Nice bus, even nicer sister

[pondoras box]

Don’t toss that old floor! It’s not scrap metal, someone only needs to patch sections of their floor would love to get their hands on it. I’ve adopted an old Native American saying at my shop. “None of the buffalo goes to waste” we use anything that’s left. My bus has other bus metal, bug metal, old computer server cabinets, and even metal from a wrecked Tesla on it now.

But I love your attention to detail!
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Looking for anything from Hal Casey Motors out of Hamburg New York, from license plate surrounds to matchbooks.

1961 23 Window (Bobo)
1965 11 Window (Zelda). https://www.thesamba.com/vw/forum/viewtopic.php?t=563183
1965 13 Window (Lucas)
1957 Oval ragtop
1960 hardtop
1964 hardtop
1965 hardtop
1988 Cabriolet VR6 conversion
Plus a lot of other rusty junk

[EverettB]

Wow, I didn't know you could remove and reinstall the materials inside the air cleaner through the holes.

This must have taken many hours?
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Stop dead photo links! Post your photos to The Samba Gallery!

[Eric&Barb]

Yes, hopefully you can help others with the parts of the old new floor you had to remove. Heck, wish you were closer, we could use the areas right over the jack points for our 1960 walk thru panel camper.

Wow, on your work to preserve the air cleaner! Personally would have just soaked it in Evaporust or the clone recipe of that to remove the rust. Followed with a rinse with water and once quickly dried, wiped down with Ospho, then prime and paint. Once the engine is run the inside of aircleaner will be coated with oil.
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In Stereo, Where Available!

[BarryL]

That has to be record in tedium.

[thom]

That's quite clever; I currently have an air cleaner I need to restore; I wanted to powder coat it but they told me the filling would cause problems.

[bcs]

Hello Pandoras Box,

the removed cargo-floor-parts were already stored in my workshop

After the bus-project will be finished, all the remaining parts will be offered at one of the VW swap-meets.

You have welded in old computer server cabinets and metal from a wrecked Tesla?!

I’m excited about your sustainable bus project!

Many thanks.
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benjamin

[bcs]

Hello Everett,

removing the old material and threading in the new material did not take so much time (approx. 40 minutes)

More time-consuming was the subsequent pulling apart of the new material inside the air filter until the entire room was filled (approx. 45 minutes).

Many thanks.

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benjamin

[bcs]

Hello Eric&Barb,

sorry that our distance is so far, but I’m sure you will find the needed part in your neighbourhood

I have to admit that sometimes I'm not sure if the efforts are right.

This is one reason why this project is taking so long.

Many thanks.
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benjamin

[bcs]

Hello Barry,

this work was very calming

And so quiet, no comparison to cleaning for hours the cavities with a vacuum cleaner.

Many thanks.

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benjamin

[bcs]

Hello Thom,

many thanks. I wish you good luck for restoring your air-cleaner!

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benjamin



[quote="thom"]That's quite clever; I currently have an air cleaner I need to restore; I wanted to powder coat it but they told me the filling would cause problems.

[bcs]

The next focus were the seat-benches:

The spring cores were worn out and too soft.

The upholsterer's work should start on a stable base.

I also don't want to sink in later due to my weight

Fortunately, there is a reliable workshop in southern Germany that is specialized in reproducing innersprings.

Unfortunately, he is always very busy and it took about 1,5 years until he finished my order.

To be on the safe side, the guy put some extra springs into the front-seat-bench for the heavy driver

Here are the comparison photos of the old and new seat-spring-cores:

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benjamin

[thom]

My fat ass needs something like that

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-Thom
1956 Single Cab
1957 Porsche 356A Sunroof
1957 23-Window Deluxe
1957 Mercedes Westfalia single cab
1963 Unimog 404
1965 E-Type

[bcs]

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benjamin

[bcs]

The following topic is one of the highlights of this project

I never thought I would find NOS Snowflake-material for restoring the kickpanels.

But by a very lucky coincidence, the material was found at one of the largest classic car parts markets in Europe called Veterama in Mannheim

The old seller told me, that he got the sheet metal in the 70s / 80s when a VW-warehouse was cleaned out and closed.

He had no idea for what this sheet-metal was used, but he kept it over all the years because of its nice Snowflake-design.

Fortunately he just stored it very carefully

Here is the comparison between the NOS-material (above) and the kickpanel-trim (below):

The challenge was to form the sheet metal into the correct and needed dimensions.

Numerous different attempts were made until the right solution was found.

First the longitudinal bead was made with the beading-machine …

The prepared sheet metal was cut into the right form for the next step ...

To be able to craft the correct bending, a knocker-molding-form was created and built …

After about 700 … 800 hammer hits, the bending is finished completely …

The correct dimensions were controlled and the fit was checked on a kick-panel …

After that the riveting was done step by step …

… and the NOS Snowflake-trim is fixed …

The steps for preparing the long trim are identical but more time-consuming due to the larger dimensions


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benjamin

[matthew henricks]

Talk about pucker factor on the kick panel. Very nice work. I bet your in-box is filling up with others wanting one...
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1964 Original Owner build Thread. https://www.thesamba.com/vw/forum/viewtopic.php?t=702135&highlight=

Ambulance Fan's. https://www.thesamba.com/vw/forum/viewtopic.php?t=627707&highlight=

Parts i am looking for:
64 bug nice used front/rear Black LHD floor mat.

[bcs]

[bcs]

To complete the Snowflake-topic, here are also the details about the long Snowflake trim for the rear-seat-bench kickpanel …

A further knocker-molding-form was built to get the identical measurements of the original long trim.

I have to admit, that manufacturing the short trim is much more comfortable because of the smaller dimensions

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benjamin

[bcs]

The next job: The 5 rims and the clips for the hub-caps.

Some clips were still original but bent, some were broken off and some were exchanged in the past to reproduction ones.

For an uniform appearance, all clips should be replaced.

That means to do the riveting process 25 times

My first attempts with the riveting tool and a hammer were unsuccessful due to my weak arms

So a rim-holder was designed that the riveting could be done by using a workshop press.
The basis: 15mm thick steel-plate / threaded rods M14.

The original clips (left) have the little upgoing tail which is missing at the reproduction versions (middle).
After a long search reproduction-clips with the little upgoing tail like the original ones were found (right).

Because of this tail the riveting tool had to be sanded down slightly.
After that it was welded onto the plate.

The workshop-press made a good job: After 5,5 tons and the rivet was smooth

Just 3 clips were installed to test the riveting-process and the fitting of the hubcap.

After that the rivets and clips were removed. The rims will be given now to a sandblaster …

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benjamin