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Nova Scotian 54 standard restoration
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sgellis
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PostPosted: Sat Oct 25, 2025 6:01 am    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Think I have the transmission hump panel figured out.

I will press in the ribs and use a 3 D printed die to help with the bend.

Now to start pressing.

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Huetti_1989
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PostPosted: Sat Oct 25, 2025 2:46 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

I love that pressing tools!
They are a game changer Smile

-Christian
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sgellis
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PostPosted: Sun Oct 26, 2025 12:22 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Ruff pressing done. Lots of tidying to do but will wait until it is almost finished too fix a lot of the details.

The ribs positions came out matching the original. I am getting better at estimating the shrinkage.

Next I will form in the hump. Hopefully it will take up most of the extra metal but may need to heat shrink.

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PostPosted: Mon Oct 27, 2025 3:11 am    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

sgellis, that is stunning! You are a master.
Applause Applause Applause

sgellis wrote:
Ruff pressing done. Lots of tidying to do but will wait until it is almost finished too fix a lot of the details.

The ribs positions came out matching the original. I am getting better at estimating the shrinkage.

Next I will form in the hump. Hopefully it will take up most of the extra metal but may need to heat shrink.

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sgellis
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PostPosted: Wed Oct 29, 2025 5:10 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Bit more done. Not an easy part to get flat. I may need to put in a couple relief cuts.

It is good enough to put in the long bends so will see how the back reacts to the bend. Maybe I can get away with some more shrinking.

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sgellis
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PostPosted: Sat Nov 01, 2025 2:52 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Bends in. The 3D printed die worked great at getting the ribs around the 50 mm radius.

The bulge over the transmission is not working out so will cut it out and create that part separate. Too much extra steel there to take up.

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sgellis
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PostPosted: Thu Nov 06, 2025 7:55 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Getting bits fitted. I will need to do some repairs to the original parts before welding them together.

Always super satiating to lay an old rusty part on the new piece and having the ribs lay together perfectly. Smile

I have to do a repair to the vin. A few of the stamping were very deep and the rust from the rear made a few pin hols in the bottom of the digits. Plan is to spread a thin layer of JB weld on the back and sand smooth. I will spay a few layers of zinc on the front to prevent the JB weld from coming through. The zinc is easy to remove after.

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matthew henricks
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PostPosted: Fri Nov 07, 2025 8:29 am    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

sgellis wrote:


I have to do a repair to the vin. A few of the stamping were very deep and the rust from the rear made a few pin hols in the bottom of the digits. Plan is to spread a thin layer of JB weld on the back and sand smooth. I will spay a few layers of zinc on the front to prevent the JB weld from coming through. The zinc is easy to remove after.


Can you please expand on this and show us when you do it?
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D-train
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PostPosted: Fri Nov 07, 2025 3:34 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Bloody amazing!!
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sgellis
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PostPosted: Sat Nov 15, 2025 3:34 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Finally done... Mostly. Still a few details to add.

If doing it again I would make two parts and seam along where the fire wall panel meets.

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D-train
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PostPosted: Sun Nov 16, 2025 1:34 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Looks like a bought one! That’s impressive!
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myklsmyth
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PostPosted: Mon Nov 17, 2025 10:31 am    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Well done sir
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sgellis
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PostPosted: Thu Nov 20, 2025 7:27 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

On to the rear wheel wells.

Inner panels needed to be removed as they are very rusty along the seams. One seat bolt cover was rusted and needed removing. It had an excessive amount of spot welds. Decided I should remove the other one also.

Started patching the left side. Would be much faster to just make new ones.

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sgellis
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PostPosted: Sat Nov 29, 2025 4:03 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Left wheel well finished, mostly

I need to trim 10mm off the lower front of the inner panel. I wasn't 100% sure of the size until everything was fitted. Always easier to trim than to add some on.

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My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
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Last edited by sgellis on Mon Dec 01, 2025 4:58 pm; edited 1 time in total
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Two Glove Boxes
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PostPosted: Sun Nov 30, 2025 8:59 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Looks great!!
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ryans65
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PostPosted: Tue Dec 02, 2025 2:15 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

you're a madman, I expect no less from the barndoor forum though!!
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sgellis
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PostPosted: Sat Dec 06, 2025 1:19 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

I needed a quick part to build so finished off the front valance.

I clamped the panel in place to insure the bumper bracket holes were lined up.

The angle is 18g. Curved it with the stretcher. I clamped the panel on high and spot welded the angle on to ensure it had the correct curve.

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My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)
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Huetti_1989
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PostPosted: Mon Dec 08, 2025 2:02 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Ready for the bumper now! Very Happy

-Christian
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My 1957 SC
http://www.thesamba.com/vw/forum/viewtopic.php?t=605363&postdays=0&postorder=asc&start=0
MY 1967 Sparsamba:
https://www.thesamba.com/vw/forum/viewtopic.php?t=757182
My 1952 Panel:
https://www.thesamba.com/vw/forum/viewtopic.php?t=797388
My 1954 Deutsche Bundespost:
http://www.thesamba.com/vw/forum/viewtopic.php?t=621802
My 1961 SO34:
https://www.thesamba.com/vw/forum/viewtopic.php?t=716285
My 1991 Westfalia California:
http://www.thesamba.com/vw/forum/viewtopic.php?t=650751
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