View original topic: 20-020744 "The Tocksfors Rhd" Page: Previous  1, 2, 3, 4, 5, 6, 7, 8, 9, 10  Next
brettsvw Sun Feb 07, 2016 7:04 am

dockmaster wrote: 73sports wrote: I just keep thinking how cool it would be to see the chassis taken out for a spin before the body is reconstructed.

I second this!

I've seen beetle chassis driving. No bus chassis on YouTube yet.
There's a chance to be the first.

This is an epic build, I will be following.

mandraks Sun Feb 07, 2016 10:49 am

I, too, will be watching. No doubt

Scotty Mon Feb 08, 2016 6:14 am

Paul Wisk drove his 54 deluxe chassis around a field before he attached the body back on

busben Mon Feb 08, 2016 8:51 am

Crimson wrote: I was the one who found and checked the number on the bus .. remember I got tons of mail after I posted pictures on the meanbugs forums .. a few years since the last time I was working on vw:s.. but my friend patric sent the link to me regarding the bus so I just had to register again to see the awsome work you done to it. Keep up the good work👍🏻😊

Glad you like the thread dude. I sent Patric the link because he'd been asking me a few times if I'd started the build yet. I think he's really pleased to see it being restored after helping save it :D

As for getting the chassis driving, Scotty's right that Wiskers took his for a spin and there is a video of it somewhere. Anyway, it's a bit late for that now I'm afraid as we started this project up again a few days ago after a month on other things. I'll pull my finger out and get some progress photos up soon ;-)

busben Fri Feb 19, 2016 11:02 am

So .......... next step after a New Year break was to get started on the roof. When we rescued this bus from the forest most of the roof was paper thin but I really wanted to keep the front end just to retain some of the identity of the bus. I managed to source an early roof to use for the rear 2/3, and in OG dove blue as well, although it's got black paint over the top but this will hopefully strip off.

First job was to spot weld the inner strengtheners onto the new section of roof. Not many Barndoors had these and the jury is out to exactly why they were installed, but maybe something to do with extra strength for roof loading ...... maybe for places with heavy snow?? All I know is that mine had them as you can see from this photo ......

........ and so they're going back on. Not surprisingly they are the same profile as the cargo doors and side panels so an easy fix.

Then the front gutter was replaced with some KF sections

and then we had to work out what to do with this!! The roof was pretty badly beat and so it had quite a lot of work just to get it back into the right shape before we could do anything with it!!

When we started tacking the old front section in position we also had to fabricate some of the lower edge that attaches to the gutter as this was toast in places on the original clip

but the main problem area was the right hand side that had been sat buried on the forest floor

I came up with the solution of using the scraps of rear roof to fix this section to try and retain the heavy patina, and so the front section was trimmed up ready

and the lower edge sorted with a fabricated piece

and then this piece of original rear roof was used ..............

which I think worked out pretty damn well!! :D

and cleaned up it looks even better

one more minor repair on the front as this skin is pretty thin in places

and the roof is fixed and ready for use!!

busben Fri Feb 19, 2016 11:15 am

Next up, back to that front end. First we got the new cab floor into position

and then repairs started on the rusty, beaten up, mis-shaped front panel....

first the instrument pod was fixed

then the front skin was worked back into something like the correct profile, and the rusty headlight bucket removed and replaced

then the right hand side was trimmed up and new metal grafted in off a donor clip, plus a-posts on and lower dash support metal work repaired / replaced

and finally the new screen on and ............ We have a solid front end again!

then one of my favourite parts of a build this big - the front end attached to the chassis :D

busben Fri Feb 19, 2016 11:34 am

Deja Vu :D

Hellberg Fri Feb 19, 2016 12:02 pm

freakin awesome! As always :D

Huetti_1989 Fri Feb 19, 2016 4:57 pm

Good work!!

How do you do all the measurment?

Do you use any Kind of template?

low54 Sun Feb 21, 2016 1:37 pm

Amazing work as always going on there 8)

ian macdowall Sun Feb 21, 2016 2:29 pm

Great skills and a lot of patience, love it 8)

The Rascals Cats Sun Feb 21, 2016 3:12 pm

This is pretty awesome ... Crazy work but the result is incredible ... :wink: Good luck guys

Scotty Mon Feb 22, 2016 6:24 am

Superb as usual

busben Mon Feb 22, 2016 4:53 pm

Thanks chaps :D

Huetti_1989 wrote: Good work!!

How do you do all the measurment?

Do you use any Kind of template?

Hey Christian, yeh getting everything correct takes FOREVER! We have the chassis jig which is a good start, and I have various cuts and clips in the shop to reference. I'm lucky to have my '51 panel which is pretty unmolested and original and a very good reference so I check things A LOT! It's sometimes a slow process but worth getting right!

Anyway, time to see what it looked like with a roof on :twisted: Luckily I managed to borrow a fork lift for the occasion!

and then after some repairs ...........

............ we have a b-post and bulkhead in position

and a few more final pieces added to the front clip

With this lot done we had to work out what to do with the back end, and how to get everything lined up properly. The back end isn't brilliant but can be saved, and the long side had rotted away completely in to the forest floor. The cargo doors were complete scrap when we hauled them from the forest too ....

but I'm an optimist and I wanted to use them. Scrap too much and what is left of the original bus? Sadly they looked like this when I dug them back out the shed, and I had no real idea how to even start trying to make them useable

Anyway, I'm lucky enough to have some very talented and equally enthusiastic friends so I gave Mark Spicer a ring to see if he fancied trying to work his magic on them. Mark's a massively talented metalwork guy and one of the biggest Barndoor enthusiasts that I know. He's currently restoring the Austrian Kohlruss Coachbuilt Barndoor that one of his friends lumbered him with 8) and if you've seen the amount of work going into it then you'll know what he's capable of. He's also a very nice guy, and possibly even felt quite sorry for the idiot on the other end of the phone, and so he agreed to take them on and see what he could do. I should say that he was also very insistent when I dropped them off that he wasn't sure whether they could be saved, but I had every faith in his skills and just several days after our very pleasant lunch he sent me a couple of photos ........

the first door beaten back into shape with outer skin repaired

and the pair of doors fitted into his Kohlruss

They looked pretty damn good, but the bad news was that the internal frames were all so toasty that they had to be completely removed and these doors were now just bare skins. No problem for Mark though, he just knocked up some new ones! Frame one ........

and the almost completed door fitted for size

then working on frame 2

And finally the completed doors when he dropped them back off with me, all ready to start getting the rear of the bus fixed into place

Spicer - you are a bloody star!!!

mandraks Mon Feb 22, 2016 5:14 pm


nane_cox Mon Feb 22, 2016 11:16 pm

What talent !

Scotty Tue Feb 23, 2016 6:12 am

Wow, superb effort Mr Spicer!

djfordmanjack Tue Feb 23, 2016 3:11 pm

the man ! 8) !
great efforts by all involved!

Bendango Wed Feb 24, 2016 6:33 am


Austrian Kohlruss Coachbuilt Barndoor <<< this sounded interesting. Any links?

PeteSC Wed Feb 24, 2016 6:59 am

burwin wrote: WOW

Austrian Kohlruss Coachbuilt Barndoor <<< this sounded interesting. Any links?

There's a build page for it on Facebook:

Powered by phpBB © 2001, 2005 phpBB Group