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MorkC68
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Joined: December 23, 2015
Posts: 610
Location: Nottingham, England
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PostPosted: Wed Nov 15, 2017 3:38 pm    Post subject: Cab Floor area sorted! Reply with quote

With the welding on the rust spots near the driver/passenger seat belt anchors sorted & oxide primed, we bought a tin of the Rustoleum Combi Colour Yellow (RAL 1028) to colour coat it all. The shade was slightly different but nothing to worry about!

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We also gave the left hand battery tray a couple of protective coats

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Ive got to refit the mats sometime soon, Ill do a bit here and there!

I removed the tailgate seal to see what the recess is like around the bottom corners - the left handside radius has rust holes in places. Photos to follow Sad
_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Joined: December 23, 2015
Posts: 610
Location: Nottingham, England
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PostPosted: Wed Jan 03, 2018 3:03 pm    Post subject: Re: Hello from the UK! Reply with quote

As I said in my previous post, the tailgate seal was removed. Quite messy too, looks like water was trapped behind it causing rust holes to form. Luckily it was localised.
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We fabricated some new sections and welded those in place:
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Etch primed all the way around, gentle skim of filler to even it all out and we're sorted Smile
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_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Joined: December 23, 2015
Posts: 610
Location: Nottingham, England
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PostPosted: Wed Jan 03, 2018 3:14 pm    Post subject: Re: Hello from the UK! Reply with quote

The rear vents have suffered from rusting internally, on investigation quite badly in the beltline/bulge area, hidden away from an easy line of sight.
It was not easy but we managed to rub it down, rust treat it and prime.

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After a blast of Schultz stone chip with rust inhibitor, we managed to blast some colour in, the spray gun was a bit large and didn't cover as good as we hoped. We will source a smaller modellers style spray gun

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_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Joined: December 23, 2015
Posts: 610
Location: Nottingham, England
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PostPosted: Wed Jan 03, 2018 3:18 pm    Post subject: Re: Hello from the UK! Reply with quote

Moving on to the rear of Major, we prepped all of that in readiness to paint it. It turned out quite good too Smile
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The tailgate was resprayed in 2013, based on 30 plus years of aging, needless to say it needs doing again!
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New side marker light fitted to celebrate a good few days Very Happy
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_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Joined: December 23, 2015
Posts: 610
Location: Nottingham, England
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PostPosted: Tue Feb 06, 2018 3:29 pm    Post subject: Re: Hello from the UK! Reply with quote

Ive not updated this thread in a while, been quite busy sorting the right hand side of the bus out.
The bodywork itself right along the right, from the rear corner to the front panel has been flattened back to find any rust blemishes, which their was, they are all sorted now, the right hand rear window aperture had some rust and pitting under the seal

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cleaned up, rust treated, light coat of paint and some fine filler

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The sill under the sliding door had some excessive rust, which cleaned up quite nice and shows no signs of needing replacement

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That saves us some work! Smile
_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Joined: December 23, 2015
Posts: 610
Location: Nottingham, England
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PostPosted: Tue Feb 06, 2018 3:37 pm    Post subject: Re: Hello from the UK! Reply with quote

The right hand front / rear wheel arch tubs supposed to be Dinitrol protected, however, the "professional" who did the work, didn't do a very good job as the rust is everywhere. We figured that we ought to sort those out at the same time

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the wheelarch lip cleaned up okay for now, will re visit those later, however, we did Vactan treat them

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We found a section which had been lead loaded, possibly due to damage, but that sorted okay!

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_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Joined: December 23, 2015
Posts: 610
Location: Nottingham, England
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PostPosted: Tue Feb 06, 2018 3:42 pm    Post subject: Re: Hello from the UK! Reply with quote

To aid us doing the rear wheelarch, we removed all of the hubs, brake assemblies, and spring plate for cleaning and painting & replacement of the two rubber donut bushes and brake cylinder

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the wheelarch tubs look bad but underneath the muck, aren't too bad he says hopefully!

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_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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zerothehero
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Joined: March 16, 2008
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Location: Derbyshire
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PostPosted: Tue Feb 06, 2018 3:59 pm    Post subject: Re: Hello from the UK! Reply with quote

Nice progress Mark!
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I like caves..
Caves are cool
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1979 Devon Moonraker 1600 twin port
1978 Oz Microbus 2000 FI Auto
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MorkC68
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Joined: December 23, 2015
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Location: Nottingham, England
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PostPosted: Tue Feb 06, 2018 4:02 pm    Post subject: Re: Hello from the UK! Reply with quote

zerothehero wrote:
Nice progress Mark!


Thanks mate, we have a long way to go!
_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Posts: 610
Location: Nottingham, England
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PostPosted: Thu Mar 01, 2018 3:04 pm    Post subject: Re: Hello from the UK! Reply with quote

Over the past few weeks we have been busy working on repainting spring plates, axle hubs and wheelarches.

The right hand wheel arch looked quite rough after the Dinitrol & underseal was removed

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The areas showing severe signs of rust cleaned up nicely to shiny metal and had no rotten areas at all, which was in our favour. A generous application of Vactan, and a few coats of POR 15 made things look much better

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_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Joined: December 23, 2015
Posts: 610
Location: Nottingham, England
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PostPosted: Thu Mar 01, 2018 3:11 pm    Post subject: Re: Hello from the UK! Reply with quote

Once that was tidied up we could stone chip the wheelarch tub and work toward rebuilding it all.

Stonechip applied

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A couple of good coats of Rustoleum made the effort well worthwhile

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We had started on rebuilding the running gear until snow stopped play. The assembly has all been given a good covering of undercoat and black rustoleum top coat

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We have also replaced the rear brake cylinder, new solid brake line, torsion bar rubber donuts, the A arm rubber bush was new around 1500 miles ago, as was the damper and also the rear brake shoes.

Slowly slowly catchy monkey Very Happy
_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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WildIdea
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PostPosted: Thu Mar 01, 2018 5:37 pm    Post subject: Re: Hello from the UK! Reply with quote

Being all up under a wheel wheel with arms overhead is never fun. It’s looking like it can take whatever a tire can throw at it now.
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MorkC68
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Location: Nottingham, England
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PostPosted: Fri Mar 02, 2018 1:39 pm    Post subject: Re: Hello from the UK! Reply with quote

WildIdea wrote:
Being all up under a wheel wheel with arms overhead is never fun. It’s looking like it can take whatever a tire can throw at it now.


Its a pain to do, but when you get results, its satisfying! Front right next Smile
_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Joined: December 23, 2015
Posts: 610
Location: Nottingham, England
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PostPosted: Wed Apr 18, 2018 1:20 pm    Post subject: Re: Hello from the UK! Reply with quote

Well, since the last update, we haven't been sat with idle hands, we have been focusing on the right hand front end.

As with the r/h rear wheelarch, it looked pretty messy, again, the Dinitrol was applied over rusty areas which had no preparation Sad

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We found a 2" square rotten section where the two bungs are where the waxoyl points are located

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Scraping off the old Dinitrol revealed no other nasty surprises, which was good Smile

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_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Joined: December 23, 2015
Posts: 610
Location: Nottingham, England
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PostPosted: Wed Apr 18, 2018 1:25 pm    Post subject: Re: Hello from the UK! Reply with quote

Once we had cleaned everything up, rust treated the nasty areas, we could get some red oxide primer on and get the metal protected

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and a new section welded in
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Time to refresh any old seam sealer and get some stonechip laid down along with colour!

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_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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Location: Nottingham, England
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PostPosted: Wed Apr 18, 2018 1:36 pm    Post subject: Re: Hello from the UK! Reply with quote

As part of the paint process, we decided that the suspension arms needed refreshing too, along with the brake caliper and disc backplate.
However, we also found that the taper bearing on the axle hub grumbled so we replaced those at the same time.

The caliper was covered in rust & the piston corroded to the seal. One rebuild kit and it was easily sorted!

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descaled
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and repainted
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new pistons & seals
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Ready to be remounted
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Disc backplate repainted
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The suspension arms are looking tidier, the backplate remounted. Stub axle has new wheelbearings, the clearance set correctly, new kunifer brake pipe.

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I'm pleased with how this has gone, progress! Very Happy
_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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PostPosted: Fri May 25, 2018 2:14 pm    Post subject: Re: Hello from the UK! Reply with quote

We have been busy these past weeks, getting the right hand side painted up nice and fresh.
The prep work went really well and has a nice shine to it - we need to leave the paint to harden some more before it gets a good polish.
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First coat of colour
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Clear coated & sorted!
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I'm happy with the results Very Happy
_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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MorkC68
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PostPosted: Fri May 25, 2018 2:27 pm    Post subject: Re: Hello from the UK! Reply with quote

However, moving on to the left hand side to prepare for paint, removed the louvre window and the frame was okay, some surface rust but nothing to worry about. The rear window was a different story
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Oh my Sad

Alan Schofield does a three piece repair kit, which arrived quickly!

We plan to do a section at a time so the panel doesn't warp when we weld it, so we cut away the first part successfully

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We had some pin holes to repair where the spot welds didn't clean up when we removed the rotten section, we had to use a copper heat sink, again avoiding warpage which went well.
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Cleaned up & rust treated in the recesses ready to try and paint.

More to follow Very Happy
_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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orwell84
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PostPosted: Fri May 25, 2018 5:57 pm    Post subject: Re: Hello from the UK! Reply with quote

Good solid bus. Nice work too, not cutting out more than required, tidy welding and back together. It gives me hope for my respray as it is quite similar. I did my windshield and rear window frames, painted them and put it back together with new seals. If I pull too much apart, I always underestimate the time it will take, things get lost and my bus might as well be a dumpster.
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MorkC68
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Joined: December 23, 2015
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Location: Nottingham, England
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PostPosted: Sat May 26, 2018 1:02 am    Post subject: Re: Hello from the UK! Reply with quote

orwell84 wrote:
Good solid bus. Nice work too, not cutting out more than required, tidy welding and back together. It gives me hope for my respray as it is quite similar. I did my windshield and rear window frames, painted them and put it back together with new seals. If I pull too much apart, I always underestimate the time it will take, things get lost and my bus might as well be a dumpster.


Thanks buddy, we are lucky it’s a nice solid shell but I did let the bus down by leaving it stored for two years with no use. I underestimated the rust starting to spread but we are on it now.

We wanted to be able to retain as much original bodywork as possible, which I think we are succeeding with, and enjoying it too!
_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/
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