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Rusty's '63 11 window
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Mid West Dubber
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PostPosted: Wed Mar 24, 2021 2:38 am    Post subject: Re: Rusty's '63 11 window Reply with quote

still ticking off the jobs...

Front roof bow has been removed to make it easier to sandblast the gutter at the sides. I have also blasted and primed the roof bow...

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Left side gutter has been removed...

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New gutter clamped on and getting lined up..

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Welded in and tied in to the rear corner...

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Muthashabubu Premium Member
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PostPosted: Wed Mar 24, 2021 12:11 pm    Post subject: Re: Rusty's '63 11 window Reply with quote

Popcorn

Have been reading and watching...amazing work!
Applause Applause
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Two Glove Boxes
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PostPosted: Wed Mar 24, 2021 12:37 pm    Post subject: Re: Rusty's '63 11 window Reply with quote

Applause Applause
_________________
1951 Split Standard Hoffman Build

1960 Dove Blue Double Cab Patina Build

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Mid West Dubber
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PostPosted: Sun Mar 28, 2021 3:56 am    Post subject: Re: Rusty's '63 11 window Reply with quote

The seal channel/ cargo door upper catch piece was slightly damaged, so I decided to order a new one. When it arrived I compared the profile and details of the original vs the new KF one. The shape was way off and the cargo door rod holders not even close. So I had no other option but to repair and reuse the original. I couldn't reshape the KF panel as the strengthening pressing would be in the road... Bummer..

Sandblasted, repaired and straightened out...

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Some comparison photos...

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Refitted to the new gutter and tied back in. Much better...

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Mid West Dubber
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PostPosted: Fri Apr 02, 2021 1:32 am    Post subject: Re: Rusty's '63 11 window Reply with quote

Started work on the front sections on gutter. These weren't rusted out but had been beaten up and out of shape. Looks like they tried to relocate the drain location but made a mess...

Left side damage..

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Cut away, blasted underneath and repaired with a section from and Autocraft panel...

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Right hand side damage..

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Cut away, blasted underneath and reapiared, Autocraft panel used again for this side...

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Mid West Dubber
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PostPosted: Thu Apr 15, 2021 3:54 am    Post subject: Re: Rusty's '63 11 window Reply with quote

Front roof bow is welded back on and sandblasting the airbox and gutters...

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Primed...Looks much better without the surface rust

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Mid West Dubber
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PostPosted: Wed Apr 21, 2021 2:53 am    Post subject: Re: Rusty's '63 11 window Reply with quote

Sandblasting the airbox revealed one small section that had rust swelling in a seam.

View from inside the cab...

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View from inside the air box...

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Top section cut out and sandblasted to see how much needed repairing...

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Bottom edge cut out and repaired...

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Top section fabricated and welded in. Happy with the result...

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Mid West Dubber
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PostPosted: Sat Apr 24, 2021 8:13 pm    Post subject: Re: Rusty's '63 11 window Reply with quote

Got the new roof strengtheners welded in on the sides...

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Rear hatch tapping plate put in place and the rear strengthener welded in...

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Rear roof bow supports were removed from the old bent bow and installed along with the new bow...

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The new roof suspended above the bus after a trial fit. Primed and painted the internal parts of the roof, air box and gutters that wont be accessible later on. While the roof was sitting on I marked out all of the areas which will be bonded and ground them back to bare steel. I used masking tape to cover these areas while priming and painting...

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Mid West Dubber
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PostPosted: Fri Apr 30, 2021 12:25 am    Post subject: Re: Rusty's '63 11 window Reply with quote

The roof is on! Cool

Really happy with the fit of this new roof. I used a combination of 3M panel bond, spot welds and plugs welds to make it secure.

In place with clamps holding areas that were glued and spot welded...

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Plug welding completed...

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Panel bond after full cure and all welding finished off...

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mdege
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PostPosted: Fri Apr 30, 2021 4:37 am    Post subject: Re: Rusty's '63 11 window Reply with quote

Starting to look like a bus again Applause

Keep up the good work.
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1965 21F: Restoration of a former '65 firetruck
1963 Typ3 Notchback project
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BarryL Premium Member
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PostPosted: Fri Apr 30, 2021 6:10 pm    Post subject: Re: Rusty's '63 11 window Reply with quote

Yes it looks well done. Did the 3M try to catch fire?
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Mid West Dubber
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PostPosted: Fri Apr 30, 2021 6:39 pm    Post subject: Re: Rusty's '63 11 window Reply with quote

BarryL wrote:
Yes it looks well done. Did the 3M try to catch fire?


I did a test on some scrap steel and the 3M did on that because I welded too close. For the real job I went a little bit further away then the manufacturer recommended and had no issues
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Mid West Dubber
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PostPosted: Sun May 09, 2021 1:59 am    Post subject: Re: Rusty's '63 11 window Reply with quote

A little bit more progress...

Cargo floor starting to come out. There was steel plate welded over the floor that needed to be removed first so that I could see what I was working with...

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ryans65
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PostPosted: Sun May 09, 2021 6:35 am    Post subject: Re: Rusty's '63 11 window Reply with quote

hell yeah that's one of those moments you can take a step back and truly appreciate your hard work!
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Mid West Dubber
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PostPosted: Sun May 23, 2021 1:59 am    Post subject: Re: Rusty's '63 11 window Reply with quote

More work on the cargo floor. Original plan was to try save as much as possible but the i beams, top hats and cross members had been cracked and butchered from work completed many years ago. There was also a step welded to them underneath and the welds had blown holes in the i beams and the decision was made to make a fresh start.

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Previous repairer used bog and fly wire mesh to cover a rust hole...
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Back to the chassis rails...
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Two Glove Boxes
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PostPosted: Mon May 24, 2021 8:25 am    Post subject: Re: Rusty's '63 11 window Reply with quote

Damn good work! Applause Applause Applause You made that roof job look easy.

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_________________
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1960 Dove Blue Double Cab Patina Build

Two Glove Boxes

DLK
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pittbull
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PostPosted: Tue May 25, 2021 2:41 pm    Post subject: Re: Rusty's '63 11 window Reply with quote

Awesome work you do, love the metalwork.
Keep it going!
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Mid West Dubber
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PostPosted: Fri Jun 04, 2021 2:12 am    Post subject: Re: Rusty's '63 11 window Reply with quote

First chassis repair ticked off. This inner section was very thin and needed replacing. Inside the chassis rail was sandblasted, treated, primed and painted for future protection.

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Huetti_1989
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PostPosted: Fri Jun 04, 2021 2:19 am    Post subject: Re: Rusty's '63 11 window Reply with quote

that looks clean!

-Christian
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andybla
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PostPosted: Fri Jun 04, 2021 4:06 am    Post subject: Re: Rusty's '63 11 window Reply with quote

Very nice works!!
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