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Quality Sound 1954 Barndoor Deluxe Puzzle
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busben
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PostPosted: Sun Jan 25, 2015 10:47 am    Post subject: Reply with quote

Haha. Thanks guys. Yeh the dash was a real sweet find G. I was considering a cheaper repro for a minute there but Dai pointed out that after all my work in trying to save as much OG metal and paint as possible, I'd be the one driving around looking at a reproduction dash all day. He's pretty good with advice that involves me spending money. What a handy friend to have Laughing

So, the bus. Paul has a table he uses for chassis building so we removed the remaining pieces of cargo floor and cleaned up the front and rear lumps ready to weld in a nice new centre section.

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One worry I had was the strength of the new chassis. All the cuts in this bus had been done with a gas torch as there was no plan to ever weld anything back together. This left nasty great gaps everywhere so we decided to remove sections around the cuts in the chassis and reinforce the joins. By accessing the inside of the boxed sections we could clean up and weld the "inside" of the chassis, before reinforcing the new joins with laser cut formas, and then grafting a piece back onto the "outside". Stronger than factory and nice and safe Very Happy

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Then the rear chassis leg that had sustained the accident damage was cut off and straightened out before being reattached to the rest of the chassis. For the first time since the 1980's this thing was back on its wheels!!

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busben
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PostPosted: Sun Jan 25, 2015 11:07 am    Post subject: Reply with quote

For one reason or another this project then had a little hiatus. Paul had a lot of work on, and I had the '51 Basket Case to build,
http://www.thesamba.com/vw/forum/viewtopic.php?t=467457
and then my panel when that got sold back to Sweden, and a few other bits and bobs in between, so this got packed up and stored at the back of the shed for a rainy day.

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Anyway a while back talk turned to dusting this project down and getting stuck back in. Mainly this talk took place while drunk at LeMans Classic with Dai and Mark when we all decided that we should be taking Deluxes of some sort in 2016 Cool With other projects finished I grabbed the parts from my shed and hauled them all up to JC Welding Services in Sileby. Jeff's a good friend and a guy who I trust completely with this sort of project, and I knew I didn't have the time to weld this beast up all on my own so I was more than happy to dump this pile of parts on him Razz

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We drank some "tea" and worked out a vague plan of attack, but the first problem that I was had was the hacked a-post and lack of a windscreen and front roof.

A knarly front clip gave up its a-post and outer front skin to repair the lovely door removal cuts of yesteryear ....

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and I had recently been able to buy a really nice screen / roof clip from JP at Dawerks in Canada (thanks dude!) which, together with a front roof section that Florian had sold me a while back would piece together the front nicely.

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Last edited by busben on Sun Jan 25, 2015 11:25 am; edited 6 times in total
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busben
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PostPosted: Sun Jan 25, 2015 11:16 am    Post subject: Reply with quote

so with the front screen in place......

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..... the front clip could now be reunited with the rest of the chassis. Again the join was reinforced with a laser cut forma, and all internals were liberally coated with a rust inhibiting paint.

So to answer your question G, here's the old girl as she stands this weekend.

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I don't know about you guys but that photo makes me smile a lot and I can't stop looking at it. She's coming together at last. Watch this space! Very Happy
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mandraks
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PostPosted: Sun Jan 25, 2015 2:18 pm    Post subject: Reply with quote

we sold this one because the semaphores were welded up and it had aftermarket lights hacked in, look at the wiper.... I salute you!
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djfordmanjack
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PostPosted: Sun Jan 25, 2015 6:00 pm    Post subject: Reply with quote

whoah Ben, that are some MAJOR efforts Shocked
I just love how you collect the bits and pieces. looking forward to your '16 DLX tour. wonna see all of them on the road !
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busben
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PostPosted: Mon Jan 26, 2015 1:25 am    Post subject: Reply with quote

Thanks Dude. It was easier getting stuff shipped across from Canada than a Friday morning - Sun evening 2600 mile drive to your place to collect the panel van via Switzerland and France to collect parts! Very Happy Mind you that trip was more fun and they say sleep is for the wEEk Twisted Evil

Still on the look out for more OG paint parts for this bus so if anyone has a decklid, bumpers, glass, etc, etc hidden away in their stash that they might sell me PLEASE give me a shout!! Barndoor or early split stuff. I'd be a very grateful buyer!! Very Happy Cheers!!


Last edited by busben on Thu Jan 29, 2015 12:03 pm; edited 4 times in total
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BulletBus
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PostPosted: Mon Jan 26, 2015 6:17 am    Post subject: Reply with quote

Holy crap man. This is awesome. Very few would be able to see the potential in this one and actually take it on. Very cool to have skilled friends also! I will be watching this one. Nice work.
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rikki james
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PostPosted: Tue Jan 27, 2015 11:29 am    Post subject: Reply with quote

There was a time when you could assess a man by the type of vehicle he drove..... what does this say about you Ben?!?!?! Laughing

Great work fella.... gonna be ready for the Volksworld show?
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busben
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PostPosted: Tue Jan 27, 2015 12:16 pm    Post subject: Reply with quote

Haha. no comment!! Laughing

Doubt this'll be at VoWo I'm afraid dude - it is only 2 months away Rikki!. We'll probably be in a bus you haven't seen before though Cool
Looking forward to a few beers, (or more likely bottles of Vodka), with you fella. Not long now Very Happy

So Jeff got the door hinge hacks tidied up for me:

Old gas torch mess trimmed up, then spot welds drilled out to allow the front panel to be pealed off of the a-post. Then the donor a-post was welded into place, and the front panel folded back over and welded back on. Note the unfinished welds on the bottom of the front screen. We decided to leave these unfinished until the roof is on in case we need to tweak anything into place before the final welds:

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Then we used the front panel sections to carefully repair the hacks on the front skin:

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Looks better eh Very Happy

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busben
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PostPosted: Tue Jan 27, 2015 12:53 pm    Post subject: Reply with quote

we decided that the forward top hat, outriggers and jack points had been a very optimistic attempt to save OG metal so they got removed to reveal rust on the main rails.

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A lot of rot can get hidden in these cavities but all is now repaired.

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and work can continue with finishing the chassis.

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vwdrue
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PostPosted: Tue Jan 27, 2015 12:56 pm    Post subject: Reply with quote

Great progress!
I heard whispers you tracked down a pair of og paint cargo doors off a cut up 52 deluxe from some other bus enthusiast?
Handsome man im told.
Great with the ladies.
Anyway, keep up the good work!
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busben
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PostPosted: Tue Jan 27, 2015 3:45 pm    Post subject: Reply with quote

vwdrue wrote:
Great progress!
I heard whispers you tracked down a pair of og paint cargo doors off a cut up 52 deluxe from some other bus enthusiast?
Handsome man im told.
Great with the ladies.
Anyway, keep up the good work!


Thanks dude Very Happy Yeh a good mate gave up a super clean pair of OG paint cargo doors for this build. Top bloke, but no idea of his prowess with the fairer sex Razz More details later ........... you're more premature than RS, and from what I hear it's a real problem of his Laughing
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busben
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PostPosted: Tue Jan 27, 2015 3:51 pm    Post subject: Reply with quote

Got a PM re the screen clip earlier today too. Seems it was cut out of a '54 single cab many years ago.

http://www.thesamba.com/vw/classifieds/detail.php?id=96009

Kind of nice to know a little history on the parts I'm using, and lucky for me that it didn't get used by someone else in the last 10+ years! And it's even the correct year Twisted Evil

Thanks for the info Jason.
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dawerks
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PostPosted: Tue Jan 27, 2015 9:25 pm    Post subject: Reply with quote

busben wrote:

and I had recently been able to buy a really nice screen / roof clip from JP at Dawerks in Canada (thanks dude!) which, together with a front roof section that Florian had sold me a while back would piece together the front nicely.

Image may have been reduced in size. Click image to view fullscreen.


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Ohmygod! I'm so glad it's going on a Barndoor Deluxe! (My heart literally skipped a beat when I saw it!) I've always wanted a BD Deluxe, and I'm super stoked that you're going to be able to use it Smile

/I'm putting this in my feedback unless you say otherwise!

And shipping from Canada is super easy. I'm glad you got it picked up, I forgot about the clip until you emailed me back. Will be watching closely and good luck with your project!

Oh yes, the obligatory, I am very envious!! Very Happy
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streetwagens
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PostPosted: Wed Jan 28, 2015 2:09 am    Post subject: Reply with quote

Great work Ben, Looking forward to rolling windows with you next year! Cool
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busben
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PostPosted: Wed Jan 28, 2015 2:20 am    Post subject: Reply with quote

streetwagens wrote:
Great work Ben, Looking forward to rolling windows with you next year! Cool


Right. There it is dude. You said it. There's no backing out now Very Happy
And everyone wondered who the hell the pikeys were when we rolled the early ones over there last year ...........

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Ace video too Cool

https://www.youtube.com/watch?v=v4TOlKhnlPc&feature=youtu.be
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djfordmanjack
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PostPosted: Wed Jan 28, 2015 2:36 am    Post subject: Reply with quote

way cool pic !
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'51 Brezel project, Azurblau mit Rheumaklappen
'52 BD Coachbuild project
'55 Wolfsburg panel project, all original paint
'55 Oval Sunroof project with my son
'56 Oval og paint og chrome og everything
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Scotty
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PostPosted: Wed Jan 28, 2015 6:17 am    Post subject: Reply with quote

It's coming along nicely dude!
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carl12
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PostPosted: Wed Jan 28, 2015 12:06 pm    Post subject: Reply with quote

Looking Forward to seeing this,Good Luck Ben Very Happy
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Demian_S
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PostPosted: Wed Jan 28, 2015 2:14 pm    Post subject: Reply with quote

Nice updates!!

Do you have any pictures, before it was butchered?
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