Nova Scotian 54 standard restoration

[sgellis]

[sgellis]

Finally somewhat satisfied with the dimensions I recorded. Once I discovered the rear torsion beam was to the right 4 mm and forward 2 mm on right and twisted 2°, things started to come together.

Removed the laser alignment system.

Started removing doors. Tried an impact screw driver but wouldn't remove one screw. Welded on the screws and backed some out. Twisted one off in every tapping plate but figure I will make new ones anyway. The rear cargo door I just drilled out the screws as it was faster.

One cargo door hinge still had the rubber plugs in.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[myklsmyth]

I bet that feels pretty good! Looking good sir.

[sgellis]

[djfordmanjack]

my favorite way of screw extraction. drilled out 8mm (13mm wrench) nuts.

you could try to get out the twisted off screws, by drilling them with base diameter(6.8mm) slightly off center, so you can get ahold and pick a few threads with a metal pick, so much until you can start a (ground flat on top) 8mm tap and recut the rest of the threads. This has often worked for me with great results ( ie saving the original threads without having to remove, weld or insert-nut the original fastener plate). Sometimes ( when you get them moving) it is also easier trying to drive the broken screws IN, so they fall down inside the A post. you need to fish for them with a magnet through a hole, because of the reinforcement brackets inside the a pillar, some won't fall out on the bottom.
I am sure you know all of these tricks anyways...
_________________
Hotrods, Fords, Veedubs and Triumph Twins !

52 Barndoor DLX Coachbuild project
55 Wolfsburg panel project, og paint Taubenblau L31
62 Dickholmer, custom color Seeblau L360
63 1500 Notch, og paint Rubin Rot L456
67 1500 Käfer, og paint Lotus weiß L282 w/red interior

[sgellis]

Few more parts off today.

Fuel tank is not as good as I thought. Could still repair it but may be just as quick to build from scratch. Either way I would need a 80mm spout, let me know if you have a spout Spare tire tray is bad but I will rebuild it. Had good luck 3D printing press dies so shouldn't be a problem creating the missing bits.

Not going to worry about bolt on parts untill the body is done anyway.

Almost time to remove the body!

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[sgellis]

Body off.

I wasn't planning to remove it today. It kinda just happened.

I cut the roof 20mm up from drip rail so I can easily replace the lip.

Freed the rear body from frame. Just the few spot welds to rear frame. Turns out the rusty rear of a bus is not very heavy so pulled it off.

Freed the front by cutting across the bulkhead. It was rusty where the panels welded to it anyway. Heater duct and a short bit of floor was all the was left after.

Now I need to document all the parts as I remove them from the frame.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[djfordmanjack]

^
that is a novel way of pulling a Barndoor body !

I mean, if the roof drip rails were rusty all around, it may have been necessary to remove the roof skin anyways. You got yourself into a pretty wild big puzzle.

on the other hand it will give you plenty of room to straighten out parts and square it up from the very foundation. your chassis looks quite good !
_________________
Hotrods, Fords, Veedubs and Triumph Twins !

52 Barndoor DLX Coachbuild project
55 Wolfsburg panel project, og paint Taubenblau L31
62 Dickholmer, custom color Seeblau L360
63 1500 Notch, og paint Rubin Rot L456
67 1500 Käfer, og paint Lotus weiß L282 w/red interior

[sgellis]

Most of the drip rail looked great from the outside but I knew it would be bad inside and replacing all the drip rail will make reassembly much easier. Most of this roof is garbage. I have two newer donor roofs so will make one from the three. It will be easier to just replace the 20mm around the roof edge than try to split the rusty seam anyway.

Interestingly the lip on the roof was very poorly shaped. Some areas have a large radius like this section and some spots a sharp bend. Also the lip width varies a lot and is not very straight. Almost looks like it was hand bent on the roof after pressing.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[sgellis]

Found this interesting.

I noticed the front ceiling liner hooks were doubled up at both sides but only one was used.

I documented where they all were. Quite sure they just put them on at random.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[djfordmanjack]

Those cuts are superb and rarely seen ! Thanx for showing that. I believe that a lot of 'non-cutting-up-things' bus people have no idea at all how the inner structure of our buses were designed and why often the rain gutters rust out from INSIDE.
I see your point in completely cutting the roof away. (While it may have been possible to get away with a partial treatment of surface rusted areas and flooding cavities with wax on a patina type of restoration).
Luckily my donor roof is rotted all around as well, so I will also have to rebuild the whole perimeter. May be a good decision on the long run, compared to saving the original structure, only to find bubbles on fresh paint ( coming from inside) after a few years!

[djfordmanjack]

same here, interestingly enough my 1955BD donor clip has the twin hooks in exactly the same spot as yours and the same inner hook hasn't been used. maybe not a mistake or coincidence?

_________________
Hotrods, Fords, Veedubs and Triumph Twins !

52 Barndoor DLX Coachbuild project
55 Wolfsburg panel project, og paint Taubenblau L31
62 Dickholmer, custom color Seeblau L360
63 1500 Notch, og paint Rubin Rot L456
67 1500 Käfer, og paint Lotus weiß L282 w/red interior

[sgellis]

[LAGrunthaner]

This build shall too be epic. Clear explanation, I feel like I’m there
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Maui Roadsters
www.mauiroadsters.com
http://www.oacdp.org

[sgellis]

Gathering all the details before anything gets removed.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[sgellis]

What is this hole?

Was there when factory paint was applied. I though there was just something stuck to the metal but it turned out to be a rubber plug in this hole.

_________________
My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

[BeaterBarndoor]

Interesting to see there was a plug there. Just last week I was asking around to confirm this was factory and not a hack on my bus(although I found images of my older buses with it as well)
It seems the only logical reason for it was drainage maybe? Certainly odd for just one side.
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www.thebustransfer.com

Whaaaaat?

[sgellis]

[EverettB]

[RockStock]

One up, one down headlining rod prong pair at the outer edges is a thing

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-StockRocks-