1964 Light Grey Kombi

[junichi]

Thanks AC Mack!

It’s gotten too cold for painting so I’ve moved to popout window rebuilding and restoration. I picked up a bunch of used frames and got a couple good ones from that. The rest I cut and welded back together using originals as a jig. It seemed to work- test fit #1 was a success. Still need to find the right tap to redo the screw holes and find somewhere warm to paint!
In many cases I didn’t even have a good half to start with- this rusty one is one of the better ones but still beyond useable.

First I clamped the 2 pieces being assembled together and cut them as one, so the cut line is in the same place. This ensured that the 2 useable pieces will be the right lengths. I then clamped the cut pieces on to a good stock one to use as a jig while welding. The toughest part here is the complex profile- I made up some aluminum and some copper pieces that I could fit in and back my welds so they didn’t bleed through and ruin the profile. It’s very hard or impossible to grind or file in some places. I assume any bumps on the inside of the frames could affect the fit of my windows and rubber.

Test fit with new rubber- needed clamps to get them to close up:

3 more to finish weld and test this weekend, then on to paint!
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1964 Kombi- http://www.thesamba.com/vw/forum/viewtopic.php?t=640048
Sold: 1985 Transporter Doka,1978 Westfalia, 1975 bay x 2, 1986 syncro vanagon, 1965 beetle, 1980 vanagon, 1967 deluxe bus, 1988 golf

[junichi]

Part of the process for my shoddy frames is also drilling out the old screws and repairing oversized holes that someone drilled. I guess this is why they were sold on. The first one took an hour and a half just to drill out screws and repairing oversized holes. 3 more to go!
Here’s what I’m starting with- holes drilled out:

I use this brass tool to back the welds

Then a cutting wheel to grind smooth

then insert the other half on top to use as a drilling template

And finally redrill and countersink

Buying new frames would be much easier but the good steel ones have gottten very pricey!
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1964 Kombi- http://www.thesamba.com/vw/forum/viewtopic.php?t=640048
Sold: 1985 Transporter Doka,1978 Westfalia, 1975 bay x 2, 1986 syncro vanagon, 1965 beetle, 1980 vanagon, 1967 deluxe bus, 1988 golf

[junichi]

The other part of this is drilling out the screws of these tabs. I was able to drill them on the drill press, though I often struggle to find the middle. This one, for instance was broken off at an angle and partly below the surface, so I couldn’t flatten it out and punch the centre. No matter, I drilled off center and was able to punch out the rest. Some of them uncoiled around the drill bit when I drilled the next size up.

As mentioned before, the profile makes welding tough- here I have made a thin tab of aluminum that I use as a backer so I can weld the outside but not make any bumps on the inside, which are near impossible to grind out.

I’m no expert, but all this seems to be working well. Hopefully this can help someone else get through this process.
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1964 Kombi- http://www.thesamba.com/vw/forum/viewtopic.php?t=640048
Sold: 1985 Transporter Doka,1978 Westfalia, 1975 bay x 2, 1986 syncro vanagon, 1965 beetle, 1980 vanagon, 1967 deluxe bus, 1988 golf

[mdege]

Looks good! I have done similar with a vent-wing.
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- Michael

1965 21F: Restoration of a former '65 firetruck
1963 Typ3 Notchback project
1988 Multivan Magnum 112i
1984 Standard: My son wanted a bug for his first car

[junichi]

Progress has been slow. My compressor tank got a pinhole and had to get a new tank and swap everything over. Also upgraded my sandblaster with a bottom feed siphon hose (works way better).
I had been using chemical paint stripper first but it was messy and time consuming. Also tried wire wheeling and it was also slow. Went to the good old paint scraper and it worked well.

Sandblasted frame ready for a bit of filler and primer/paint:

_________________
1964 Kombi- http://www.thesamba.com/vw/forum/viewtopic.php?t=640048
Sold: 1985 Transporter Doka,1978 Westfalia, 1975 bay x 2, 1986 syncro vanagon, 1965 beetle, 1980 vanagon, 1967 deluxe bus, 1988 golf

[junichi]

Over the last couple weeks I re-assembled all my windows and stripped and painted the interior of the cargo doors and rear hatch. Next up are the front doors. I’m trying to get everything on the inside painted so I am ready to paint the exterior. Exterior paint may not be this year, but hopefully soon! Many hours went in to wire wheeling the doors, primer, filler and paint. It’s not perfect by any stretch, but should look pretty good. Just waiting for paint to harden before reinstalling.

And here is my paint booth. Cheap pop up tent and sides from Amazon. Much cheaper than an inflatable booth and also no risk of it deflating from a blown breaker. I don’t have space for anything permanent or semi-permanent.

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1964 Kombi- http://www.thesamba.com/vw/forum/viewtopic.php?t=640048
Sold: 1985 Transporter Doka,1978 Westfalia, 1975 bay x 2, 1986 syncro vanagon, 1965 beetle, 1980 vanagon, 1967 deluxe bus, 1988 golf

[junichi]

Well, I made a big push the last few weeks. Between weekends, evenings and a couple extra days off work I got the cab stripped and primed and painted. Also got the doors done on the insides.

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1964 Kombi- http://www.thesamba.com/vw/forum/viewtopic.php?t=640048
Sold: 1985 Transporter Doka,1978 Westfalia, 1975 bay x 2, 1986 syncro vanagon, 1965 beetle, 1980 vanagon, 1967 deluxe bus, 1988 golf

[junichi]

Reassembly is getting there. Went with Kilmat and Reflectix insulation after L reading a lot on the Samba.

I’ve since learned my door handles are on backwards..on the to do list if I have to open up the doors again.

Painted safari windows look so much better!

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1964 Kombi- http://www.thesamba.com/vw/forum/viewtopic.php?t=640048
Sold: 1985 Transporter Doka,1978 Westfalia, 1975 bay x 2, 1986 syncro vanagon, 1965 beetle, 1980 vanagon, 1967 deluxe bus, 1988 golf