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jtauxe 
Samba Member
Joined: September 30, 2004
Posts: 5780
Location: Los Alamos, New Mexico
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 Posted: Thu Jan 14, 2021 9:17 am Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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| deepcflea wrote: |
Finally got the gas tank area cleaned up, treated with some metal prep (didn't get an after pic, was too excited to get it done), painted with POR-15, then sprayed POR-15 grey top coat. Pretty close, or close enough for me to the original grey that was in there. Also, applied new seam sealer.
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Oh, man I did that job, too. Twice (two different trucks). Did you enjoy working in the cramped gas tank compartment with solvents and paints as much as I did (not)? What a miserable job, getting all contorted to reach in there... can't even turn over without getting out first... I hated doing that. But the final result makes it worth it! Nice work.
_________________
John
"Travelling in a fried-out Kombi, on a hippie trail, head full of zombie..." - Colin Hay and Ron Strykert
http://vw.tauxe.net
1969 Transporter, 1971 Westfalia, 1976, 1977, 1976, 1977, 1971, 1973, 1977 Westfalias,
1979 Champagne Sunroof, 1974 Westfalia Automatic, 1979 Transporter, 1972 Sportsmobile, 1973 Transporter Wild Westerner, 1974 Westfalia parts bus, 1975 Mexican single cab *FOR SALE*, 1978 Irish 4-door double cab RHD
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Thu Jan 14, 2021 9:28 am Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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Yeah John, that was a miserable job that I wouldn't wish upon my worst enemy! Grunts, groans, heavy breathing, uncomfortable, getting stabbed by the tank hold down bolts, getting shirt snagged while trying to get out... ahhh yes, all while wearing a respirator. Horrible!! Soooo glad it's done!!
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Fri Jan 15, 2021 6:55 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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Got the engine bay painted using Wolfsburg West L90D Pastel White rattle can paint. I can finally start putting this thing back together!! Yahoo!!
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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earlybayjim
Samba Member
Joined: July 12, 2013
Posts: 249
Location: East Dubuque, IL
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| Posted: Fri Jan 15, 2021 7:40 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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It turned out amazing! I'd never guess that was a rattle can job!
_________________
1971 Chianti Red Westfalia x2
1985 Westfalia
1984 tintop |
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bvolks
Samba Member
Joined: April 26, 2004
Posts: 845
Location: New Brunswick, Canada
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| Posted: Fri Jan 15, 2021 7:49 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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| jtauxe wrote: |
| deepcflea wrote: |
Finally got the gas tank area cleaned up, treated with some metal prep (didn't get an after pic, was too excited to get it done), painted with POR-15, then sprayed POR-15 grey top coat. Pretty close, or close enough for me to the original grey that was in there. Also, applied new seam sealer.
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Oh, man I did that job, too. Twice (two different trucks). Did you enjoy working in the cramped gas tank compartment with solvents and paints as much as I did (not)? What a miserable job, getting all contorted to reach in there... can't even turn over without getting out first... I hated doing that. But the final result makes it worth it! Nice work. |
I think I'm going to have to lose a few pounds before I tackle that area on mine. Lol. Unfortunately, mine needs some rust repair in there too.
_________________
1985 Diesel Jetta Coupe (temporarily retired at
756,000 km)
1971 Doublecab project
1995 Golf CL
1974 Beetle
1978 Westfalia |
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Tue Jan 19, 2021 5:02 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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Got the gas tank cleaned up and painted. Used the POR15 tank sealer... before I read some threads on it might not be a good idea  we'll see...
Then got it installed with new vent lines, felt pads, and filler neck. Don't like how the filler neck to metal tube to other filler neck fits (yes, I got the double cab filler neck)... I guess I'll have to keep an eye on the first fill up and drive around.
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Tue Jan 19, 2021 5:18 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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So a long time ago I read a thread about heat duct options and read about this AeroDuct stuff used in the aviation field, seems like it will last forever. Not concerned with heat, so it's more cosmetic than anything. Anyway, bought some and sprayed it with rubberized undercoating to give it a more stock look.
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Wed Jan 20, 2021 8:46 am Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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Started reinstalling the wiring harness back to the engine bay. As you can see, I left it exposed vise putting in a new wire harness tube in center frame area.
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Wed Jan 20, 2021 5:24 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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So some before and afters of the rear suspension parts.
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Wed Jan 20, 2021 5:27 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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Time to get the rear axles put together. New torsion bar bushings. Rear bearings looked good, so I just cleaned and repacked. New seals installed. New bolts from Belmetric for bearing housing.
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Wed Jan 20, 2021 5:34 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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New backing plate. New soft brake lines. New emergency brake cable. New Koni shocks.
Before...
After...
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Wed Jan 20, 2021 5:44 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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Question... So the old backing plate did not have the brake hold down pins or anti rattle pins, whatever you want to call them. I know they did away with them in year ??? but my new backing plates have the holes for them as well as the brake shoes. I have some of the pins, should I put them in or no?
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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busdaddy
Samba Member
Joined: February 12, 2004
Posts: 51144
Location: Surrey B.C. Canada, but thinking of Ukraine
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| Posted: Wed Jan 20, 2021 5:49 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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Looking good. 
| deepcflea wrote: |
| I have some of the pins, should I put them in or no? |
Can't hurt, if you have them use them....
Don't throw out those old backing plates, there's guys in the rust belt that would give their left nut for nice examples like that.
_________________
Rust NEVER sleeps and stock never goes out of style.
Please don't PM technical questions, ask your problem in public so everyone can play along. If you think it's too stupid post it here
Stop dead photo links! Post your photos to The Samba Gallery!
Слава Україні! |
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Wed Jan 20, 2021 6:00 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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Yeah I held onto them. Got new ones cause there is a rust hole above the adjusters. I just cleaned them up and put them in my "OG parts replaced on bus" box. If someone was really motivated for some OEM ones they could have them repaired. I just had the new ones sandblasted and powdercoated so hopefully they last forever.
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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jtauxe
Samba Member
Joined: September 30, 2004
Posts: 5780
Location: Los Alamos, New Mexico
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| Posted: Thu Jan 21, 2021 1:27 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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That is looking great. It is sooooo satisfying to be in reassembly mode, no? Like putting the wires back in the fresh engine bay. It feels like new vehicle. So sweet.
_________________
John
"Travelling in a fried-out Kombi, on a hippie trail, head full of zombie..." - Colin Hay and Ron Strykert
http://vw.tauxe.net
1969 Transporter, 1971 Westfalia, 1976, 1977, 1976, 1977, 1971, 1973, 1977 Westfalias,
1979 Champagne Sunroof, 1974 Westfalia Automatic, 1979 Transporter, 1972 Sportsmobile, 1973 Transporter Wild Westerner, 1974 Westfalia parts bus, 1975 Mexican single cab *FOR SALE*, 1978 Irish 4-door double cab RHD
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Thu Jan 21, 2021 3:09 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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| jtauxe wrote: |
| That is looking great. It is sooooo satisfying to be in reassembly mode, no? Like putting the wires back in the fresh engine bay. It feels like new vehicle. So sweet. |
Yes!! So excited to be in this phase! Love how it all looks brand new! Pretty satisfying after all the hard work to get it to this point.
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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dstimm
Samba Member
Joined: June 29, 2018
Posts: 153
Location: Encinitas, CA
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| Posted: Thu Jan 21, 2021 4:17 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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| bvolks wrote: |
| jtauxe wrote: |
| deepcflea wrote: |
Finally got the gas tank area cleaned up, treated with some metal prep (didn't get an after pic, was too excited to get it done), painted with POR-15, then sprayed POR-15 grey top coat. Pretty close, or close enough for me to the original grey that was in there. Also, applied new seam sealer.
|
Oh, man I did that job, too. Twice (two different trucks). Did you enjoy working in the cramped gas tank compartment with solvents and paints as much as I did (not)? What a miserable job, getting all contorted to reach in there... can't even turn over without getting out first... I hated doing that. But the final result makes it worth it! Nice work. |
I think I'm going to have to lose a few pounds before I tackle that area on mine. Lol. Unfortunately, mine needs some rust repair in there too.
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I am doing the same job right now on my double cab. I was under there with a vacuum, a wire wheel, and rust inhibitor. What a horrible job. Can't wait to get it even better and clean it so it can be painted. What cleaners did you end up using?
_________________
1979 Sage Green California Westy. |
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Thu Jan 21, 2021 4:34 pm Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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| dstimm wrote: |
| bvolks wrote: |
| jtauxe wrote: |
| deepcflea wrote: |
Finally got the gas tank area cleaned up, treated with some metal prep (didn't get an after pic, was too excited to get it done), painted with POR-15, then sprayed POR-15 grey top coat. Pretty close, or close enough for me to the original grey that was in there. Also, applied new seam sealer.
|
Oh, man I did that job, too. Twice (two different trucks). Did you enjoy working in the cramped gas tank compartment with solvents and paints as much as I did (not)? What a miserable job, getting all contorted to reach in there... can't even turn over without getting out first... I hated doing that. But the final result makes it worth it! Nice work. |
I think I'm going to have to lose a few pounds before I tackle that area on mine. Lol. Unfortunately, mine needs some rust repair in there too.
|
I am doing the same job right now on my double cab. I was under there with a vacuum, a wire wheel, and rust inhibitor. What a horrible job. Can't wait to get it even better and clean it so it can be painted. What cleaners did you end up using? |
Same thing you are doing to start off with. Vacuumed the crust of dirt and crud in there. Then lots of wire wheeling, even some needle gunning, vacuum, blow out using L.P. air. Then I used the POR-15 system. POR-15 degreaser first, rinse, blow dry... POR-15 metal prep, rinse, blow dry... Then I had some silver POR-15 paint leftover, brushed that on. Used the POR-15 filler/seam sealer on the seams. Then I had some flat grey POR-15 spray paint for the final coat. Horrible job! If you use any of the POR-15 stuff in there... definitely use a respirator. It's nasty stuff.
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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jtauxe
Samba Member
Joined: September 30, 2004
Posts: 5780
Location: Los Alamos, New Mexico
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| Posted: Fri Jan 22, 2021 9:17 am Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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It's a horrible job, indeed. I think it is the worst VW job I have encountered. The hardest part is getting on the back side of the wheel buckets. It's a collection point for dirt, with only a small drain hole accessed from in the engine compartment, as seen here (the drain is the small "outie" at the bottom of the vertical panel):
That's poor design, if you ask me. Hard to get stuff out, and even once you think you have it cleaned out, you are painting blindly.
And yet, it has to be done.
_________________
John
"Travelling in a fried-out Kombi, on a hippie trail, head full of zombie..." - Colin Hay and Ron Strykert
http://vw.tauxe.net
1969 Transporter, 1971 Westfalia, 1976, 1977, 1976, 1977, 1971, 1973, 1977 Westfalias,
1979 Champagne Sunroof, 1974 Westfalia Automatic, 1979 Transporter, 1972 Sportsmobile, 1973 Transporter Wild Westerner, 1974 Westfalia parts bus, 1975 Mexican single cab *FOR SALE*, 1978 Irish 4-door double cab RHD
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deepcflea
Samba Member
Joined: June 06, 2006
Posts: 150
Location: Sumter, SC
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| Posted: Fri Jan 22, 2021 11:09 am Post subject: Re: 1978 Double Cab - Marilyn - Refurb thread |
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| jtauxe wrote: |
It's a horrible job, indeed. I think it is the worst VW job I have encountered. The hardest part is getting on the back side of the wheel buckets. It's a collection point for dirt, with only a small drain hole accessed from in the engine compartment, as seen here (the drain is the small "outie" at the bottom of the vertical panel):
That's poor design, if you ask me. Hard to get stuff out, and even once you think you have it cleaned out, you are painting blindly.
And yet, it has to be done. |
I agree, poor design. That area collects dust, dirt, rocks, etc... and traps moisture. Mine was filled, and hardened to almost cement.
I used a long curved air gun to get into that area from inside the gas tank area and blow out the dirt and rocks that were in there. Must have done that 100 times and stuff just kept coming out.
Eventually I had to weld a new piece of metal in that area after I found it had some cancer. Then used some Eastwood internal frame coating that came with a long hose and sprayed... blindly, back in that area from inside the gas tank area.
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd
Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy |
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