1963 15 Window resurrection

[Navydave73]

I am so glad you are taking these pictures, my bus roof looks exactly the same. This forum is invaluable to my restoration process. And by the way, Mastercoat should be sending you some commission for all the paint I’m buying from them. I also have a quart of PPG 33127 fleet gray for the underside.

I’m also planning on spraying the internals of the front while i have the nose off.

[braddick]

Once again, love your work
Really enjoying your build

[diegormz82]

Nice Job! I'm working also in my 1963 15 windows and definitely all this process you're describing here will be very helpful!!

regards

Diego R

[Burlyhammer]

[Burlyhammer]

[Burlyhammer]

[Burlyhammer]

I still haven't decided exactly what I am going to do with the roof. I was going to save as much of the OG roof that I could, but what is left currently will still need repairs There are rust holes from where the roof was dented in, etc.). I am trying to decide if I should replace the whole skin. I would still need to use multiple pieces since I do not have an entire clip. I am getting all of the pieces prepped so we could go either way, I am leaning towards replacing the entire roof skin. Here is where we are:

The front donor section fits well:

Punching holes:

Prepped:

Final fit:

Ready to weld (if I replace the whole skin, I am going to remove the donor section going over the cargo doors. That piece will need to go on the other side to repair the rusted donor piece)

The other main roof section is from the 60 15 window bus hanging on the shop wall. The spot welds from the 65 roof clip had spot welds holding the skin to the drip rail spaced about every 1/2" The guy welding the roof on the 60 must have been paid for each spot! Maybe he was new and trying to be impressive!

I'm going to prep this roof with the intention of using the entire rear section, and see what happens:

I stopped last night around 6 Hopefully the rust haze has cleared up.
Happy Thanksgiving. I hope everyone gets to spend some quality time with family, and in the shop!!!

[sgellis]

[Burlyhammer]

[DSweinhagen]

Nice work on the roof so far! As you found out, it's very difficult to dissect a donor roof and save all the pieces. I've found those spot welds right next to each other before, making a continuous weld. I think your approach of grinding the gutter and support away from the skin is a good one. Your gutter and upper support doesn't look too bad but can't tell? It's nice that Autocraft makes those parts now and WW sells them here but some of those pieces are difficult to ship so not sure if that helps you.

Anyway, looking forward to see how you sort this all out and great to see you getting near the end. Thanks for sharing!
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David S

[KWZ]

My mind is blown! I’m sitting here pretending to watch the Macy’s Thanksgiving Day Parade with the kids while mentally tossing off to this thread. Incredible work. Every bus I cut up in the 90s was restorable apparently ....
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'57 sunroof Standard
'63 15 window
'65 Westy SO44

[mcarls]

I've enjoyed this particular thread from day one. Just amazing the skills and patience that's gone into this great build. Thanks again for sharing. The roof is going to be awesome-I can already tell!

[BarryL]

Does that one rear roof have speaker mounts?

[Burlyhammer]

[Burlyhammer]

[Burlyhammer]

[Burlyhammer]

[Burlyhammer]

I fixed the rusted hole in the drip rail:

I cleaned up the rest of the drip rail and started prepping the main donor roof section:

The 63 roof had 7 tabs in the rear of the roof to hold a rod for the head liner. The 60 only had 3 and they were farther forward than the ones on the 63:

Now the fun begins:

[edgood1]

Wow... just....wow.
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1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia

[Burlyhammer]