Nova Scotian 54 standard restoration

[ddutch]

Sublime A-pillar surgery, the disassembled patient should be happy.

[Burlyhammer]

Awesome work Stan!!!

[sgellis]

Still have a few details to finish on the A pillar but started a new piece anyway.

Kick panel had quite a bit of rust on the left side and needed that side of the lower rib replaced. 3D printed some bead roller dies to get the perfect shape.

I put a lip on each side of my replacement part and stretched the lips to get the correct curve. After rolling in the rib I needed to add a little more curve. Part came out better than expected on first try.

Now I will print dies to press the termination.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[sgellis]

Kick panel finished.

I printed a press die to get the correct rib termination. It matches the right side lower termination but the upper one was not as defined.

Still have a few small imperfections to cleanup. The zinc brings them out.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[sgellis]

Started the dash bar.

Cut out most of the rust and media blasted.

I found two screw holes in the bottom. One close to the dash pod ( see photo) and one mirrored on other side. I didn't think they were original but they are mirrored accurately. Is there something that uses these holes?

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[myklsmyth]

I have a pretty messed up support that has 3 holes, all which appear to be symmetrical, however they are in a slightly different placement than yours so I don't think that will help and I can't confirm whether it is original or not either. I would like it if someone could confirm as well.

I put tape behind the holes to highlight them in this photo

[sgellis]

[myklsmyth]

Thank you sir

[sgellis]

Dash beam roughed out.

Biggest problem was the center patch. With a bunch of hand forming, stretching and wheeling I got the front curve. After I added the lower lip. If I had made it in two parts it would have been much easier. It took me almost 3 hours to make and fit that patch.

Was a bit of work to keep it perfectly straight when welding all the patches in. Very happy with how it is coming along.

One unknown is how far up the windshield it extends on the a pillars. With the rough welds and rust I can't see exactly where the panel ends. One side looks like it extends up about 10mm but the other looks closer to 25mm. My 64 looks to be about 20mm but I changed the dash it it so not original.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[sgellis]

I found a photo of a nos beam and they look closer to 25mm. I will scale the photo tomorrow and see if I can get more accurate number.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[sgellis]

Finished up the dash beam today.

Took some time to get it smooth but happy with how it can out. I left the end windshield bits a little large so I can trim them when fitting.

Copied the panel holes form the rusty bit. They were quit random.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[Käfer2]

Looks good! I'm following your thread with admiration.

[sgellis]

Started the windshield frame

After stripping it I decided to just replace the upper and lower profiles. There was a lot of deep pitting and holes. Will be easier to replace than patch anyway.

When removing the center interior filler I discovered it was leaded to the dash beam. Maybe done for strength or to fix a bad fit.

Before disassembling the nose I made a friction fit window plug. That will allow me to clamp sections in place before welding and ensure accurate shape.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[brass gears]

Stan, just wanted to chime in and say your Ship of Theseus is coming along nicely. Mad metal work skills. All this takes so much time never mind producing and editing videos and then there is the CAD files!
Enjoying the videos. Nice presentation followed by the time lapse of the procedures. Saturday afternoon you tube staple.
-Rob
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‘70 transporter
‘ 64 beetle

[LAGrunthaner]

Wow, Stan was lead used on the finish work on busses regularly or just for repairs? I've had friends replicate lead use on restorations as an old school method.
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American Red Cross Safe And Well:
https://www.redcross.org/about-us/news-and-events/...bsite.html
Maui Roadsters
www.mauiroadsters.com
http://www.oacdp.org

[sgellis]

[sgellis]

Windshield frame repair parts made. Not going to be much original frame left. Lot of deep rust on the back side.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[scarabee]

Stan, you ARE the man! Cheesy, I know...

[sgellis]

One side welded. Having the plug made it relatively easy. It would be a pain to do this without it.

Removed the mirror spacer. I thought it was one piece of steel but was actually two layers.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[ddutch]