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1967 Double Cab
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c21darrel
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PostPosted: Fri Mar 02, 2018 5:08 pm    Post subject: Re: 1967 Double Cab Reply with quote

Thanks Alan. I am not going to weld the frame. Thats above my pay grade. My buddy who will work on that is very experienced in these types of repairs. Ima let him complete that. In fact Im not going to weld in any of my gerson metal...my guy is really good and Im not. Crying or Very sad My welder is a Hobart 140, I only weld the easy stuff. I did this one.

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And thats why I only do the easy stuff.
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John Ghia
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PostPosted: Fri Mar 02, 2018 8:08 pm    Post subject: Re: 1967 Double Cab Reply with quote

sheet metal is the hardest thing to weld.
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c21darrel
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PostPosted: Tue Sep 25, 2018 4:30 pm    Post subject: Re: 1967 Double Cab Reply with quote

Im still working consistent, just not consistent with updating this thread. This was my next mistake.
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So, no turning back.
Afterwards I got it in PPG DP and sanding primer over the top. Its sanded with 100 and 220 dry. Bed, engine area, rear wheel wells, gas tank location...

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Sanding in the gastank area has to be one of the worst sanding jobs I ever had to do. There is no comfy position and there is always the divider under your back and the gas tank retaining studs (hold the straps) ripped at least 3 different shirts. Im not even sure how I am going to get paint back there.

Got my gas tank painted.
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Nose stripped, DP'ed, sanding primer, down to 220 dry.
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Sanding the front wheel wells now. Next I think I'll get my wheels sandblasted. I need to re-build my beam. Still deciding on trans work and engine.
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c21darrel
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PostPosted: Mon Mar 18, 2019 4:23 pm    Post subject: Re: 1967 Double Cab Reply with quote

Spent the last month inside the middle where the gas tank lives. This is the most miserable location to work. There is no comfortable position to get into, no matter there is a bolt and the raised area in your back or ribcage. Unless you are a small sub 100lb. high school girl you cant roll over either. I dropped a boatload of F bombs from frustration of not being able to move. Seriously how does anyone paint this?
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I decided not to spray it, instead decided to use light Grey Masterseries frame paint. Same stuff I painted the DC bottom with. I painted the roof, the supports, the wheel wells, gas tank spot, everything behind the divider top to bottom.
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2 coats, had to sand before the second coat because rain caused too much time between recoat.

I finally got the "ok" from my friend he had space for my bus. He is going to cut out all the bent and weld in my Gersons metal. Its only been 2 1/2 years of waiting. I picked up the trailer in the AM and texted several if they could assist with the loading after lunch. As is usual, no one showed up so I did it solo. The cart the bus sits on is only 36 inch wide so that makes a top heavy load. I captured the slow motion loading with a few pics. Note that I had only an inch and a half or the wheels could drop into ramp storage hole. Look close in the dark area in the second pic. Its not just a shadow, thats a hole. My driveway also isnt exactly level, a few times I was concerned it was going over. I needed several lengths of 2X4's, floor jack, several small pieces of plywood to get the caster up onto the ramps and lots of patience. I used a come-a-long and inch by inch pulled it onto the trailer. The actual loading took about an hour but I must have aged a week. 7 mile ride w/o issue. Un-loading was on better more level ground and I got help.
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Other stuff ive been working on.
I have my bumpers broken down, stripped and body worked awaiting primer.
I have glass out of the pop outs, frames stripped and ready for primer. I only cracked one piece.
Seats are all stripped, de-rusted, painted and hanging in the garage ready for upholstery.
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BulliBill
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PostPosted: Wed Mar 20, 2019 11:49 am    Post subject: Re: 1967 Double Cab Reply with quote

Way to go, we'll be following your progress! DC's are the BEST!

Bill
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squarebirch
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PostPosted: Mon Mar 25, 2019 2:49 am    Post subject: Re: 1967 Double Cab Reply with quote

Awesome work - and a cool crew cab too! Cool
Geri
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c21darrel
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PostPosted: Mon Mar 25, 2019 3:15 pm    Post subject: Re: 1967 Double Cab Reply with quote

Thanks^^
When I bought the DC it had 2 beetle wheels and no spare. It is a 67 but both bus rims were dated 8/64 so I went searching for 3 more. One Pomona swap and one OCTO and I found 3 more 8/64, 14 inch rims. A few months ago I had them sand blasted and did some repairs. I spent a little time with a BFH and wasnt getting the results. I went to a local tire shop and asked about repairing them. A younger kid helped me out. He went and got a crescent wrench and showed me it was so much easier to slide it over the edge and pull the ding back out with leverage than to hammer them out. Lesson learned. Next I sprayed them with PPG DP90 epoxy. I was just a little short on catalyst but sprayed them anyway. I expected a slow dry/cure and got it. They sat in the garage the last couple months so I assumed they had completely cured. It ended up taking all weekend sanding them, the paper was loading up way too fast, 10 sheets of 80 and 100 grit to get them ready for a mechanical adhesion to the next primer. That was another miserable sanding experience. Moving on. I took Monday morning off and got all 5 into sanding primer. I want to get these painted next week. Taking the trans to a friend in Whittier for rebuilding next week or so. I want to have tires or at least tires size picked out to figure out trans gearing. Pics.

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c21darrel
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PostPosted: Fri Jan 17, 2020 3:26 pm    Post subject: Re: 1967 Double Cab Reply with quote

9-10 months, time sure flies. I left off with priming my rims...
but I quit. I quit on painting these rims. Confused
The primer kept popping and cracking off... even after cleaning and respraying. I went and had them powder coated satin black. When I paint the bumpers I will also spray the wheels the same white.
BTW, I wont quit on the Double Cab.
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c21darrel
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PostPosted: Fri Jan 17, 2020 3:33 pm    Post subject: Re: 1967 Double Cab Reply with quote

My metal repair started at the B pillar, all Gersons metal.
The rocker under the 3rd door was pushed back, floor crunched behind pillar. Damage actually went up the B pillar, most of it came off too.
Andrew, my welder is patient and slowly worked through this area. We needed to cut it all open and pulled it out it to where it needed to be. We kept and straightened the original floor metal. After it was all in the right place we closed it all back up.




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c21darrel
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PostPosted: Fri Jan 17, 2020 3:42 pm    Post subject: Re: 1967 Double Cab Reply with quote

My door was next. The lower few inches were tweaked from previous accident/s. I had the inner and outer lower 6 inch door repair piece. The Gerson piece is a little lacking. We needed to scavenger from my original door the lower receiver part for the thru rod that locks the door. I had read about this so no surprise. Pics of it welded in place. The other side just needed a slice and spread to fit. We needed to tweak on the upper hinge to get the door to open and close and latch well. Trying to get good door seams made everything take extra time, but worth it. The B pillar is welded in except on the front side of it. Rocker back in place. Inner floor complete.


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c21darrel
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PostPosted: Fri Jan 17, 2020 3:56 pm    Post subject: Re: 1967 Double Cab Reply with quote

On to the frame repair. I had acquired replacement frame piece from front bumper to behind the beam. There must be a slight difference from early to late split busses, as it would not line up perfectly. It was wider behind the beam bolts as seen in pic. The front cross support ended in a new location, not a big deal. What we did was splice my repair piece in half, removed the back side. We left my original back part in place. We lined up bolt holes to get all in correct location. Then made a couple slices to get the metal to line up. Removing the original frame was piece by piece a slow process. The floor had to be sliced up and massaged into correct location above the frame and seat base. For such a small accident there was a lot of fixes that needed to be done so all would be correct. Now its 100% again.



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c21darrel
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PostPosted: Fri Jan 17, 2020 4:07 pm    Post subject: Re: 1967 Double Cab Reply with quote

At this point it was confirmed I needed another piece of funky green, the lower A pillar. We only used the lowest few inches of it...about the height of inner panel. We also removed the lower nose section. I had purchased inner/outer and outside Gerson panels up to under the headlight.
We went down to Harbor Freight (cmon, plenty of their stuff actually works Smile )
bought their spot welder so we could do it like the factory. We made 3 sets of prongs for different needs. I'll post some pics of them later.
pics of inner panel welded in and epoxy primed.

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c21darrel
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PostPosted: Fri Jan 17, 2020 4:11 pm    Post subject: Re: 1967 Double Cab Reply with quote

My battery tray was just so-so. I bought the replacement. Spot welder in action.

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mdege
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PostPosted: Sat Jan 18, 2020 1:19 am    Post subject: Re: 1967 Double Cab Reply with quote

Nice work!

I replace the part from the front axle beam mount to the first out rigger and was wondering why it didn't line up on mine. it never came to me, that the shape of the frame might have changed over the years. Your experience explains why the repair section didn't fit.
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Restoration of a former '65 firetruck (21F)


1988 Multivan Magnum 112i
2006 T5 (sold)
1986 Caravelle C (sold)
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Tizian
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PostPosted: Sat Jan 18, 2020 3:57 am    Post subject: Re: 1967 Double Cab Reply with quote

mdege wrote:
Nice work!

I replace the part from the front axle beam mount to the first out rigger and was wondering why it didn't line up on mine. it never came to me, that the shape of the frame might have changed over the years. Your experience explains why the repair section didn't fit.


From the Progressive Refinements:

1. Mar. 1955 20-117 902 (start of non-Barndoor)


Shift rod coupling:
now: mounted from bottom
side of vehicle. Shift rod
and transmission shift rod
with two recesses

Reinforcing frame:
Now: modified front end of
longitudinal members
Now: accelerator, clutch
and brake pedals modified
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c21darrel
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PostPosted: Sat Jan 18, 2020 12:00 pm    Post subject: Re: 1967 Double Cab Reply with quote

mdege wrote:
Nice work!

I replace the part from the front axle beam mount to the first out rigger and was wondering why it didn't line up on mine. it never came to me, that the shape of the frame might have changed over the years. Your experience explains why the repair section didn't fit.


thank you for your comments.
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c21darrel
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PostPosted: Mon Jan 20, 2020 12:57 pm    Post subject: Re: 1967 Double Cab Reply with quote

As promised. These are the tongs my friend made to get to "hard to get to" places.

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c21darrel
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PostPosted: Fri Feb 28, 2020 11:56 am    Post subject: Re: 1967 Double Cab Reply with quote

We have been working on the panel under the rear driver side window. It is a complicated panel to replace. Parts had to be welded in non original order, no way to weld in the boxed off section and the support pieces on the reverse.
First we had to repair the corner of the floor. Then we had to spot weld the B pillar back cover on. We made our own right side panel, I used the metal I cut off under the window to make the far right side of the new repair piece. Used a shrinker and stretcher to bend the metal to the rocker shape. We spot welded the two together. Probably had to fit and re-fit a dozen times to get it right.
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Next we worked on installing the supports on the back side. Had to cut the ends off because its the only way to place the entire piece in the hole. We will weld in-situ last.
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c21darrel
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PostPosted: Fri Feb 28, 2020 2:42 pm    Post subject: Re: 1967 Double Cab Reply with quote

Left/Driver side dog leg is next.
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c21darrel
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PostPosted: Fri Feb 28, 2020 2:53 pm    Post subject: Re: 1967 Double Cab Reply with quote

Final pics of under 3rd window repair.
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Its in.

Dogleg. This side I only replaced the outside piece, kept original inside piece but that didnt make it simple. Needed to move plenty to get a perfect fit.
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Apologies for the blurry pics Embarassed
Moving on to the nose. Inner and outer lower plus the 8 inch lower nose sections.
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