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MorkC68
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Location: Nottingham, England
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PostPosted: Thu Jan 12, 2017 4:18 pm    Post subject: Re: Hello from the UK! Reply with quote

Earlier this week we took the westy for his MOT test; passed okay, advisories include grumbling front wheel bearings, handbrake inefficient and he advised we change the fuel filter.

Next part for attention is the drivers door, the skin has cracked badly in several places:
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Its had some form of repair around the mirror' bolt
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The bonding on the door braces has gone brittle and broken away and one of the braces is loose inside the frame. It needs sorting!
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The plan is to reskin the door, the frame is excellent so we're going to remove the old damaged one, clean up all of the Dinitrol and treat any rust, paint it up etc before welding the new skin on and paint!

Unpicking the spot welds is slow going Sad
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MorkC68
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PostPosted: Sun Feb 19, 2017 3:11 pm    Post subject: Re: Hello from the UK! Reply with quote

So we started to take the spot welds off the lower half of the door to remove the skin only, we ended up taking the whole outer door skin off as the spot welds had gone all round the top of the window frame. It looks like its been welded before Sad
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I think the door has had something happen to it in the past, the bracing inside the door frame was broken off, the hole where the mirror passes through was not how it should be and we need to make some new bits for the brace around the mirror nut Surprised
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On a plus side, we got a small crack on the inside welded up, the outer skin fits okay and we treated some rust with Vactan. We just have to rebuild the bracing and get that cleaned and painted up. The door frame itself is mint, just surface rust, no real rot aside of some little bits where spot welds have broke.
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MorkC68
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PostPosted: Sun Feb 19, 2017 3:16 pm    Post subject: Re: Hello from the UK! Reply with quote

Progress has been slow this past week, been de-sealing, rubbing back, welding and painting the bracing on the door after fixing the mirror nut back into its recess, looks good!
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But, so much for our "very good" rust free inner door, part of it is peppered with holes Sad
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Luckily Schofields do a repair panel with the correct profile Smile

http://www.alanhschofield.com/ourparts/prod_252712...1105D.html


Whilst this was on order, we applied some more Vactan to the top door frame
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MorkC68
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PostPosted: Sun Feb 19, 2017 3:19 pm    Post subject: Re: Hello from the UK! Reply with quote

Had a few good sessions on the door and got all of the rotten underside cut out, the inner brace bar cleaned up, rust treated and a coat of paint applied. Progress is good Smile
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The Schofield repair section is very good however, the profile on the inside slightly different to the old one, the edge on the new one is sharper, no bother it can be made good!
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MorkC68
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PostPosted: Sun Feb 19, 2017 3:25 pm    Post subject: Re: Hello from the UK! Reply with quote

The new bit is all welded in place, fits well, the steel didn't bow during welding, which is a plus, to correct the profile on the inside lip, we chopped it out, reshaped it and welded it back in.
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I didn't get any photos before a layer of filler was applied to neaten it up, however, we did get carried away, good job its easy sand Very Happy
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Whilst we waited for the filler to go off, we checked the fit of the door skin and marked it out for the brace bars
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lil-jinx
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PostPosted: Sun Feb 19, 2017 8:59 pm    Post subject: Re: Hello from the UK! Reply with quote

Did you just fill that long hole with filler?
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https://www.thesamba.com/vw/forum/viewtopic.php?t=668799
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MorkC68
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PostPosted: Sun Feb 19, 2017 11:46 pm    Post subject: Re: Hello from the UK! Reply with quote

lil-jinx wrote:
Did you just fill that long hole with filler?


No, I realised afterwards we didn't take a photo of the metal welded back in. We reshaped the bend to match the profile on the door and remade it good. The filler was added afterwards.

Ill grab some more images later today and do another update when we have made some more progress
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lil-jinx
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PostPosted: Mon Feb 20, 2017 8:21 am    Post subject: Re: Hello from the UK! Reply with quote

Great work! On your 73,what is that profile at the bottom of the front doors,I have not seen that before,It looks good.
I just got to get to the UK for a look around.
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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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cliveawn
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PostPosted: Mon Feb 20, 2017 8:28 am    Post subject: Re: Hello from the UK! Reply with quote

Hello mate! Cool busses...
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notchboy
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PostPosted: Mon Feb 20, 2017 9:54 am    Post subject: Re: Hello from the UK! Reply with quote

Great job mork! Major looking good aND sorted. Cool
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MorkC68
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PostPosted: Mon Feb 20, 2017 1:03 pm    Post subject: Re: Hello from the UK! Reply with quote

lil-jinx wrote:
Great work! On your 73,what is that profile at the bottom of the front doors,I have not seen that before,It looks good.
I just got to get to the UK for a look around.


the doors are gen. VW ones for the Brazilian watercooled buses, the swage line looks okay as it connects with the lower lip on the front panel Smile

The UK has lots of places to explore in a bus, we love getting out and about Very Happy
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MorkC68
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PostPosted: Mon Feb 20, 2017 1:04 pm    Post subject: Re: Hello from the UK! Reply with quote

cliveawn wrote:
Hello mate! Cool busses...


Hiya Clive, hope alls well with you & the new job is going well!
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MorkC68
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PostPosted: Mon Feb 20, 2017 1:08 pm    Post subject: Re: Hello from the UK! Reply with quote

notchboy wrote:
Great job mork! Major looking good aND sorted. Cool


Thanks Jason, we're a long way off being sorted, the front panel needs changing, new battery tray, left hand rear corner and a few more odds and ends!
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LazyLightning75
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PostPosted: Mon Feb 20, 2017 2:12 pm    Post subject: Re: Hello from the UK! Reply with quote

Wow! That's an impressive amount of work going on. When you're done you really will know your bus inside and out. Looking forward to seeing it all come together.
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MorkC68
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PostPosted: Mon Feb 20, 2017 2:15 pm    Post subject: Re: Hello from the UK! Reply with quote

LazyLightning75 wrote:
Wow! That's an impressive amount of work going on. When you're done you really will know your bus inside and out. Looking forward to seeing it all come together.


Thanks buddy, we are using what we learned from the restoration of our '73 and putting it to good use here. Its all good fun (he says) Smile
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MorkC68
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PostPosted: Sat Mar 11, 2017 12:36 pm    Post subject: Re: Hello from the UK! Reply with quote

Bit more progress this past couple of weeks, mostly painting the inside of the door frame ready for welding back up.

cant beat a bit of red oxide
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then a good coating of Rustoleum Smile
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Finally, we got some bonding on the support brace which holds the mirror in place
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fingers crossed we're reskinning the frame next week!
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MorkC68
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PostPosted: Wed Apr 19, 2017 3:09 pm    Post subject: Re: Hello from the UK! Reply with quote

Well, the door is almost done. Finally welded back up, filled and a couple of coats of primer layed down, its taken a while but we have got there!

Door skin on and spot welded:

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Window Frame welded back on:
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Filled and flatted back:
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MorkC68
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PostPosted: Wed Apr 19, 2017 3:13 pm    Post subject: Re: Hello from the UK! Reply with quote

And finally some paint!

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Top coat Smile

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Tomorrow we will pop one final finishing coat of paint on, leave the paint to harden over the weekend in readiness for clear coating.
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MorkC68
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PostPosted: Sun May 21, 2017 1:40 pm    Post subject: Re: Hello from the UK! Reply with quote

Its been a few weeks since I updated the project, work has got in the way and we have been busy as a result!

Anyway, we got the door finished and the results are good - one final coat of colour and a couple of light coats of clear coat, I'm happy with the outcome!

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We have also moved Major from our unit up to the garage for the welding to take place, however, the roof had to be removed to get him inside! Smile

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MorkC68
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PostPosted: Sun Jun 04, 2017 12:29 pm    Post subject: Re: Hello from the UK! Reply with quote

With the westy moved up to the garage to do the bodywork, we started at the rear left hand corner and tackled the rust bubbles there:

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We also found that the rear outer valance has lots of rust pinholes on the top lip:

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Lucky for us the inner valance was in excellent condition.

The worst of the rot was confined to a 2" square section with slightly less on the inner d post.

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

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