Bay Window Roof Repair

[Cheetahking]

Hello all -
I recently inherited my parents 1978 bus. They have had it painted (with some poor bodywork) a few times, and it was stored outside, in Laguna Beach. As such the rear portion of the roof has some pretty good rust issues - it has gone into the hinge support as well.
I really want to get this fixed and workable to keep the bus on the road.
I have never posted on the Samba but have read through a ton of information here. I'm hoping someone can point me in a good direction for a few things:

1. I'm looking for some photos of how the rear roof structure actually is set up (I haven't cut the roof section out yet).

2. I see that Heritage Parts in the UK has a rear third roof section available (and they don't ship it I don't think), but I haven't been able to find anything in the US. Is there a source for this piece?

I'm looking forward to the next phase of this car's life, as I grew up in it.

Thanks for any help!

James

[aeromech]

Get ready to be in shock. Rust never sleeps.

_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[SGKent]

welcome. Don't get discouraged if you don't hear what you want to hear from any of us. The good people here who have been thru these things know what a job you will be undertaking.

A bay roof is a pretty serious repair. If you are used to autobody work you can probably pull it off but if not it may be a challenge for a novice. They often rot from the inside out because some of the sections are sandwiches of metal - the rust gets in between the layers and eats outwards. In that case all the structure involved has to be replaced. Your easiest solution is to see if Interstate VW, in 29 Palms now, has any donor sections that your body shop will need.
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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[Manfred58sc]

I have that section, super dry Southwest donor. It is shippable ( won't be cheap).PM for details
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Fat chick owner/operator

[Cheetahking]

Thanks everyone! I'm not discouraged - I appreciate honesty and even differing opinions. Areomech - that looks a lot like what I'm dealing with. Did you do your own work on that - or a body shop? I'd pay a shop (I realize its not cheap) but I hear so many horror stories with shops and older cars I want to understand my options. If anyone has a recommendation for someone to tackle this I would take that as well.

I've done bodywork - but nothing that extensive (I have a 1972 Datsun 510 as well so I understand rust!). I'm just trying to get a handle on what I'm looking at and how its put together.

Manfred - will reach out.

Any more photos would be appreciated (or if someone knows a build thread to point me to as well.

[aeromech]

This bus belonged to my customer. He took it to a body shop in San Diego. It ended badly but the bus was finished at some point and eventually sold.

Be very careful who you hire to do this work. Many are liars and drug abusers.
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[Cheetahking]

Yes - that's what I worry about. I think most of the quality shops make their money on insurance claims and the true restorers who have knowledge and are honest are harder to find. Thanks for the info!

[skills@eurocarsplus]

[SGKent]

With that bus being near the ocean all its life and un-protected, I'll bet there is a lot more rust in it than imagined. It gets really humid at night near the ocean so things get wet internally too from condensation. Add in the salt in the air... I've lived near the ocean several times in my life and corrosion is always present in things left outdoors at night.
_________________
“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[Cheetahking]

[SGKent]

think of it this way. A guy wants to make $90K a year after expenses. If he takes on 3 buses a year he is pretty aggressive on rust repairs because each owner wants it like it was when it left the factory. Each bus owner has to pay $30K plus expenses, parts and materials to cover that guy's time. That is what you are up against. It is not like an 8 hour repair. But if the repairs take so much time that he can only do two buses a year, which includes the time chasing parts etc., then the price goes to $45K a bus plus parts, expenses and materials. No bus owner will pay that so there is no market for it unless you are dealing with someone who lives in a rural area of the USA where real estate costs are low, where he likes to putz around working on things rather than take a job in town. That isn't SoCal unless you can turn the hands of time back to 1960.
_________________
“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[Cheetahking]

I understand completely. It's a tough needle to try and thread. I'm keeping my eyes open....

[skills@eurocarsplus]

what you're asking isn't impossible, it will just take the right shop/person to get it done.

any time someone reaches out for work like that, or any other major (expensive) work I always ask "is this your forever bus?" because if it isn't and you plan on selling in a few years then it just isn't worth the expense.

as long as you realize that and you're really and truly ok with spending the money then that's fine...

I have actually talked about 4-5 people out of doing stuff because they felt like they were just going to drive it for a season or 2 and move on....that's fine. we all pretty much know we'll never recoup the $$ we pour into these but for many it's about the memories, new or old and being able to keep making them with kids/grandkids etc.

I always make it crystal clear before someone starts in on something like this.
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