Nova Scotian 54 standard restoration

[sgellis]

Finished another part. The 61 part had two differences from the 54. A small rib pressed in near the bottom and a round pressing at top of bulkhead. Both areas were rusted and needed replacing anyway.

I made a quick press to make the interior panel brackets. It wasn't quite even so I just rotated the parts and pressed them again.

I recovered the semafor nut as my new ones are not quite the same. Made a new pocket for the top of the semafor.

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

[sgellis]

Right A pillar cleaned up and ready to start rebuilding.

Was better shape than the left side but almost same amount of work. I completely removed the seal channel. It looked quit good but after some tapping with a pick I found the small lip was rusted from the inside most of its length. A spot that wouldn't get a good layer of paint. I plan to replace it on the left pillar also.

Tapping plates for the hinges were both perfect so will remove the snapped screws and reuse.

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

[sgellis]

Right A pillar mostly finished.

I will wait until fitting up the front to trim and weld on the seal channel. Will also remove the remaining channel from the left pillar and replace it. There was more rust in the channels than I liked and so decided not to try splicing them.

_________________
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 was in the shop for a few minutes and could not resist setting up the front structure.

Few little bits to finish on each part but will fit everything to see if any adjustment need to be done first. Looks good but expect it will take a bit to get everything positioned perfectly.

The nose panel and doors will get fitted before any welding.

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

[ddutch]

That looks very good and very promising already.

[Burlyhammer]

Nice work Stan!

[ddutch]

If you set up the right side C-pillar with both cargo doors for a test fit too, you're already halfway there.

[Two Glove Boxes]

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1950 Deluxe Sedan Build

1951 Split Standard Hoffman Build

1960 Dove Blue Double Cab Patina Build

Two Glove Boxes IG

[sgellis]

Back form 10 days on the road in our 64 and in the shop for a bit.

Cleaned up the front panel and clamped on. I did not try to straiten it as I know it was the correct shape around the perimeter before removing.

Cleaned up the doors and removed a few bits. I wanted to check the door profiles to ensure they were not bent. Made a pattern off the right door and it matched the left one perfectly. Right door was in better shape than I remembered so was not concerned about it being off.

I put the pattern up to my 64 doors and they are quit different. Same left and right. Parameter and inner frame appear the same but panel bulges out more. I will check a few old doors I have and see how they look. The 64 doors did have some damage but not enough to be that much off.

Anyway, one door on and it looks good so far (Top of Left A pillar is adrift in the photo). I will need to bend the A pillar slightly at the upper hinge as I suspect it pulled it when welding in the patch.

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

[vw356]

Thank You Stan. This thread and your videos are awesome to see! I have seen every post and am learning alot! This bus will be better than when it was new!
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Current projects:
1950's Volkswagens!
51,52,54's,55,56's,57,58's,'60's And then a bunch of '60's, but the '50's are my favorites..

[Jimone]

always impressive! i love this build.
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november 1952 ragtop
november 1954 single cab

[sgellis]

Front aliened. Was worried it would not all work out perfect. Very happy with how it came out.

I did need to add a bit of bend to the right A pillar and straiten out the left side some. I did not finish them as I was quite sure they would be off. I made a pattern but left and right were different so was unsure.

Getting the windshield panels flat was a bit of work. Originally I tried with the dash in but was not quite correct. Now the dash looks close but will fit it after pillars are welded. May need a little rework to fit perfect.

So everything is in place and square and matches my 64. Was very helpful to have the 64 to check everything. Especially the windshield angles.

Now that everything fits I will mark positions and disassemble. Bulkhead and parts need some work to get perfect.

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

[sgellis]

Bulkhead and inner B pillars welded.

Once I ensured everything would fit properly with the B pillars and bulkhead in their correct position I was able weld them in. I had not welded the bulkhead gussets when I installed the bulkhead incase it needed adjustment.

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

[sgellis]

A pillars finished.

I need to fit the pillars so I can trim the seal channels.

Cut a hole in the left pillar to install the mirror nuts that I forgot.

_________________
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 am hoping someone can get me this dimension. I feel like the dash beam may have straitened out some while welding.

I get 85mm holding a strait edge on the door seal channels. if it was 92mm or more things would fall together perfect. Before I start welding things in I would like to have more confidence in how everything is fitting.

I have been trying to match my 64 but it is quite different side to side and nothing X measures correct. I am probably just trying to get things perfect and these were not.

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

[sgellis]

A pillars welded. Well the bottom anyway.

Had to move the bottoms back 3 mm but that actually made the valance ends fit the pillar better. Just needed to cut some floor away to let them move back.

I didn't weld the drip rail yet. I want to fit the windshield frame and dash beam first. I will match the windshield angles to my 64 and adjust the dash beam if needed.

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

[sgellis]

Windshield frame fitted, dash bar and heater duct welded in.

Dash bar turned out to be good and only needed the ends tweaked a bit to fit. I had the angle wrong on the front drip rail and that was causing the fit issues. I matched the windshield frame angles to my 64 and that allowed everything to fit perfect except the drip rail so easy fix.

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

[ddutch]

Nice progress on this epic rebuild.

Stan, you've probably already seen and read this article about this well known and pretty similair younger sister of your Bus, but I share the link in case you've don't; https://issuu.com/hayburner/docs/mag_didgital_issue_50/148?ff

I can see why you like the original colours of your bus, they are fantastic. It's typical how much darker the original brown seems to be compared to most repaints. No need for Sepia filters when making pictures of this bus and if anyone starts selling coffee out of a Split bus, this would be the most perfect colour combo; Coffee & Cream (out of Duraclean... )

[sgellis]

Disabled some of the rear. I need to rebuild the transmission hump panel and wheel wells next.

The metal around the VIN is still very good.

I noticed the firewall was notched buy hand at the belt line.

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

[sgellis]

Did a little experimenting with the transmission hump panel.

I bead rolled in the ribs and made a quick die to stamp in the square bit. That all worked quite well. I decided I will press in all the ribs as it is easier to get perfect ribs.

Now I need to 3D print a die set to put the 50mm radius bend across the ribs.

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