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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Sun Jun 04, 2017 12:40 pm Post subject: Re: Hello from the UK! |
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With all of the rotten metal cut away, we could Vactan rust treat any areas hidden away, sort out new metal, get that welded in nicely and painted up ready for the new rear valance.
New section welded into the edge of the rear corner
And finally the new rear valance.
We're pleased with how this has gone, all that remains is a few welds to dress, some etch primer and we're done _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Sun Jul 16, 2017 1:49 pm Post subject: Re: Hello from the UK! |
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We managed to get the rear valance etch primed followed by a coat of high build primer, that's another little job out of the way, I'm pleased to say!
Our attention is now focused on replacing the front panel, parts of the windscreen lip had bad corrosion, as did the bottom.
Removal of the lights and grill showed up some nasties:
the section where the airbox assembly had a large gap, tapering further apart as it went towards the drivers side
We had suspicions of accident damage. _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Sun Jul 16, 2017 1:56 pm Post subject: Re: Hello from the UK! |
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As we started to remove the front panel, it became more obvious that something was amiss
the inner windscreen panel was miss shaped and needed replacing but not only that, complete removal of the panel revealed a very badly damaged airbox
it was pushed back considerably, dented and again, we felt needed replacement. _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Sun Jul 16, 2017 2:03 pm Post subject: Re: Hello from the UK! |
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The logical thing to do was to source a new airbox, FBI VW came up with one luckily. We stripped the front bare to check for further damage, none was found
The left and right hand A pillars are all good, luckily!
Inner screen panel replaced, the new front panel was used to get the alignment set correctly before it was welded up securely and painted
Front panel rechecked for fitting
hopefully we will be able to weld the airbox up next _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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Wasted youth Samba Member
Joined: July 06, 2012 Posts: 5134 Location: California's Hot and Smoggy Central Valley
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Posted: Sun Jul 16, 2017 10:50 pm Post subject: Re: Hello from the UK! |
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That's an impressive amount of work! Are you happy with the way those panels are fitting up? What brand are they? |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Mon Jul 17, 2017 1:46 pm Post subject: Re: Hello from the UK! |
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Wasted youth wrote: |
That's an impressive amount of work! Are you happy with the way those panels are fitting up? What brand are they? |
The rear valance was a superb fit, that was made by Autocraft here in the UK, the inner windscreen repair panel is Genuine VW, quite a good fit but not as good as the original.
The front panel is IGP, it looks good and offering it up, I think we will be fine - trial runs suggest this will be fine.
We know that measure, measure, measure and do one final measure is essential. We rebuilt our '73 kombi a couple of years ago and with the westy, we plan to use lessons learned to do a better, more sympathetic restoration. _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Wed Aug 09, 2017 1:45 pm Post subject: Re: Hello from the UK! |
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Got quite a few odds and ends done this past couple of weeks, heated rear window switch replaced and sorted..working as it should now, the wiring had been hidden and the switch removed.
Whilst the Dashtop was off, we repainted it Satin Black, installed a Rev Clock and Oil Pressure gauge, ensured the wiring was nice and tidy in sleeving, nice and neat!
The replacement airbox is from an earlier bay, possibly up to 1975 - the steering column support plate was different, couple of holes drilled to line up with the ones on the airbox and we're sorted and the plate bolted up securely.
_________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Wed Aug 09, 2017 1:52 pm Post subject: Re: Hello from the UK! |
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Got the new airbox mounted and lined up with the inner windscreen panel, couple of runs of weld once it was lined up okay & its looking something like reasonable again. We gave the out of sight areas a good coating of Rustoleum to keep any rusting to a minimum
Front panel is now on and spot welded on the airbox, windscreen lip and bottom lip, lining up very well!
The front panel is all welded up, etch primed, high build primed and the deformation panel has had a coat of Schultz Stone chip protection
We have some seam sealing to do followed by a final coat of high build primer before colour _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Fri Sep 15, 2017 1:22 pm Post subject: Re: Hello from the UK! |
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Made a huge amount of progress since I last updated this thread.
The front panel is seam sealed where necessary, painted and clear coated:
The indicators and headlights have been refitted and wired back up, working correctly
Radio aerial fitted and working
Wiper motor refitted and the associated seals fitted, washer jets reconnected.
Fresh air flaps refitted, linkage set up okay
Fly screen and front grill back on
Next up, refit the dashtop and windscreen/wipers. _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Wed Sep 27, 2017 1:36 pm Post subject: Re: Hello from the UK! |
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Made some really good progress this past couple of weeks, the front end is pretty much complete aside of fitting a VW emblem and the front bumper (which can wait till its been resprayed).
The dashtop and vents have all been refitted along with wiring up an oil pressure gauge and rev counter. Grab handle and padded top cleaned up, refitted & tightened up snug
The windscreen has been refitted successfully as have the wiper arms & blades
Our next section to work on is the left hand battery tray, which needs replacing as the PO cut a hole in it to allow a remote oil cooler to get air blown over it
_________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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KentABQ Samba Member
Joined: September 11, 2016 Posts: 2406 Location: Albuquerque NM
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Posted: Wed Sep 27, 2017 4:32 pm Post subject: Re: Hello from the UK! |
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That's quite a facelift you've accomplished in a relatively short amount of time. Your bus is looking great! Keep up the good work. And thanks for posting updates on the progress. _________________ -Kent-
1976 Riviera, 1.8l FI chrome yellow VAN - "Chloe"
"I must say, how can you be in a bad mood driving this vehicle full of vibrant color.
Cars of today are so bland in comparison. It's like driving a celebration!" ---WildIdea
Bus ownership via emoticons:
---williamM |
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Wasted youth Samba Member
Joined: July 06, 2012 Posts: 5134 Location: California's Hot and Smoggy Central Valley
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Posted: Wed Sep 27, 2017 7:10 pm Post subject: Re: Hello from the UK! |
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That really is a lot of work! You should get many great years of service out of that. Very inspiring!
Did you replace the white plastic air vent hinges on the two fresh air flaps? Mine should be replaced, but I have not looked at a source yet. |
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Sloride Samba Member
Joined: February 09, 2002 Posts: 926
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Thu Sep 28, 2017 4:48 am Post subject: Re: Hello from the UK! |
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KentPS wrote: |
That's quite a facelift you've accomplished in a relatively short amount of time. Your bus is looking great! Keep up the good work. And thanks for posting updates on the progress. |
Thanks Kent, we had worries when we revealed the damage to the front however, we took our time, measured everything several times over and luckily, have our '73 for reference.
We have quite a lot to do yet, work wise _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Thu Sep 28, 2017 4:50 am Post subject: Re: Hello from the UK! |
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Wasted youth wrote: |
That really is a lot of work! You should get many great years of service out of that. Very inspiring!
Did you replace the white plastic air vent hinges on the two fresh air flaps? Mine should be replaced, but I have not looked at a source yet. |
Thanks dude, we are hoping for a good few years out of the bus, we've had him six to date & used it a heck of a lot! Notchboy's westy got me going on the restoration as the bus had been parked in the garage doing nothing for a couple of years. It was a shame it was sat!
The plastic air vent hinges where okay, just a smear of lube on them and all was well, no wear present.
I don't know who may have any, a breaker I guess _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/
Last edited by MorkC68 on Thu Sep 28, 2017 4:54 am; edited 1 time in total |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Thu Sep 28, 2017 4:52 am Post subject: Re: Hello from the UK! |
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Sloride wrote: |
Looks good and all done in that small garage. I thought I was the only one working under those constraints. |
I can be cramped in there, at times, we are in the process of moving house to one with a big garage (the one in the photo's is at my parents). We will have a bit more room to work with _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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tommu Samba Member
Joined: November 15, 2011 Posts: 618 Location: L.A.
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Posted: Thu Sep 28, 2017 7:07 pm Post subject: Re: Hello from the UK! |
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MorkC68 wrote: |
Sloride wrote: |
Looks good and all done in that small garage. I thought I was the only one working under those constraints. |
I can be cramped in there, at times, we are in the process of moving house to one with a big garage (the one in the photo's is at my parents). We will have a bit more room to work with |
That drive looks pretty steep too. A worry when you're going for a test drive. _________________ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Fri Sep 29, 2017 4:43 am Post subject: Re: Hello from the UK! |
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tommu wrote: |
MorkC68 wrote: |
Sloride wrote: |
Looks good and all done in that small garage. I thought I was the only one working under those constraints. |
I can be cramped in there, at times, we are in the process of moving house to one with a big garage (the one in the photo's is at my parents). We will have a bit more room to work with |
That drive looks pretty steep too. A worry when you're going for a test drive. |
The steep drive is temporary, a flat drive beckons! But not till March 2018
We keep our fingers crossed and hope the brakes dont fail _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Fri Oct 27, 2017 1:54 pm Post subject: Re: Hello from the UK! |
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The battery tray is now done, went really well I'm glad to say.
Tack welded in place to check alignment.
Welded up and seam sealed.
When the engine bay gets repainted, we will attend to the battery tray & paint in body colour. _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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MorkC68 Samba Member
Joined: December 23, 2015 Posts: 610 Location: Nottingham, England
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Posted: Fri Oct 27, 2017 1:59 pm Post subject: Re: Hello from the UK! |
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With no particular order in how we are tacking the various sections of the bodywork etc, we moved back up front to tackle the cab floor.
The swivel base needed removing, degreasing and freeing up. We did find two little areas behind each seat belt mount which had rusted through, noting too big, 25mm x 25mm at most.
Left hand side
Right hand side
The cab floor is in great condition, surface rust only. This has been cleaned up, Vactan treated and red oxide painted
The cab floor has got colour on it, I'm just waiting for it drying _________________ Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System
My blog: https://twolatebays.wordpress.com/ |
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