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mdege
Samba Member
Joined: January 16, 2018
Posts: 940
Location: Niederkruechten, Germany
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 Posted: Sun Nov 24, 2019 10:19 am Post subject: Re: Restoration of a former '65 firetruck (21F) |
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The weather gods were favorable with me this weekend and i was actually able to get some stuff done on the van.
Yesterday I puttied some of the welded areas like the left rear corner, the short rocker panel on right and the nose panel. I post some picture once i sand the areas.
Last week I tried to straighten out the rear cargo door by adding tin or pewter to the area where the repair panel was welded to the old door-skin. The was a total disaster. The whole panel warped. I then decided to replace the complete lower door-skin.
Fitting the new door-skin:
I still need to clean the inner frame and then I will spot-weld the new skin to the frame.
Next I installed the last part of the heating duct, unfortunately one or both of the sections was too short and the long one is a bit small in diameter. I added a 6cm adapter between the long and the short pipe.
And I spray painted the heater pipe and the engine compartment.
_________________
- Michael
1965 21F: Restoration of a former '65 firetruck
1963 Typ3 Notchback project
1988 Multivan Magnum 112i
1984 Standard: My son wanted a bug for his first car |
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Jimb0w
Samba Member
Joined: September 08, 2016
Posts: 36
Location: France, Clermont-Ferrand
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| Posted: Mon Nov 25, 2019 12:38 pm Post subject: Re: Restoration of a former '65 firetruck (21F) |
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good job as usual  I want to try tin too on my welds but keep panels from warping is not an easy job ! |
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djfordmanjack
Samba Member
Joined: June 15, 2009
Posts: 2177
Location: Graz, Austria, Europe
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| Posted: Mon Nov 25, 2019 4:29 pm Post subject: Re: Restoration of a former '65 firetruck (21F) |
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guys, our US friends call this 'lead' work. ('tin' is cheap quality sheetmetal).
leadwork is not easy and I feel it is not necessary today. VW only used it to reinforce the body joints like on the A and B pillars. the lead is not the problem , but the heat and especially the acid to clean the surface and prepare for soldering is the problem. I believe there is no way to completely remove the acid from the seams. today it is better to do clean and solid welds and use quality filler and bonding plastic. JMHO.
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Hotrods, Fords, Veedubs and Triumph Twins !
52 Barndoor DLX Coachbuild project
55 Wolfsburg panel project, og paint Taubenblau L31
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63 1500 Notch, og paint Rubin Rot L456
67 1500 Käfer, og paint Lotus weiß L282 w/red interior |
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mdege
Samba Member
Joined: January 16, 2018
Posts: 940
Location: Niederkruechten, Germany
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| Posted: Mon Nov 25, 2019 10:27 pm Post subject: Re: Restoration of a former '65 firetruck (21F) |
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I have used tin/lead successfully in some areas like the front nose. I use it to fill up the areas where I need more material. Places where I would need too much filler (Bondo).
I use an acid free flux, which doesn't work as well as the old stuff, but it is not as aggressive.
I recently watched a documentary on the VW Classic workshop in Hannover where they specialize on the restoration of old Type 2s. They use tin/lead on basically all welds even in locations which won't be visible once all panels are installed.
I think a big flat panel like a door-skin is probably really tricky not to warp it when using heat. But parts which are smaller or are sturdier due to their form are easier to work on with heat.
_________________
- Michael
1965 21F: Restoration of a former '65 firetruck
1963 Typ3 Notchback project
1988 Multivan Magnum 112i
1984 Standard: My son wanted a bug for his first car |
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TRS63
Samba Member
Joined: December 17, 2017
Posts: 999
Location: Stuttgart - Germany
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WOB-SAM
Samba Member
Joined: May 28, 2007
Posts: 60
Location: Fatherland an SOCAL
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| Posted: Fri Dec 06, 2019 10:06 am Post subject: Re: Restoration of a former '65 firetruck (21F) |
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Amazing work 
One Question - when you placed the front valance/ cover what are the upper spot welds connected to?
Isn‘t the upper part just sticking free?
Or connected to the inner valance?
Doing kind of the same thing right now.
SAM
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WOB-SAM
Samba Member
Joined: May 28, 2007
Posts: 60
Location: Fatherland an SOCAL
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| Posted: Fri Dec 06, 2019 10:10 am Post subject: Re: Restoration of a former '65 firetruck (21F) |
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Amazing work
One Question - when you placed the front valance/ cover what are the upper spot welds connected to?
Isn‘t the upper part just sticking free?
Doing kind of the same thing right now.
SAM |
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mdege
Samba Member
Joined: January 16, 2018
Posts: 940
Location: Niederkruechten, Germany
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WOB-SAM
Samba Member
Joined: May 28, 2007
Posts: 60
Location: Fatherland an SOCAL
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| Posted: Fri Dec 06, 2019 4:49 pm Post subject: Re: Restoration of a former '65 firetruck (21F) |
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Danke Michael,
So where did you source your Dogleg Replacement Parts?
THX
SAM  |
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mdege
Samba Member
Joined: January 16, 2018
Posts: 940
Location: Niederkruechten, Germany
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| Posted: Sat Dec 07, 2019 1:27 am Post subject: Re: Restoration of a former '65 firetruck (21F) |
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You are welcome Sam
I source most of my parts at either of the two local places:
https://en.hoffmann-speedster.com/
https://www.bus-ok.de/
The owner of Hoffmann Speedster meantioned, that a lot of the better metal comes from Wolfsburg West. They don really tell you where the stuff is from. And they peal off the original labels. It's kinda silly.
What I did not like about the doglegs is that they came already welded together. That makes it impossible to correctly weld (hidden) them to the B-pillar. I pulled them back apart and welded in the outer part first and then the inner part. I was able to spot weld most of the welds. For some I had to use the MIG.
_________________
- Michael
1965 21F: Restoration of a former '65 firetruck
1963 Typ3 Notchback project
1988 Multivan Magnum 112i
1984 Standard: My son wanted a bug for his first car |
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mdege
Samba Member
Joined: January 16, 2018
Posts: 940
Location: Niederkruechten, Germany
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TRS63
Samba Member
Joined: December 17, 2017
Posts: 999
Location: Stuttgart - Germany
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mdege
Samba Member
Joined: January 16, 2018
Posts: 940
Location: Niederkruechten, Germany
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| Posted: Mon Dec 30, 2019 12:56 pm Post subject: Re: Restoration of a former '65 firetruck (21F) |
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I continued the reassembly of my van.
Unfortunately I was only able to salvage two front brake cylinders. I had a whole bunch of old ones but most of them were in a too bad shape to save them.
I had bought two new rear break cylinders. I opted for the TRW ones thinking I would get decent quality, but I had to de-burr and surface the mounting hole on both of them. If I had known, that Varga belongs to TRW, I would have gone for the ATE cylinders, which cost three times as much as the TRW. I really wonder how bad the even cheaper ones are.
I tipped the bus on it's side for the last few things. I installed the steering box.
And the insulation for the heating tubes. The two long sections were NOS parts which were given to me by the local VW dealer in 1989, when they cleaned out some old parts they didn't need anymore.
Now the time has come to remove the van from the rotisserie.
Today a friend came over to help me reinstall the axles. First we installed the NOS spring plates with NOS rubber bushings.
Then the transaxle.
And then the front axle.
What really got us was the orientation of the special washers for the front axle. according to the shop manual they are supposed to point to certain directions. But, it was impossible to get the top rear washer into the defined direction. The holes would not lineup. I finally looked at my spare axle and it had the same issue, but I could clearly tell from the marks on the axle that the original washer was installed pointing downwards and not to the rear.
_________________
- Michael
1965 21F: Restoration of a former '65 firetruck
1963 Typ3 Notchback project
1988 Multivan Magnum 112i
1984 Standard: My son wanted a bug for his first car |
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mdege
Samba Member
Joined: January 16, 2018
Posts: 940
Location: Niederkruechten, Germany
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| Posted: Sun Jan 19, 2020 10:07 am Post subject: Re: Restoration of a former '65 firetruck (21F) |
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Time for an update.
Meanwhile I finished the brake assembly
Using an original NOS felt seal
Installed the gastank
Drilled hols for the license plate and painted the engine lid
Rewired everything in the front and reinstalled the gauges and switches
Installed the extra turn signals which are a special feature of German firetrucks of this vintage
It was a stupid idea to hang it to dry, now I have some nasty runs
also painted an installed the left cargo door, the right one will eventually also be restored and repainted
Cleaned and repainted the starter
_________________
- Michael
1965 21F: Restoration of a former '65 firetruck
1963 Typ3 Notchback project
1988 Multivan Magnum 112i
1984 Standard: My son wanted a bug for his first car |
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wcfvw69 
Samba Purist
Joined: June 10, 2004
Posts: 13389
Location: Arizona
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| Posted: Sun Jan 19, 2020 10:48 am Post subject: Re: Restoration of a former '65 firetruck (21F) |
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Beautiful work. It's coming together very nicely!
Keep the updates coming!
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc
Decades of VW and VW parts restoration experience.
The Samba member since 2004.
**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours** |
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TRS63
Samba Member
Joined: December 17, 2017
Posts: 999
Location: Stuttgart - Germany
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mdege
Samba Member
Joined: January 16, 2018
Posts: 940
Location: Niederkruechten, Germany
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| Posted: Sun Feb 09, 2020 11:31 am Post subject: Re: Restoration of a former '65 firetruck (21F) |
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Yesterday it was time to reinstall the motor.
I had a bit of trouble with the fuel pump and one of the carbs. The carb was overflowing. I measured the fuel pressure and it was approximately 4-5 times as high as it is supposed to be. The rebuilt fuel pump was putting out way too much pressure. I fixed that by taking some of the tension out of the membrane spring.
Unfortunately that didn't fix the carb problem. I checked the needle valve and added a thicker washer but still it was overflowing. You could really see the gas flowing out of all possible openings and you could also hear it bubling once the engine was shout off. I have no idea what is wrong with it at the moment.
Here is the culprit:
Luckily I have second one and that one works fine.
Today I put on some old wheels
and took the van off the jack-stands. Then I torqued the rear axle nut and drove the van out of the garage for the first time under its own power since probably 2005.
_________________
- Michael
1965 21F: Restoration of a former '65 firetruck
1963 Typ3 Notchback project
1988 Multivan Magnum 112i
1984 Standard: My son wanted a bug for his first car |
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djfordmanjack
Samba Member
Joined: June 15, 2009
Posts: 2177
Location: Graz, Austria, Europe
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mdege
Samba Member
Joined: January 16, 2018
Posts: 940
Location: Niederkruechten, Germany
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swiss_bulli
Samba Member
Joined: February 17, 2017
Posts: 123
Location: Switzerland
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| Posted: Sun Feb 09, 2020 2:57 pm Post subject: Re: Restoration of a former '65 firetruck (21F) |
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Awesome progress and congratulations to your „first“ drive. I‘m looking forward to the moment it will happen to mine as well. But my progress isn‘t that fast, but you remind me of updating my own build thread...
Take care while storm Sabine is approaching!
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Recent pics from my SO-42 rebuild: https://www.instagram.com/anni_vintage_bus/ |
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