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TheRealMacGyvers 1977 Restore On A Budget Thread
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TheRealMacGyver
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PostPosted: Tue Jun 26, 2012 8:31 am    Post subject: Reply with quote

Pete: So once I use the oven cleaner the paint will bond? I thought about getting in there with the grinder and wire wheeling as much as I can, but there are areas I know I will not be able to get to. I still have Randy's number, just been waiting to have a complete laundry list together before I go. I'm also thinking I want a swivel seat like you! Might just see if he has one of those and tackle the job!

Bugger: Thanks for the link, I think I read that at some point. It makes me feel better that mine is not nearly as bad as yours! My frame is all pretty good, it's just right at the end where the bumper bolts on that is a bit crusty.

Devon: So, I guess if I end up without the hole it won't be that big of a deal. Only the true VW nut will notice! If I get a piece with the hole I'll keep it, but otherwise I'm not going to drill a hole just to match OG.

Thanks all.
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Devon-Dyno-Soar118
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PostPosted: Thu Jun 28, 2012 6:53 am    Post subject: Reply with quote

Heres a few shots of a very budget repair I did to a similar age bus to yours, showing what probably lurks around the battery tray!
Image may have been reduced in size. Click image to view fullscreen.

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Note piece of daylight where the rear engine mount was!
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TheRealMacGyver
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PostPosted: Thu Jun 28, 2012 8:04 pm    Post subject: Reply with quote

I bought an ElCheapo metal brake from Harbor freight. It's not great, but it's way better than the way I've been bending metal!
Image may have been reduced in size. Click image to view fullscreen.


So I figured on the door I would bend a piece of metal to fit under the rotted area. To get the profile I used a weird kind of method. I took a favorite friend called Durhams Rock Hard, a flour-like material used mainly for wood putty. I wanted to get the profile under the window so this is what I came up with!
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After mixing it with water in a ziplok bag I shoved it under the lip of the window to form the profile I would want to replicate with my metal.

When I was done I got a chunk of the hardened material like this:
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So this was the area I was tackling:
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With the metal piece in it looked like this:
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After a bit of welding:
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And some more:
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Starting to look better:
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So I can do it, just going to take a bit of time. What you have seen is just a short piece about 10-12 inches between 2 of the support up rites.

I haven't tackled the other door yet, but so far it's looking promising.
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Devon-Dyno-Soar118
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PostPosted: Fri Jun 29, 2012 12:38 am    Post subject: Reply with quote

Neat bit of work!
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TheRealMacGyver
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PostPosted: Fri Jun 29, 2012 8:48 am    Post subject: Reply with quote

Thanks Devon, by the way I inspected my frame in the area you had to cut out and I think I'll be okay with the exception of the very end on bath sides where the bumper bracket goes. Maybe just the last 3 inches (75mm) might need to be redone. Your repair looks a lot like bugger101's.
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Devon-Dyno-Soar118
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PostPosted: Sat Jun 30, 2012 12:44 am    Post subject: Reply with quote

That's good news, you can just make that section out of 2 90 deg bends. Bumper mounts can be made by drilling holes to match the originals and welding captive nuts on the inside.
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TheRealMacGyver
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PostPosted: Tue Jul 03, 2012 2:43 pm    Post subject: Reply with quote

Devon-Dyno-Soar118 wrote:
That's good news, you can just make that section out of 2 90 deg bends. Bumper mounts can be made by drilling holes to match the originals and welding captive nuts on the inside.

Thanks, that's what I'll do. I just got to get in there and clean it up again and get my brackets of the bumper to align them.

In the meantime I've been working on the front doors. The passenger door is 99% now, just some minor imperfections to work out, but rust free and enough to make me happy.

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

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So I got to working on the drivers door. Before I tore it all down I noticed the lower drain area was pretty wasted! So I cut out the rot:
Image may have been reduced in size. Click image to view fullscreen.

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Then I got to fabricating a replacement.
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And voila:
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I still have to redrill the drain holes. Not to brag or anything, but I impressed myself on this. I'm ready to tackle that nose now for sure!
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babysnakes
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PostPosted: Tue Jul 03, 2012 3:00 pm    Post subject: Reply with quote

Hey MacG, looking great. Hope to see the bus at BugJam this fall.
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TheRealMacGyver
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PostPosted: Tue Jul 03, 2012 3:26 pm    Post subject: Reply with quote

babysnakes wrote:
Hey MacG, looking great. Hope to see the bus at BugJam this fall.


Thanks, I'm not sure the bus will make it this year, but I'll be there for sure. I still have more body work, then putting it all back together.
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grandpa pete
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PostPosted: Tue Jul 03, 2012 3:46 pm    Post subject: Reply with quote

why wait till then August 3 4 +5 come ride around Sebring race track Shocked Shocked ....might cheat and do hotel;don't tell anyone Embarassed Cool
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babysnakes
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PostPosted: Tue Jul 03, 2012 3:56 pm    Post subject: Reply with quote

So Pete, your gonna make Sebring? I'm still up in the air. Confused
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PostPosted: Tue Jul 03, 2012 4:09 pm    Post subject: Reply with quote

How could you miss a chance to drive around the track?.......walked the "WALL" at Daytona years ago;the model a wouldn't go fast enough to stay on the severly banked corner Laughing Laughing
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TheRealMacGyver
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PostPosted: Tue Jul 03, 2012 6:05 pm    Post subject: Reply with quote

Sebring huh? What's that all about? Is there a website for this? Pray tell!
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PostPosted: Tue Jul 03, 2012 6:12 pm    Post subject: Reply with quote

This is what it's all about...

http://www.thesamba.com/vw/forum/viewtopic.php?t=516164
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TheRealMacGyver
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PostPosted: Tue Jul 03, 2012 6:19 pm    Post subject: Reply with quote

babysnakes wrote:
This is what it's all about...

http://www.thesamba.com/vw/forum/viewtopic.php?t=516164


Ahhhh, that explains it. Will have to think about it. About a 1-1/2 hour drive from here I think. How is this compared to BugJam? Better?
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TheRealMacGyver
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PostPosted: Sat Feb 08, 2014 5:38 pm    Post subject: Reply with quote

Well I haven't updated this thread in about a year and a half, so here goes some updates! Had to put the bus on hold for a bit due to life getting in the way, but I have been back at it for a few months now. I am not going to post the boring stuff, but I am getting closer to painting. Today I was able to weld in the lower windshield metal that was rotted.

Here is before and through the process.
Image may have been reduced in size. Click image to view fullscreen.


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I welded a strip to the backside of the new piece, you can see the spot weld.
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The grinding is worse than the welding!

Tomorrow I plan to deal with this, it is looking up into the freshair box.

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

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PostPosted: Sat Feb 08, 2014 10:15 pm    Post subject: Reply with quote

I love following your thread! Great work on a budget
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Mr. Unpopular
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PostPosted: Sun Feb 09, 2014 11:32 am    Post subject: Reply with quote

Good seeing you back at it!

If you ever want to sell one of your automatic setups, or trade it for a 4 speed setup, let me know. I'd love to convert our bus to auto so my wife wouldn't be so intimidating driving a motor home with a clutch Laughing
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TheRealMacGyver
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PostPosted: Sun Feb 09, 2014 3:18 pm    Post subject: Reply with quote

Mr. Unpopular wrote:
Good seeing you back at it!

If you ever want to sell one of your automatic setups, or trade it for a 4 speed setup, let me know. I'd love to convert our bus to auto so my wife wouldn't be so intimidating driving a motor home with a clutch Laughing


I thought I read here that converting an auto to manual was next to impossible. I doubt it's that bad, but I don't know. Have you ever done it?

Also, have you found the perfect spot for a radiator yet? I was thinking it would be cool to hide one in an old suitcase on top in the rack, but I don't know how you would get the plumbing up there!

Pandamanda22: thank you very much.
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PostPosted: Sun Feb 09, 2014 3:53 pm    Post subject: Reply with quote

I can't see why everything wouldn't be a bolt in between the two, but maybe I'm wrong. If anything, the auto would be a bolt in, and the 4 speed would be tougher if the clutch cable tube were missing?

I recently purchased a front radiator grill setup from a Mexican/Brazillian bus. It won't be hidden, but will look pretty well done and will definitely cool!

I've seen a fake suitcase up front, and a radiator on the roof, but not a mixture of the two. That would be pretty interesting, but more suited to an early bay camper with the luggage rack at the rear.
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