09, 2020 9:45 pm

I am trying to get one panel done a day (after working a full day and making dinner for my family). The next panels are going to be the tough ones; the long panel and the front doors.

Here is where I'm at now.

I found a new trick for aligning the upholstery when sticking it down. I am now aligning the piece unglued, taping it along on the mating edge, then folding it over to apply the contact cement. Once the cement has set up , slowly fold the material over laying it down gently while smoothing it out. This may help a boatload on the long panel.

Gordo.

Fri Jul 10, 2020 11:30 am

flemcadiddlehopper wrote: I would like to somehow cover the gap in that area to minimize the amount of black painted metal seen between the windows of the cargo doors.
What color are your window frames? Assuming they are the top color you will have the surround black rubber then the frames so it should look tidy.

Sano job all around.

Sat Jul 18, 2020 1:21 pm

Well there is always something that comes up that seems to weasel it's way in front of the Bus project for time and money. This time it was the septic field... shitty job, but someone has to do it. Fortunately for me, my Brother-in-law used to do this for a living and I used to work for him. So we did it all in a day.

So now my weekends are being taken up with clean-up and yard work I just have evenings to work on the Bus.
One of the main reasons I chose to make my own door panels, was that many of the big guys (TMI in particular) does not offer the long panel in one piece. Most likely because of shipping sizes.
I was able to lay the material out, tape down the one edge, glue it and flip it method. Which seemed to work well for me.

The arm rests are made of bamboo and a 1/4" layer of Birch plywood. The bamboo was sourced form dollar store cutting boards, which were cut, laminated and then shaped. The coating on them is West systems epoxy resin and then coated with a lacquer to help with UV stability.

Now I am starting on the walk-thru rubber kick wrap around and trim. I have my old pieces of trim which will help in the shaping of them.

Gordo.

Mon Aug 24, 2020 5:44 pm

Bit of an update, on me not the bus. Due to the covid-19 situation and the inability of the Subaru dealership, where I work, to follow the Guidelines and protocols set out by the Human rights act, work safe B.C., the C.D.C. and interior health....I no longer work for them. Sad...no. Every cloud has a silver lining. I applied at one shop. The first shop on my bucket list of places I would like to work...and I got the job. I now work at Conquer Custom Rods.

https://www.konquer.ca/konquer-custom-rods

I have an okay resume, I guess, but what I think sealed the deal was that the manager is a Stutgart trained VW tech. And, for the final stamp of approval, I showed him my steering wheel.

I had been worried about once my bus was done and I was driving it to work, where I would park it? Well, now it looks like I will just park it line with all the other hot rods in front of the shop. Simply awesome.

Gordo.