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74 bay window campmobile rocker rust,corner rust
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orwell84
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PostPosted: Tue Sep 26, 2017 4:27 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

lil-jinx wrote:
Thanks Pinetops,
Playing connect the dots today,I fastened a piece of aluminum to the back side to held stiffen it a bit,I was going to use it as a backer for the butt joint ,but I find if I have any space between the backer and the panel I get more blow thru.I welded the outer rocker onto the patch before installing the it.

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How did you end up getting it to fit? Curiuos as I did this exact same repair 2 summers ago with pretty much the same panels. My side wall fit properly but I had to do a little tweaking on the shrinker to get the profile right. I didn't have a problem with the quarter because the front end of the old panel was still intact and I left it there. I think Gerson's panels for that area are the best out there. I was not bothered by the tweaking I had to do to get it all to fit. It's just how it goes if you want the lines to look right. It's a lot of panels and sections going together there in one of the few places the bus actually has curves and to think it's all just going to go together like tinker toys is an unrealistic expectation.

I also found that having a little more space between the panels at the side panel butt joint is helpful. I saw one video recommending the width of a nickel. The panel expands as you weld and the gap gets smaller. The are some places I had to make relief cuts with a cutoff tool along the seam and reweld to get proper penetration. I thought I was doing better work by keeping the gap as small as possible. There are a lot of good videos on Youtube that show some good tricks for doing this kind of weld. I spent a lot of time dry fitting the panels, but found that it will only get you so far as the metal will behave differently when you start welding. It looks like you are doing good work though.
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lil-jinx Premium Member
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PostPosted: Tue Sep 26, 2017 5:39 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Thanks for looking,I also had to use a shrinker to recurve the panel.After the first few tacks my gap closed up,I ran a thin dremel cut off disc the length of the panel to open it up,and the back of the panel it still puckered out a little,from too small a gap,I'm hoping to hammer it down after i remove the stiffener.
I am pleased with the panels and I did fuss with them quite a bit,as you said that was expected.
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PostPosted: Wed Oct 18, 2017 1:28 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

The door was rusted out on bottom,Luckily the door from the parts bus was not too bad,so I will use it.
Also started the patch at the rear arch,just got to get the cut right for the easiest weld.

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https://www.thesamba.com/vw/forum/viewtopic.php?t=620186
https://www.thesamba.com/vw/forum/viewtopic.php?t=668799
1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy
1974 parts bus
A smart man learns from his mistakes,a very smart man learns from other's mistakes.
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Pinetops
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PostPosted: Wed Oct 18, 2017 3:53 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

I'm impressed, thanks for the updates. I always love to see these kinds of pics.
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Yarkle Premium Member
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PostPosted: Wed Oct 18, 2017 5:33 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Yes, X2. I also used your bottle jack under the stuck brake drum trick yesterday after spending a few hours trying to get the damn thing unstuck.

Im gonna have to try fixing my doors the way you did
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lil-jinx Premium Member
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PostPosted: Tue Oct 24, 2017 7:10 am    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Yarkle did the jack trick work for you?I got lucky,the door on my parts bus is in much better condition just a bit of rust at the top and two small repaired at the bottom,should be easier then fixing the one pictured above.
I have welded in the arch patch and made a patch for the seat belt mount,This brings me back to where I started at the left rear corner.now I will go around it again and get it ready for primer and seam sealer.and I still have to replace the floor section at the rocker.

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1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy
1974 parts bus
A smart man learns from his mistakes,a very smart man learns from other's mistakes.
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RBurn
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PostPosted: Thu Nov 23, 2017 9:41 am    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Wow, just read through the thread. This is a major undertaking and just think you will have saved a Bus.
Great work!

Here's a question, did you treat the old and new metal on the backside before installing. What did you use?

Rob
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PostPosted: Thu Nov 23, 2017 3:29 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Hi Rob,thanks for looking,I used weld-thru on the patchs that were not accessible from the back side.
When I finish with the body and paint I will spray Krown rust protector into all the nooks and crannies,that should stop any rust from forming.
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1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy
1974 parts bus
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PostPosted: Fri Dec 08, 2017 1:24 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Still at it,cleaned and put some rust converter on the wheel well,patched the rear seat belt anchor point,small patch at floor and wheel well,then started on the door.I cut up an old door to get the channel patch.
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https://www.thesamba.com/vw/forum/viewtopic.php?t=668799
1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy
1974 parts bus
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orwell84
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PostPosted: Fri Dec 08, 2017 6:26 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

That came out really well, lines up nicely and clean welds. From the pic it looks like you won't much filling to do. I can't tell if there is already filler in it above the repairs. I did my side panel about 20 years ago with a different panel. I made a lot of mistakes and there was already a lot of warping from a previous repair a friend of mine had done brazing in a repair panel some years before. I ended up taking the whole panel back down to bare metal and it took me ages to get is straight first with the stud welder, then filling. I ended up covering a large area with filler though not deep. I have this theory that the rust starts with water coming in through rust holes starting in the window frame below the smokers window. I deleted mine as well as the hole for the electrical box. I am also considering using something besides those channels spot welded to the rear window frames to hold on the side covers. They are just asking to rust. I love stock, but rust prevention is my first priority.
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PostPosted: Fri Dec 08, 2017 7:33 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

I am also thinking of deleting the elect outlet hole,and the vent window will be going,not sure if i use the jalouse windows or not,I am pleased with the way it out,I think the aluminum strongback, that I fastened on the inside just above the weld line,helped to keep the warping down.There is no filler above the repair,just lots of paint 3 different colours.My grinding skills are much better then my welding.
Thanks for looking.
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1968 Dune Buggy
1974 parts bus
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orwell84
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PostPosted: Sat Dec 09, 2017 8:46 am    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Curious as to your location in NB. I spent a little time there in my younger days driving out to PEI in my bus following a summer French immersion course in 3-Pistoles, Quebec. I keep telling myself I will do that trip again, one of my best, but it's hard to find the time.

Nice work on your bus.
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Yarkle Premium Member
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PostPosted: Sat Dec 09, 2017 10:58 am    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

The channel patch picture!!!!! Now i see how you did it. Ive got to practice some welding first, but then im going to try and ressurect the doors i thought were solid enough to install, I was just having trouble visualizing how you did it, but now i see outside and inside, i think i can handle it.
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1973 VW Bus [o____o] "the Thing" thread:
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1969 VW Bus deluxe 221 -belongs to the boy
"Weld Busler" Bus rebuild thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=630499 1600SP
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PostPosted: Sat Dec 09, 2017 2:25 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Orwell84,I live just outside of Moncton,on the road to Fundy Park.
Yarkle,I know how you feel about welding,I have to plan every tack,and go thru the motion each time before pulling the trigger,I space the tacks out and grind them down after I do 4 or 5 of them that gives it time to cool,thing that really makes a mess is the under coating, behind the panels, that I can't clean up.
You may notice that I left a small piece of the corner in place,I left it there as a guide when I get it all fitted up I will remove that small piece.
Good luck with your project.
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1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy
1974 parts bus
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PostPosted: Wed Dec 13, 2017 3:19 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Welded in the door patch.

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1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy
1974 parts bus
A smart man learns from his mistakes,a very smart man learns from other's mistakes.
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PostPosted: Wed Dec 13, 2017 4:43 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

NICE! i just got a deposit on the thing, so im hopefully rolling MY bus into the garaj soon.
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1973 VW Bus [o____o] "the Thing" thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=8272498#8272498 1.7 914? engine with weber progressive clone (soon to be 72 dual carb setup)
1969 VW Bus deluxe 221 -belongs to the boy
"Weld Busler" Bus rebuild thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=630499 1600SP
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bvolks
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PostPosted: Wed Sep 05, 2018 11:50 am    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Any updates? I'm tackling the driver's side of my double cab right now and your thread has been very helpful.
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PostPosted: Thu Mar 07, 2019 5:48 pm    Post subject: Re: 74 bay window campmobile rocker rust,corner rust Reply with quote

Installed this floor patch,,and finished welding the b pillar before welding the patch,The block of wood is the pattern of the bottom of the pillar,I cut it out before starting and used it to ensure the new piece went back as it was.

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1968 Dune Buggy
1974 parts bus
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