TheSamba.com :: View topic - Body Panel Replacement

Tue Apr 22, 2025 7:16 am

So, I did bite the bullet and cleaned up the original side cover tracks. They weren't too bad, the window frames where they were attached were actually in worse shape. Sprayed them with epoxy and 2k and welded them back on.

I put some seam sealer along the top where the track and the body meet. Hopefully this keeps water from getting into it again.

400 grit sanding was a PITA. Shoulder is done, but I got through it, touched up a few spots where I burned through and then did the same with the 600 grit.

Bagged and tagged for door frame and inner door spray

First spray of original VW Sage Green

Pretty happy with it, a couple of runs, but I will be more careful with the exterior spray. I also picked up the original VW Chaulk White for the roof. I had painted it a few years back with Rustoleum white, so I guess I'll be stripping it down again so that the single-stage will adhere to it proper. Making more work for myself...

Tue Apr 22, 2025 7:47 am

Looking good!

Tue Apr 22, 2025 8:24 am

Way to get after it. It’s gonna look great!

Wed Apr 23, 2025 11:48 am

Doing some prep to rehang the doors before the next paint goes down. I'm having the same trouble with the slider door handle pulling right out as this previous post: https://www.thesamba.com/vw/forum/viewtopic.php?p=7812636

Since this was 10 years ago, just curious if anyone has found a fix for this, or if the whole mech needs to be replaced? Thx

Thu Apr 24, 2025 8:11 pm

Are you going to replace all that plastic masking before paint ? There's a reason body shops use paper. Upon spraying next to that painted plastic the wind shaking it can release paint flakes all over your fresh paint. Just saying.

Fri Apr 25, 2025 6:22 am

Hi Dan - Yes, I did experience some flakes during the primer phase, so it will be replaced for paint.

Fri Apr 25, 2025 9:47 am

plastic for auto masking has a treated surface so the overspray sticks to it,and will not be blown off into your paint ,regular plastic don,t have the treatment and the dried overspray will flake off.

Mon May 05, 2025 6:48 am

Progress update; I am not a painter... yet...

I started with the bottom, as it was the harder tape line and my next tape job is easier and could potentially fix any issues from the first.

Poured up my Sage Green, although I feel like they should name it $$$ green, because that @#$% ain't cheap!

Two coats, no real issues to report, a couple of runs, which I guess is normal considering this is my first time.

Next tape off the bottom:

And Chaulk White goes in the gun:

So, FYI, spraying in tight, hard to reach or small spaces is tough. So many runs, it's not even funny. I've been looking into fixing runs, but decided I will move forward to meet my deadline and can always go back later to try and fix them, or save some cash and pay someone to fix them ;)

Tape off

Deja-vu as I strip the top... again

Got it in 2k primer last night

Sand it and shoot it white this week and we're off to the races. Still have to get the bumpers sprayed, but reassembly has already started. Finally the fun part...

Mon May 05, 2025 10:17 am

Yup. Just get the paint on and keep going. Sanding out runs and color sanding are not that hard and makes a huge difference.

I painted one side of my bus in late October. Probably the last day it was warm enough to paint outside. Then the wind came up. What a mess. Got the paint on though. Rescued it with sanding and buffing.

Weather is perfect! Let ‘er rip!

You can always color sanding.

Tue May 06, 2025 12:05 pm

Wow, perfect mirror image. I won't be posting any pics like that ;)

Tue May 06, 2025 4:20 pm

Goach2 wrote: Wow, perfect mirror image. I won't be posting any pics like that ;)

It doesn’t look that good in real life. It’s a deliberately flattering photo. It’s not that straight and has some flaws. But it looks a lot better than right after I painted it. Drips, runs, bugs and grit. But sanding and buffing made it good enough for me. You’re doing great.

Wed May 07, 2025 7:21 am

Something else about getting it all done. If you get to a panel during your sanding and buffing that is just too much work to save, it’s easy to scuff it down and shoot it again compared to painting it for the first time. Usually it’s just the flat panels below the belt line if you really can’t live with something. I find that after awhile, a flaw that smacked me on the face just after painting it is hard to find again or doesn’t look as bad as I remember.

Tue May 20, 2025 7:11 am

Well, I started on the refresh of the jalousie windows. The only really difficult part seems to be the pinches in the tracks that the rubbers have to slide/lock into. Anyone have an effective way of reopening these pinches without too much damage or warpage to the aluminum?

Tue May 20, 2025 7:20 pm

Bus is looking fine! As far as the jalousie window repair. I don’t know, but I found a bunch of topics in FAQ. I didn’t read through any but here ya go
https://www.thesamba.com/vw/forum/viewtopic.php?t=...highlight=

Thu Oct 23, 2025 11:37 am

Well, I guess this is a 'Completion' Post, ending a thread that I started in 2017 when I was just setting out on this project. Went by fast, although the last 12 months was a big push and a lot of work. I'm very thankful to all the people that gave me advice along the way. It may not be perfect, but it is so much better than I ever expected it to be.

For anyone that's just starting out on their own journey, the approach I took to get it on the road as first priority and looking good as second really paid off in the long run. I have years of memories of good times spent with the bus and more importantly, so do my children. Peace

Thu Oct 23, 2025 11:55 am

beautiful ,quite the change from page one, may you and those you love have many happy times in your future travels.

Thu Oct 23, 2025 1:07 pm

Holy crap am I glad my bus project didn't take that long.

I hope you take your time and enjoy the fruits of all your labor.

Remember to enjoy it, its going to break. Let it. Fix it when it does.