'Let's Go! Scotland-Croatia and onwards in our Kombi!'

[mcdonaldneal]

Time for another update!
As I mention above, the Kombi has been passed on to a bodywork guy I have never met, which I was a bit anxious about.
The good news is that I have had a lot of really good communication with him now and we have agreed a plan and how deeply to take the bodywork restoration, he has started stripping back the problem areas and he is able to fabricate the panels/structural areas that cannot be purchased. It’s going to be a long haul but we are definitely moving forward!
I will add a few posts that show specific areas and the plans and also what these areas looked like when they last had (temporary!) repairs or pint from me.
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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

The worst area is the rear LHS wheel arch. This has been previously damaged and repaired several times and the first two pictures are before and after a repair in 2019.

Then a picture of the inner skin of the wheel arch when I renewed the underseal in 2021

And lastly, the current pictures. The corrosion is through both layers of panel and the repair panel that was bonded to the outside of it all! The plan is to cut out all the rust and weld in new inner and outer skins. The inners are unavailable here and so he will adapt a second outer panel…

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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

The next worst area is the line of rust where the pop top contacts the roof. This had perforated the panel even six years ago in 2018 when I did a temporary repair with POR15 and filler.
The first pics are before and after that repair:

The repair has held up not too badly for 6 years, but I will be very happy that he can cut this out and weld in two patch panels. It is a double skinned area so it could be difficult but we will see how it goes. I have a new, deluxe softer pop top seal which should prevent further damage in the future.

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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

Some other areas. The jacking point had a cosmetic splash of paint in 2020. Progressed a little since then:

2020:

And now, four years later:

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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

Current pictures of windscreen rust and front corner forward of the front door step:

Also, the gaping hole under the passenger seat that had been creatively patched (sandwiched!) with steel!

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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

The bodywork guy is sending me a million pics of the work (which I love!) but I’ll just put a selection on here for the record.
First up, the previously ‘repaired’ roof strip. New sections fabricated and welded in with weld through copper primer.

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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

Next up, a section of the lower B pillar which required a multi part fabricated piece from scratch. Certainly, I am impressed by his skills (and speed!)

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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

Other random bits of rust exposure. I’m finding the whole thing terrifying but aside from these areas he is happy that things are looking very solid!

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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

And lastly a bunch of the repair patches he’s made up:

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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[The Volkswagen Ranch]

What an incredibly skilled guy! You are truly blessed to have found him! Bob
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1963 Convertible (Lizzie) and 1964 Convertible (Patience) 1976 Westfalia (Winnie)

[mcdonaldneal]

[mcdonaldneal]

On our way back home after our ferry from Amsterdam, I finally got to meet Garry, the metalwork genius!
He is still sending me detailed pictures of the work, but I took a few myself to show you some progress!

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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[MorkC68]

Wow, that's some serious work going on.

Looks like the bus is in good hands so good luck and I look forward to seeing more good progress.
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Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/

[rsbadura]

I like it! Respect, looks good. Continued success...

Looks like a lot of work - which awaits me again in the next few years after my trips in recent years (Europe/Asia/Africa) -
first rust get's visible again, but the travels are worth it.

regards,
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Rolf-Stephan Badura
1970 VW Karmann-Ghia Coupe
1979 VW Bus L to camper conversion
1982 Eriba Pan travel trailer
2017 VW CrossPolo
HAZET classic tools