Tales from the Bulli Klinik

[Bulli Klinik]

A few other issues I had to address were the antenna hole, a dent in the upper nose and some small rust holes where the deluxe trim was attached. The deluxe holes were welded up as well.

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I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

For most hole repairs, I drill out the old hole with a uni-bit and make slugs to TIG in. Weld a stud to a roughly cut blank. Chuck it up in a drill and spin it on a grinder. Perfect size slug every time.

Finishing.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

I noticed some rust around the headlight bucket, so repairs were made. I ended up taking out both buckets, blasting them as well as the surrounds. They were treated to Ospho and painted with weld-through.

I have a love-hate relationship with this stuff. Love what it's supposed to do. Hate the process of using it. The welds are never as clean as bare metal. The time involved is a drag as well. Prep, spray, fit, then clean all the paint out of the plug weld location. It takes time, but hopefully it will keep the inevitable seam rust away. BTW, $30/can at my local paint supply store, now!!

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[CaLiBus]

Sweet skills .. Great Job

[Bulli Klinik]

Along with that process goes cleaning it up from anywhere you are spraying real paint. It states on the side of the can, 'this is not a primer'.

I blasted some of the lightly pitted areas and treated the whole nose to an Ospho bath, then sprayed on some epoxy.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

With that out of the way, I figured it would be a good time to put a set of lights together. I didn't realize how many headlight parts I've collected over the years!

Even some oldies from a Bus or two.

I put together some usable parts and even managed to find a set of nice, Bus trim rings with the drain hole on the bottom...simple pleasures.

I found these years ago. I had similar ones on my old Panel and dig the look.

These are OG. Made in England tag.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

If anyone is looking for headlight parts, I'd be happy to trade for parts I need for this project or sell off the entire lot, cheap. I'm sure you could put together at least 6 complete sets as there are about 20 housings and a gang of other parts.

Thanks for watching!
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

Started on the headlight support panel.

I put the radius bend in the bottom by folding the two blanks in the brake. I got the soft bend by laying a piece of carpet on top of the panel while it was being folded. Then TIG'd the panels together, followed by some planishing to make it lay flat.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

I made a domed, flow forming tool with a steel tubing cap and an old impact hammer shaft.

Two pieces of MDF were screwed to a piece of ply, the same width of the original beads.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

Then I clamped the sheet to the form and pounded some shape in.

This is my first time flow-forming and I'm pretty happy with the results. Once I got the technique down, the results were really nice. I formed the lower bead first and it has a few dimples from the way I held the tool. The top one came out much cleaner.

Next is cutting a template for the curvy section of the bead.

Thanks for watching!
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[KevinAlbrecht]

Great work!
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Kevin Albrecht
Wait, what...?

[Manfred58sc]

I was lucky enough to see this in person today, it looks so good. This will be a very nice,tight Bus once completed.
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Fat chick owner/operator

[notchboy]

Oh I can tell this is going to be good Mike.

I love to see a carcass brought back from the dead and then made into one of my favorite things - a camper

When you get to the Eberspacher BN4 part - Im more than happy to lend you a part or two and or help on the fire up.

Check this out when you have the time - and keep up the amazing work.

http://www.thesamba.com/vw/forum/viewtopic.php?t=614419&highlight=
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[dawerks]

Nice work! I love how you make your own panels!
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"There is only one sin; disconnection from self."

[oakman]

[Bulli Klinik]

Thanks for the kind compliments! I've learned a lot from The Samba over the years and hopefully I can give a little back.

It's always good to see you, Manfred! Thanks for the cab door and the cargo door. Every little bit helps.

If you need some parts for your project, Manfred is a good person to contact. Lots of parts from dry, Southern Colorado have made it into his stash and he's always willing to help out. A primo, VW enthusiast and a very intelligent, interesting individual.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

A little more progress.

I made a template out of MDF to mimic the wavy bead under the headlight bucket. Hammered it out with the same tool. I'm pretty excited about this whole flow forming thing. The more time I spend with the tool, the better the results. It really opens the doors for some panels I plan on making for the Bus. Belly pans will be a breeze...

Next will be tipping the flanges and stretching to get the required curve.

Thanks!
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Manfred58sc]

Ah, to spy into the master's workshop!!
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Fat chick owner/operator

[Bulli Klinik]

I managed to get the last section of bead put in as well as stretching the flanges to get the shape needed. It was no easy task getting the panel to turn, due to the large beads! It's stiff. I also turned the edges of the upper flanges.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

The lower part of the panel has these stiffening gussets.

I initially made a little jig which I thought I would clamp to one side of the panel and hammer the shape in, one half at a time, which didn't turn out as nice as I'd hoped. I figured the best way to do it was to make dies and press them in. It took a little bit of refining, but I got something I was happy with.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs