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Skim
Rants Master
Joined: April 15, 2001
Posts: 17082
Location: GFK 31 Year Vet
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 Posted: Mon Jun 11, 2018 9:32 pm Post subject: Re: 1963 15 Window resurrection |
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Home stretch baby.
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GFK
Samba since before the towers collapsed. Still here.
1953 Kabriolet
1954 Sunroof
1959 Lowlight Ghia vert
1960 Lt Grey Double Cab SMZ LEGIT
1963 Deluxe Turkis Walk Thru 15 Window OG Paint |
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Vwprok37
Samba Member
Joined: March 26, 2016
Posts: 29
Location: Brentwood, NH
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| Posted: Tue Jun 12, 2018 4:08 am Post subject: Re: 1963 15 Window resurrection |
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| Dang man!!! You're so close! Can't wait to cruise down to Flanders with ya!! |
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Tue Jun 12, 2018 6:43 am Post subject: Re: 1963 15 Window resurrection |
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| Skim wrote: |
| Home stretch baby. |
Home stretch is going to be a long one:
I'm looking into foil tape and spray foam as we speak. That's what we Mainers use to patch our rust holes to get our vehicles inspected. Works great! 
Thanks Tony! |
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Tue Jun 12, 2018 6:46 am Post subject: Re: 1963 15 Window resurrection |
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| Vwprok37 wrote: |
| Dang man!!! You're so close! Can't wait to cruise down to Flanders with ya!! |
We are getting closer for sure! It's the journey, not the destination, right? Maybe someone on the journey will bring a trailer? Haha.
3 more months, I better get on it! |
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Tue Jun 12, 2018 7:04 am Post subject: Re: 1963 15 Window resurrection |
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I started welding in the flange for the floor panel, and remembered (after I started hammering on it and it started moving) that I never welded the lip from the walk through center floor to the forward top hat. I didn't do it at the time, because I didn't want to weld above my face. That was pre rotisserie.
Last night:
I also started day dreaming about building up my beam. I asked the owner of a collision center facility if they could get the bow out of the beam. He said no because of the liability. The lower tube is pushed back less than 1/8" on the drivers side. I am going to straighten it out myself. I dug out all of the beam parts while I was at it. A few months ago, I bought a set of NOS trailing arms. I still need everything for the drivers side outside of the trailing arms. I want the pieces to match the OG passenger side, so once I clean up what I have, I will start hunting down some parts:
When I finally started welding the cargo floor flange to the front edge, the gap required some hammering. My new best friend is my air chisel. I got a blunt chisel bit, and carefully worked it up and down the seam to pull things in tight. I got one small section done this morning:
This area is next:
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Skim
Rants Master
Joined: April 15, 2001
Posts: 17082
Location: GFK 31 Year Vet
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| Posted: Tue Jun 12, 2018 8:18 am Post subject: Re: 1963 15 Window resurrection |
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| Burlyhammer wrote: |
| Skim wrote: |
| Home stretch baby. |
Home stretch is going to be a long one:
I'm looking into foil tape and spray foam as we speak. That's what we Mainers use to patch our rust holes to get our vehicles inspected. Works great!
Thanks Tony! |
I poke with Gerson about this piece this past weekend. He said its not something he offers but he CAN and WILL make it for you it has to be done by hand as he doesnt have a die made for it as of now but he has made them for people before so it may be worth looking into.
_________________
GFK
Samba since before the towers collapsed. Still here.
1953 Kabriolet
1954 Sunroof
1959 Lowlight Ghia vert
1960 Lt Grey Double Cab SMZ LEGIT
1963 Deluxe Turkis Walk Thru 15 Window OG Paint |
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Tue Jun 12, 2018 8:36 am Post subject: Re: 1963 15 Window resurrection |
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| Skim wrote: |
| Burlyhammer wrote: |
| Skim wrote: |
| Home stretch baby. |
Home stretch is going to be a long one:
I'm looking into foil tape and spray foam as we speak. That's what we Mainers use to patch our rust holes to get our vehicles inspected. Works great!
Thanks Tony! |
I poke with Gerson about this piece this past weekend. He said its not something he offers but he CAN and WILL make it for you it has to be done by hand as he doesn't have a die made for it as of now but he has made them for people before so it may be worth looking into. |
I have most of the metal salvaged from another bus. What worries me is all of the connecting pieces. That whole drivers side rear corner is rotted. When I finally get to that area after working on the front and middle for the last year, it's going to seem like a whole new project! Can't wait!
Thanks Tony. |
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sgellis
Samba Member
Joined: July 06, 2016
Posts: 2014
Location: SW Nova Scotia, Canada
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Tue Jun 12, 2018 9:10 am Post subject: Re: 1963 15 Window resurrection |
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| sgellis wrote: |
| Burlyhammer wrote: |
| ... The lower tube is pushed back less than 1/8" on the drivers side. I am going to straighten it out myself. ... |
Is the tube arched or is the outside end bent? Accurately measuring the beam could be difficult. If you can find some pipe that will slide tight inside the beam you can extend it out to exaggerate how off it is. |
Stan,
The tube is slightly arched, and the mounting flange is slightly bent. I put a carpenters square across the tubes on this beam, as well as the tubes on two other beams. The other two, the square sits flat on, this one the top tube is tight against the square, but the bottom tube is off. I documented this in the beginning of this thread. I think the offset is minimal enough, that a few extra shims on the lower link pin would fix the issue. I am still going to attempt to straighten it, though. I will post more photos once I get it cleaned up a little.
Thanks |
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Wed Jun 13, 2018 9:27 am Post subject: Re: 1963 15 Window resurrection |
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I decided to order the remaining heater tubes I needed. The ones I havd originally are very rough, and I wanted to be able to wrap up the bottom. Here is what I had:
Here is what I have now assembled:
I still need to figure out haw everything goes together. I also freed up the rusted shut diverter tube from the cab floor to the dash. I have been soaking it with PB Blaster for 3-4 months, and finally got it moving last night. I'm going to clean everything up, and finish a few other items before I install them permanently. I just put them in for a test fit.
I also got a little more done on the floor this morning:
I am hoping to finish the floor this week. We will see. |
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AlanInMass54
Samba Member
Joined: August 29, 2003
Posts: 1070
Location: Massachusetts
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| Posted: Wed Jun 13, 2018 9:31 am Post subject: Re: 1963 15 Window resurrection |
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More wonderful work! It's nice to see that old center tube where it belongs.  |
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Wed Jun 13, 2018 9:33 am Post subject: Re: 1963 15 Window resurrection |
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| AlanInMass54 wrote: |
| More wonderful work! It's nice to see that old center tube where it belongs. |
Thanks Alan. That center tube is awesome. Much appreciated. |
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Thu Jun 14, 2018 6:55 am Post subject: Re: 1963 15 Window resurrection |
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I made a little more progress:
This area is all that is left for welding on the cargo floor:
I did the easy areas first. I don't think the back edge will be that bad with the rotisserie. I am trying to decide how to handle the long panel:
There is a gap approximately 1/2" wide from the floor flange to the wall. If I bend out the flange, there will be no vertical lip left. I knew this was going to happen, but I preferred the center seam where the floor halves meet to be straight, and I would deal with that gap later. Later is now happening. I have a few ideas for what I may do. Anyone else run into this? Suggestions would be appreciated. I think this is a combination of aftermarket parts, and my "creative" engineering.
Thanks |
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KWZ
Samba Member
Joined: July 11, 2004
Posts: 1341
Location: St. Louis, Missouri
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| Posted: Thu Jun 14, 2018 7:15 am Post subject: Re: 1963 15 Window resurrection |
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Spray foam insulation. Duh.
_________________
'57 sunroof Standard
'63 15 window
'65 Westy SO44 |
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AlanInMass54
Samba Member
Joined: August 29, 2003
Posts: 1070
Location: Massachusetts
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| Posted: Thu Jun 14, 2018 7:25 am Post subject: Re: 1963 15 Window resurrection |
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| Could you cut it front to back, move the edge to the outer rocker? Then maybe flange the edge and add in a filler? It would be functional! |
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Thu Jun 14, 2018 7:38 am Post subject: Re: 1963 15 Window resurrection |
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| KWZ wrote: |
| Spray foam insulation. Duh. |
Usually spray foam is my first thought. Lightweight and flexible. 🤔 |
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Thu Jun 14, 2018 7:41 am Post subject: Re: 1963 15 Window resurrection |
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| AlanInMass54 wrote: |
| Could you cut it front to back, move the edge to the outer rocker? Then maybe flange the edge and add in a filler? It would be functional! |
I am considering this. I was also thinking about flattening out the flange and welding a new flange on. That would save welding in a spliced piece. Either way it could get ratty fast. |
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62DoKaGuy
Samba Member
Joined: May 22, 2011
Posts: 1276
Location: Surprise, AZ
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| Posted: Thu Jun 14, 2018 7:50 am Post subject: Re: 1963 15 Window resurrection |
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| Burlyhammer wrote: |
| AlanInMass54 wrote: |
| Could you cut it front to back, move the edge to the outer rocker? Then maybe flange the edge and add in a filler? It would be functional! |
I am considering this. I was also thinking about flattening out the flange and welding a new flange on. That would save welding in a spliced piece. Either way it could get ratty fast. |
Don't sell yourself short! I think you've more than proven your abilities at both fabrication and welding haha. Whatever you do to circumvent the problem will certainly reflect on your ingenuity. Looking forward to seeing your solution. Getting closer and looking badass!
_________________
,,Wenige Menschen denken, und doch wollen alle entscheiden.'' -der Alte Fritz
| EverettB wrote: |
| ...I went at it from both ends but going from the rear didn't seem to do anything, although I did spray some rust breaker in there... |
4/62 Double Cab
5/61 Panel (sold)
4/59 Single Cab (sold) |
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Burlyhammer
Samba Member
Joined: March 07, 2002
Posts: 1693
Location: Great north woods Maine
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| Posted: Thu Jun 14, 2018 7:55 am Post subject: Re: 1963 15 Window resurrection |
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| 62DoKaGuy wrote: |
| Burlyhammer wrote: |
| AlanInMass54 wrote: |
| Could you cut it front to back, move the edge to the outer rocker? Then maybe flange the edge and add in a filler? It would be functional! |
I am considering this. I was also thinking about flattening out the flange and welding a new flange on. That would save welding in a spliced piece. Either way it could get ratty fast. |
Don't sell yourself short! I think you've more than proven your abilities at both fabrication and welding haha. Whatever you do to circumvent the problem will certainly reflect on your ingenuity. Looking forward to seeing your solution. Getting closer and looking badass! |
I am leaning towards Alaninmass54’s suggestion. I think that would be the cleanest solution. Plus my son already drilled all of the spot weld holes. I may have to upgrade my Harbor Freight welding magnets.
Thanks |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 2049
Location: Plymouth, MA
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| Posted: Thu Jun 14, 2018 11:03 am Post subject: Re: 1963 15 Window resurrection |
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I'd cut the end flange off on a flat section of the floor and either butt weld in filler strip in the middle of the floor and cut off flange or just make a completely new extended flange and butt weld that in. (Just like if it we're rusted away )
_________________
1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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