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MorkC68
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PostPosted: Sun Jun 04, 2017 12:40 pm    Post subject: Re: Hello from the UK! Reply with quote

With all of the rotten metal cut away, we could Vactan rust treat any areas hidden away, sort out new metal, get that welded in nicely and painted up ready for the new rear valance.

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New section welded into the edge of the rear corner

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And finally the new rear valance.

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We're pleased with how this has gone, all that remains is a few welds to dress, some etch primer and we're done Smile
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MorkC68
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PostPosted: Sun Jul 16, 2017 1:49 pm    Post subject: Re: Hello from the UK! Reply with quote

We managed to get the rear valance etch primed followed by a coat of high build primer, that's another little job out of the way, I'm pleased to say!

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Our attention is now focused on replacing the front panel, parts of the windscreen lip had bad corrosion, as did the bottom.

Removal of the lights and grill showed up some nasties:

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the section where the airbox assembly had a large gap, tapering further apart as it went towards the drivers side

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We had suspicions of accident damage.
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MorkC68
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PostPosted: Sun Jul 16, 2017 1:56 pm    Post subject: Re: Hello from the UK! Reply with quote

As we started to remove the front panel, it became more obvious that something was amiss

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the inner windscreen panel was miss shaped and needed replacing but not only that, complete removal of the panel revealed a very badly damaged airbox
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it was pushed back considerably, dented and again, we felt needed replacement.
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MorkC68
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PostPosted: Sun Jul 16, 2017 2:03 pm    Post subject: Re: Hello from the UK! Reply with quote

The logical thing to do was to source a new airbox, FBI VW came up with one luckily. We stripped the front bare to check for further damage, none was found
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The left and right hand A pillars are all good, luckily!
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Inner screen panel replaced, the new front panel was used to get the alignment set correctly before it was welded up securely and painted

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Front panel rechecked for fitting
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hopefully we will be able to weld the airbox up next
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Wasted youth
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PostPosted: Sun Jul 16, 2017 10:50 pm    Post subject: Re: Hello from the UK! Reply with quote

That's an impressive amount of work! Cool Are you happy with the way those panels are fitting up? What brand are they?
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1968 Double Cab truck, 1973 Auto trans bus, 1978 Auto trans Sunroof bus with A/C and a 1987 Auto trans Westfalia.
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MorkC68
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PostPosted: Mon Jul 17, 2017 1:46 pm    Post subject: Re: Hello from the UK! Reply with quote

Wasted youth wrote:
That's an impressive amount of work! Cool Are you happy with the way those panels are fitting up? What brand are they?


The rear valance was a superb fit, that was made by Autocraft here in the UK, the inner windscreen repair panel is Genuine VW, quite a good fit but not as good as the original.
The front panel is IGP, it looks good and offering it up, I think we will be fine - trial runs suggest this will be fine.

We know that measure, measure, measure and do one final measure is essential. We rebuilt our '73 kombi a couple of years ago and with the westy, we plan to use lessons learned to do a better, more sympathetic restoration.
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MorkC68
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PostPosted: Wed Aug 09, 2017 1:45 pm    Post subject: Re: Hello from the UK! Reply with quote

Got quite a few odds and ends done this past couple of weeks, heated rear window switch replaced and sorted..working as it should now, the wiring had been hidden and the switch removed.

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Whilst the Dashtop was off, we repainted it Satin Black, installed a Rev Clock and Oil Pressure gauge, ensured the wiring was nice and tidy in sleeving, nice and neat!

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The replacement airbox is from an earlier bay, possibly up to 1975 - the steering column support plate was different, couple of holes drilled to line up with the ones on the airbox and we're sorted and the plate bolted up securely.

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MorkC68
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PostPosted: Wed Aug 09, 2017 1:52 pm    Post subject: Re: Hello from the UK! Reply with quote

Got the new airbox mounted and lined up with the inner windscreen panel, couple of runs of weld once it was lined up okay & its looking something like reasonable again. We gave the out of sight areas a good coating of Rustoleum to keep any rusting to a minimum

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Front panel is now on and spot welded on the airbox, windscreen lip and bottom lip, lining up very well!

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The front panel is all welded up, etch primed, high build primed and the deformation panel has had a coat of Schultz Stone chip protection

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We have some seam sealing to do followed by a final coat of high build primer before colour Smile
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MorkC68
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PostPosted: Fri Sep 15, 2017 1:22 pm    Post subject: Re: Hello from the UK! Reply with quote

Made a huge amount of progress since I last updated this thread.

The front panel is seam sealed where necessary, painted and clear coated:

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The indicators and headlights have been refitted and wired back up, working correctly

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Radio aerial fitted and working

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Wiper motor refitted and the associated seals fitted, washer jets reconnected.

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Fresh air flaps refitted, linkage set up okay

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Fly screen and front grill back on

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Next up, refit the dashtop and windscreen/wipers.
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MorkC68
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PostPosted: Wed Sep 27, 2017 1:36 pm    Post subject: Re: Hello from the UK! Reply with quote

Made some really good progress this past couple of weeks, the front end is pretty much complete aside of fitting a VW emblem and the front bumper (which can wait till its been resprayed).

The dashtop and vents have all been refitted along with wiring up an oil pressure gauge and rev counter. Grab handle and padded top cleaned up, refitted & tightened up snug Smile

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The windscreen has been refitted successfully as have the wiper arms & blades

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Our next section to work on is the left hand battery tray, which needs replacing as the PO cut a hole in it to allow a remote oil cooler to get air blown over it

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KentPS Premium Member
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PostPosted: Wed Sep 27, 2017 4:32 pm    Post subject: Re: Hello from the UK! Reply with quote

That's quite a facelift you've accomplished in a relatively short amount of time. Your bus is looking great! Keep up the good work. And thanks for posting updates on the progress.
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Wasted youth
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PostPosted: Wed Sep 27, 2017 7:10 pm    Post subject: Re: Hello from the UK! Reply with quote

That really is a lot of work! You should get many great years of service out of that. Very inspiring!

Question Did you replace the white plastic air vent hinges on the two fresh air flaps? Mine should be replaced, but I have not looked at a source yet.
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Sloride
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PostPosted: Thu Sep 28, 2017 4:16 am    Post subject: Re: Hello from the UK! Reply with quote

Looks good and all done in that small garage. I thought I was the only one working under those constraints.
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MorkC68
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PostPosted: Thu Sep 28, 2017 4:48 am    Post subject: Re: Hello from the UK! Reply with quote

KentPS wrote:
That's quite a facelift you've accomplished in a relatively short amount of time. Your bus is looking great! Keep up the good work. And thanks for posting updates on the progress.


Thanks Kent, we had worries when we revealed the damage to the front however, we took our time, measured everything several times over and luckily, have our '73 for reference.

We have quite a lot to do yet, work wise Smile
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MorkC68
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PostPosted: Thu Sep 28, 2017 4:50 am    Post subject: Re: Hello from the UK! Reply with quote

Wasted youth wrote:
That really is a lot of work! You should get many great years of service out of that. Very inspiring!

Question Did you replace the white plastic air vent hinges on the two fresh air flaps? Mine should be replaced, but I have not looked at a source yet.


Thanks dude, we are hoping for a good few years out of the bus, we've had him six to date & used it a heck of a lot! Notchboy's westy got me going on the restoration as the bus had been parked in the garage doing nothing for a couple of years. It was a shame it was sat!

The plastic air vent hinges where okay, just a smear of lube on them and all was well, no wear present.

I don't know who may have any, a breaker I guess
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Last edited by MorkC68 on Thu Sep 28, 2017 4:54 am; edited 1 time in total
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MorkC68
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PostPosted: Thu Sep 28, 2017 4:52 am    Post subject: Re: Hello from the UK! Reply with quote

Sloride wrote:
Looks good and all done in that small garage. I thought I was the only one working under those constraints.


I can be cramped in there, at times, we are in the process of moving house to one with a big garage (the one in the photo's is at my parents). We will have a bit more room to work with Smile
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tommu Premium Member
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PostPosted: Thu Sep 28, 2017 7:07 pm    Post subject: Re: Hello from the UK! Reply with quote

MorkC68 wrote:
Sloride wrote:
Looks good and all done in that small garage. I thought I was the only one working under those constraints.


I can be cramped in there, at times, we are in the process of moving house to one with a big garage (the one in the photo's is at my parents). We will have a bit more room to work with Smile


That drive looks pretty steep too. A worry when you're going for a test drive. Embarassed
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MorkC68
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PostPosted: Fri Sep 29, 2017 4:43 am    Post subject: Re: Hello from the UK! Reply with quote

tommu wrote:
MorkC68 wrote:
Sloride wrote:
Looks good and all done in that small garage. I thought I was the only one working under those constraints.


I can be cramped in there, at times, we are in the process of moving house to one with a big garage (the one in the photo's is at my parents). We will have a bit more room to work with Smile


That drive looks pretty steep too. A worry when you're going for a test drive. Embarassed


The steep drive is temporary, a flat drive beckons! But not till March 2018 Smile

We keep our fingers crossed and hope the brakes dont fail Laughing
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MorkC68
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PostPosted: Fri Oct 27, 2017 1:54 pm    Post subject: Re: Hello from the UK! Reply with quote

The battery tray is now done, went really well I'm glad to say.

Tack welded in place to check alignment.
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Welded up and seam sealed.

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When the engine bay gets repainted, we will attend to the battery tray & paint in body colour.
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MorkC68
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PostPosted: Fri Oct 27, 2017 1:59 pm    Post subject: Re: Hello from the UK! Reply with quote

With no particular order in how we are tacking the various sections of the bodywork etc, we moved back up front to tackle the cab floor.

The swivel base needed removing, degreasing and freeing up. We did find two little areas behind each seat belt mount which had rusted through, noting too big, 25mm x 25mm at most.

Left hand side

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Right hand side

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The cab floor is in great condition, surface rust only. This has been cleaned up, Vactan treated and red oxide painted

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The cab floor has got colour on it, I'm just waiting for it drying Smile
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