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'Let's Go! Scotland-Croatia and onwards in our Kombi!'
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busdaddy
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PostPosted: Fri Jul 23, 2021 4:29 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

No doubt you've studied vapour barrier threads and know of the added flap on it?
I'd be vacuuming out those doors and blowing some rust preventative wax in there before the lid goes back on, make sure the drains are clear as well (little bumps in the inner skin hidden under the seals that form a gap between the skins).

Keep it up with the adventure pics, you visit some fantastic places and it's cool to see them from a bus drivers perspective.
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mcdonaldneal
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PostPosted: Sat Jul 24, 2021 7:08 am    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

Thanks Busdaddy. Yes, any new job on the Kombi involves endless reading around in the Bentley and on TheSamba until I summon up the courage to dive in!
I removed the passenger side door panel today (our left) and was surprised to find a mostly intact vapor barrier, peeled away at the top rear, badly repaired at the bottom front and with much extraneous plastic and sellotape! It’s clear I can’t use it but I’ll inspect how it is attached in detail and work out what clips and grommets need replacement. The bottom part of the panel is kind of damaged but I can’t see yet if it is water damage, glue, foam or what. The bottom clips are rusted though but I’m sure the panel is very salvageable.


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mcdonaldneal
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PostPosted: Sat Jul 24, 2021 7:13 am    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

In a parallel project, the cleaned material of the slider panel is still too baggy and will rub against the wheel arch every time the door opens, so we’ve decided to remove it, wash it in the machine and install new foam and double sided carpet tape to stick the material to the card panel.


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PostPosted: Sat Jul 24, 2021 8:42 am    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

Colin has a great post for making new vapor barriers...
https://itinerant-air-cooled.com/viewtopic.php?f=49&t=9122
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mcdonaldneal
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PostPosted: Sat Jul 24, 2021 3:15 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

Thanks KentABQ, I am closely following Colin’s guidance!
Although my passenger vapor barrier was damaged and displaced I was able to see how it was originally installed:
The plastic nearest the card comes down as far as the edge of the flow through vent and is stuck/trapped there. That top piece actually goes straight across at one level and a second piece is added on at the lowest part of the door, and taped/stuck to the main plastic piece.
The ‘flap’ is at the level of the cut-out in the door metalwork and although it is stuck to the main piece for exactly the width of the cut-out it does extend a little at either end, kind of inside the door.
The door pull and the window winder are effectively punched through the plastic sheet.
By mounting the plastic on the removed card panel and lining up the grommet holes I get a better idea of the whole orientation.

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mcdonaldneal
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PostPosted: Sat Jul 24, 2021 3:22 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

I don’t know what the crud was at the bottom of the door card, but I carefully scraped it off with a chisel and then strengthened the water damaged card with wood glue.
Then I moved on to removing the door lock. The later door is a bit different from Bentley, so I took a couple of pics to remind me of the orientation of the door release rod and how the lock wriggled out of the door (I didn’t seem to have a ‘rear window track’ to remove).

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mcdonaldneal
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PostPosted: Sat Jul 24, 2021 3:29 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

Oh my, the door lock was unbelievably filthy! No wonder the key had been getting a bit stiff!
I have cleaned the bejesus out of it, including removing the lock barrel and cleaning it in alcohol. The lock will get lubricated with graphite and everything else will have gear oil on the rotating parts and a thin coat of grease on the sliding parts. I took pics of the special door lock rod clip and the orientation of the tiny spring that will give the key a smooth action that it hasn’t felt for years!
A good day!

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busdaddy
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PostPosted: Sat Jul 24, 2021 4:46 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

Blah!, that was dirty!

No doubt you've read up about both potential missing or broken springs, if your door doesn't unlock itself when closed with the lock button down (and not squeezing the outer handle while closing) the spring is gone. Another indicator is a very hard to turn key when unlocking. Later doors don't have that rear window track, yours is normal.

I've repaired door cards like that with polyester resin and fiberglass cloth in the past, we'll see how the glue does long term. With an intact vapour barrier and inner flap that diverts window leakage back into the door it should last a long time.
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mcdonaldneal
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PostPosted: Sun Jul 25, 2021 3:25 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

Thanks Busdaddy. The two usual springs are intact but I managed to bend another spring! The one built into the door handle that lets the trigger spring back is awkward to replace without getting it off line. Eventually sorted it so it works smoothly though!

One rewarding task today was cleaning the old adhesive, foam and dust from the door skin nearest the cabin, lovely.
The inside of the door though is a mixture of dried debris, grease, cavity wax and some surface rust. My guess is that the door has failed to drain at some stages of its life and was predominantly facing uphill, as all the rustiness is at the rear, near the flow through vent. You can see it in the pics. It is a pretty horrible area to rub down the rust, although I have attacked it with small pieces of sandpaper to some effect.
My plan is to degrease, rust convert and then use Eastwood rust encapsulator aerosol, primer and colour and eventually cavity wax or fluid film.
I will remove the grommet at the lower part of the inside door, as I would rather any water can drain out, and I will drill a new drain hole at the bottom rear as there is no effective drainage there.


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mcdonaldneal
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PostPosted: Mon Jul 26, 2021 1:55 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

So, further disassembly of the door today. I removed the door check strap to gat access to clean the hinge area and stupidly thought I could retract the strap with the assembly out of the vehicle. The 44yr old rubber parts immediately snapped and I cursed under my breath. Luckily I have a spare door check strap, but it’s a shame to have done it.
My bright idea for the inaccessible inner door to prep for paint was to spray in concentrated degreaser, leave a while and then use a pressure washer to blast all the crap out. Worked a treat and then I used the airline to get rid of most of the water and left it to dry in the sun.


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mcdonaldneal
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PostPosted: Tue Jul 27, 2021 1:29 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

Slow progress on the doors.
I’m just doing the drivers door at the moment and the weather was good enough to rust treat the inside of the door, rinse and dry and get a couple of coats of rust encapsulator. It’s not perfect, but I’ll leave it for a few days and put in some sort of wax before the trim panel goes back on.
We are going camping at the end of the week. The doors won’t be finished, but we do need the locks and handles back on! I fitted the clean, lubed hardware and it is an absolute delight to use. I spent many happy minutes clicking the lock back and forwards and opening and shutting the door!
The replacement check strap is very good quality and is working very well. With my newfound knowledge I was able to carefully remove and clean the passenger side check strap without breaking it and it too works perfectly now. (The pic is the clean, original passenger side).


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mcdonaldneal
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PostPosted: Thu Jul 29, 2021 3:41 am    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

We were planning a couple of days camping, so I didn’t want to take off the passenger side locks but I was able to clean and degrease the inside. It actually looks better than the drivers side, so I will prep and paint as the drivers door.

We had an early start this morning. Just over two hours drive to the seaside town of Ayr, near to where Shona grew up. She has gone for her dental appointment and I am sitting admiring the view with the cat. Sadly, the temperature has plummeted but we are cosy enough.


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mcdonaldneal
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PostPosted: Sat Jul 31, 2021 2:22 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

Well, we had a great couple of days away. Long walks to remote castles, churches and a very acceptable campsite in Ayr.
Time for some shopping on the way home and even managed to get the rust treatment done on the passenger door before bedtime!

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mcdonaldneal
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PostPosted: Sun Aug 01, 2021 10:55 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

I’ve almost (but not quite) finished the front door refreshment. They are both painted inside and I ‘just’ need to clean the lock mechanism on the passenger door.
However, I had an extra pair of hands today and so I took advantage by taking the sliding door off…
I wanted to clean and lubricate the hinge and rollers and I suspect the nylon block has broken recently, as it has started wobbling at the top roller.
Following a combination of Amskeptic and the Bentley I eventually got the track cover off, but it was pretty stuck with dust, grime and old paint. The track is of course filthy and in blowing away the loose dirt with the air line I revealed some rust at the lower edge of the track rails.
I was a bit despondent (as was my assistant!) but after cleaning, the rust does seem superficial, and not extending as far as the bend line in the bodywork, so I think I will be able to rub down to bare metal and prime and paint.
I’ve also cleaned the lower door track of grease and I will prep and paint that at the same time. The old seal has come out intact, so I will probably clean and reuse it.


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mcdonaldneal
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PostPosted: Mon Aug 02, 2021 1:18 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

I had a day free today, so I set to cleaning up the slider tracks. Not pleasant, but there are worse profiles to rub down and clean. A combination of abrasive paper, scotchbrite pads, scrapers and degreaser eventually got everything reasonably clean.
I have decided to use phosphoric acid prep and a rust stable primer, which is applied with a brush so should get to all the slider track surfaces. Then white primer and body colour on top. I’ll give it as long as I can to cure, but I guess it is quite likely to rub off where the rollers run but it’s hard to avoid that.
I’m leaving the sliding door furniture until I have done the paint, and I have sourced a replacement bearing and nylon block for the hinge element.


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PostPosted: Tue Aug 03, 2021 10:41 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

Thank you for posting your progress….. I check on you every night! You are a few steps ahead of me, and keep me “ going”. You are doing a great job! Best Wishes, Bob
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mcdonaldneal
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PostPosted: Tue Aug 03, 2021 11:30 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

The Volkswagen Ranch wrote:
Thank you for posting your progress….. I check on you every night! You are a few steps ahead of me, and keep me “ going”. You are doing a great job! Best Wishes, Bob


Hi Bob, thanks for the post. I had a look at your thread and you are doing great work, there are so many similarities in our buses and the work you are doing. I suspect your bus has slightly better ‘bones’, as ours has suffered from 20 years in the Scottish climate (but was very solid before that).
I always feel I am making slow progress, but I guess that’s just the way it goes, I’m impressed you have made such a good recovery from your back problems.

I don’t have pics yet, but I spent the whole day yesterday masking up the channels and applying rust treatment. Then, just as I was ready to paint, it started raining! So, I moved the Kombi into the garage and brushed on two coats of rust treatment primer and hopefully I’ll be able to spray white primer today. Like you, I’m using colour matched rattle cans, and I find it can turn out pretty well for small areas.
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PostPosted: Wed Aug 04, 2021 5:05 am    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

I am far from the worlds best painter. Too impatient.
The red primer from yesterday doesn’t have a great finish, but it’s just a base. The white primer went over the top, at which point I realised that the one very visible bit of painting is the entry step. I had made a change in my plan from spray primer to brush-on and I always forget how visible the brush marks are. So, I rubbed down the step with fine abrasive and I’ll start again on that!


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PostPosted: Wed Aug 04, 2021 8:34 am    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

In between coats of paint I started on the sliding door hardware.
Removal revealed that the hinge and roller assemblies were really caked in dirt and grease. I’m actually amazed that the door worked as smoothly as it did!
I haven’t disassembled for a proper clean yet but a toothbrush and kerosene, followed by some alcohol does at least mean I can see what’s what.
Can I be amazed also that the 44yr old felt washers under the rollers are still intact?! I wonder if I dare risk cleaning them a little?
It was a pleasure to clean off some ugly overspray on the hinge mechanism. It’s been bugging me for years!
As I had guessed, the nylon block is broken.


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PostPosted: Wed Aug 04, 2021 10:40 pm    Post subject: Re: 'Let's Go! Scotland-Croatia and onwards in our Kombi!' Reply with quote

You are doing just fine on your painting. If there’s any “ trick “‘to painting with rattle cans, I have learned that patience is the key. You have already noticed that it takes more paint of this particular color to bring up
the proper depth of color. The reason for this is that the amount of solids used to make our particular color have been reduced by EPA in the past few years. I have found that prepping a smooth surface followed by 2-3 coats of Rustoleum
“Filler primer” provides a good base for the final paint color. It is a medium grey color, and apply each coat as a thin coat. Let each dry 1/2 hour to 45 minutes. After coverage looks uniform, start applying the first 3 coats of color . Again, these are thin coats, using a “criss-cross” pattern . Again let each dry 30-45 minutes. On the 4th coat start laying down a thicker coat . You will know when you have it “ right” as it will cover evenly, and look like glass. Let this final coat dry over night. If you have an uneven coverage, too much paint, or not to your liking, just lightly sand with 2000 grit ( wet sand) then buff with Meguire’s
“ pro speed” compound with a variable speed buffer under 1800 RPM with a wool bonnet. Follow up with “ swirl remover “ and you will have the kind of finish you are looking for. I used single stage acrylic enamel to match the type of paint the MAACO shop used ( PO had it shot by MAACO). The paint job they did on the bus was maybe a 7/10. By using this method and touching up , it should look nice when I am done… many, many , many hours away from now. I may apply clear over the blended surfaces , we will see. Hope this helps. Bob
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