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Mon May 14, 2012 3:51 pm

Thought I would share the restoration process on my 55 Deluxe. The Bus
is a 1955 Deluxe with Semaphores, Factory Safari Windows, and 6 Pop outs.
Built March 26, 1955 and left the factory on April 4, 1955 delivered to Competition Motors Hollywood, CA. Located quite a few years back by
Buggen who proceeded to tear it down and start the restoration using all
NOS German panels or original donor panels and collected most of the NOS
parts needed to put the Bus back together. After losing interest he sold it to
me and it was shipped to Douglas Denlinger of Transporter Restorations to
be completed.

As discovered by a previous owner

On the trailer heading to Phoenix, AZ

Parts

Mon May 14, 2012 3:59 pm

When the bus arrived in AZ we soon realized that a previous blaster
got carried away and in just the right lighting...

Mon May 14, 2012 4:08 pm

It became apparent that the panel could not be beaten back to shape so
a replacement was ordered and the original was carefully removed by
Trevor and crew then the new panel was spot welded back on.

Mon May 14, 2012 4:13 pm

The man obviously did not shoot walnut shells on the body. There was some serious heat buildup to cause that much distortion to the sheet metal. He probably did not have the nozzle at enough of an angle to the body, too. I don't like a media being shot over "sealed" panels," e.g., rockers, because it goes through every little crack and drain hole into the panels.
That looks like a good project. Good luck.

Mon May 14, 2012 4:28 pm

goatheady wrote: When the bus arrived in AZ we soon realized that a previous blaster
got carried away and in just the right lighting...

I s that from using what kind of medium<sp for blasting..walnut shells? sand? or just the heat? just for further reference.

Mon May 14, 2012 6:38 pm

I love threads like this. Don't hold back on process and detail pictures please.

Mon May 14, 2012 10:49 pm

aa390392 wrote:

I s that from using what kind of medium<sp for blasting..walnut shells? sand? or just the heat? just for further reference.

Buggen....Matt, will need to answer the question. However, in my 25 years of restoration experience, along with the shop that handles all my blasting Pro-Strip in Mesa, AZ, for panels to warp as seen in the above picture, it's usually caused by one of the following:

Sandblasting the inside of the long side
Too much pressure
Wrong media used to blast the vehicle

In this case, I'll bet it's all 3 of the above.

Needless to say I was completely floored when I saw the side warped like that....Matt, Kirk and I spent an entire day packing the parts and bus for the road trip.....none of us noticed this....even the photo on the trailer just outside of Kingman, AZ at a slightly different angle revealed no clue of the problem.

Mon May 14, 2012 11:18 pm

So as Kirk mentioned, a new side was needed, since NOS are more than a bit difficult to locate, I called on my european friends to give me their impressions on the Autocraft metal, after several glowing reviews, an order was placed. Special thanks to BBT Bob, Enrico and of course Autocraft.

Now that the side was inventoried, the search began for the best possible way to install the panel.....to me that always means as original as possible. When I stumbled across up and coming bus super star Trevor Reis who had just landed in his new shop and had access to the "right tool for the job".

Tue May 15, 2012 12:01 am

After a bit of time to remove the warped side and prep the frame work

Tue May 15, 2012 12:02 am

So, I'm more than pleased with the results.

The Autocraft fit is nothing short of incredible.

Tue May 15, 2012 1:29 am

Wow what a bus

How many earlier post Barndoor deluxes are out there?

Keep the news/pictures of her build coming

Tue May 15, 2012 5:57 am

Hey Doug, How did Trevor spot weld along the top of panel @ beltline?

Tue May 15, 2012 6:39 am

type241 wrote: Hey Doug, How did Trevor spot weld along the top of panel @ beltline?

I always wondered about that, too. How are top edges of the panel sealed off?
Plus, in the photos it appears as though the spot welding caused puckering around the welds, is that just an optical illusion?

Tue May 15, 2012 7:37 am

Here are some pics of the NOS Case that came with the Bus on Frenchy's
bench awaiting a rebuild. After a thorough cleaning both Doug & I felt that
the finish was not up to scratch so it was shipped to Joe Ruiz (Mr Okrasa)
to be refinished using his "Gold" coating process. Frenchy is handling the
rebuild as his attention to detail is second to none.

After cleaning:

After "Gold Coating"

Tue May 15, 2012 7:38 am

Is this one getting full mani / pedi treatment from DD?

Tue May 15, 2012 8:16 am

ducatis wrote: Wow what a bus

How many earlier post Barndoor deluxes are out there?

Keep the news/pictures of her build coming

I believe this is the 2nd or 3rd oldest known to exist, post barndoor production samba, definitely the best in terms of how kind mother nature/previous owners have treated the bus.

Tue May 15, 2012 8:19 am

type241 wrote: Hey Doug, How did Trevor spot weld along the top of panel @ beltline?

Hi Greg.....the top edge was spot welded as well, a little difficult to see in the pic's. Several spot welders, with various tips were used to get in the hard to reach places.

Tue May 15, 2012 8:26 am

Douglas Denlinger wrote:

definitely the best in terms of how kind mother nature/previous owners have treated the bus.

Apart from the 'over zealous blasting by someone'. Very straight vehicle though - someone has done amazing welding work on that long panel.

Tue May 15, 2012 8:28 am

Braukuche wrote: type241 wrote: Hey Doug, How did Trevor spot weld along the top of panel @ beltline?

I always wondered about that, too. How are top edges of the panel sealed off?
Plus, in the photos it appears as though the spot welding caused puckering around the welds, is that just an optical illusion?

No puckering, that side is as flat as one that would have left the factory. The marks you see are cleaning up a bit of slag and prepping the spot weld for sealer adhesion.

The front edge on the b-pillar was plug welded

Tue May 15, 2012 8:55 am

Great work. None of my tips for my spot welder fit in this area along belt line seam.