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Nova Scotian 54 standard restoration
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sgellis
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Joined: July 06, 2016
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Location: SW Nova Scotia, Canada
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PostPosted: Wed Dec 27, 2023 4:07 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Finally back in the shop.

Finished off the steering box frame today. Old one was not savable but pedal tube was still good.

I used the tig welder to create spot welds as I never got around to ordering the copper to make custom electrodes for my spot welder. It doesn't like 14g steel anyway. Trick is to make sure the metal is tight together or you end up with a nice hole in the top layer. Smile

Drawings
https://grabcad.com/library/front-frame-structure-vw-barndoor-1/details?folder_id=13937969

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vw356
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PostPosted: Sun Dec 31, 2023 10:42 am    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Looking great! I see why you do not want to buy parts.. Yours are better!
Looking forward to your next video too!
Thank You for sharing!
Happy New Year!
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Huetti_1989
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PostPosted: Tue Jan 02, 2024 7:03 am    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

i know the problems to weld with tig to looks like Spotwelds, you need to make the lower part realy hot.

i done some sinking on the top part, it helps me to generate some quick melting thinner metal.

-Christian
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sgellis
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Location: SW Nova Scotia, Canada
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PostPosted: Thu Jan 04, 2024 6:21 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Got an unloved 54 tank. Smile
The owner decided to get a better tank and sold this one to me for a reasonable price. Good tanks are too pricey for me. Haha

Mine was so bad I figured it would be easier to build one from scratch. This one will be an easy fix. All rust is from the outside. Top has some deep pitting that will need replacing. Small hole in the filler and a section on the end will need replacing. After repair it will get a liquid liner that will take care of the flange seam where I need to replace some metal.

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sgellis
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PostPosted: Thu Jan 04, 2024 7:09 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Another part done.

My beam had swelled in the seams and had many holes so easier to build new. I saved the master cylinder bracket, accelerator bracket and spring tab, park brake washers and hook. Remainder is new.

Welds are actually better than the originals. With higher heat and wire feed you can make strong welds that look like shitty stick welding. I assume they used coat hangers and car batteries to weld these things together. Smile I am amazed at how bad some of the welds were on this bus.

Edit: I just realized I welded the master cylinder bracket on backwards. I felt something was off... Annoying but easy fix.

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sgellis
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PostPosted: Tue Jan 09, 2024 7:35 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Another assembly done.

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FritzCP
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PostPosted: Thu Jan 11, 2024 10:48 am    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

awesome work. Thanks for keeping the thread updated. To see progress like this helps keep me (and others Im sure) motivated to work on my own turd projects.
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kadeef 1
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PostPosted: Thu Jan 11, 2024 1:53 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Perfect work, there is a lot of important information and experience in your work for my renovation, I love your topic. Ivan
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sgellis
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PostPosted: Sun Jan 21, 2024 4:02 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Started the under seat panel.

Tried the bead roller but was a lot of work. I stretched the metal first with an english wheel then through the bead roller with 3D printed dies. Thinner steel would be much easier.

I decided to make a die and press them in. Will save time and look better. I was going to press in the terminations anyway. Need to pickup some 3/16" steel for the die.

Started on the splash panel. Needed a bit more hammer and dolly work. Also cut out a couple rusty bits

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The Nova Scotian Barndoor (CAD drawings)
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sgellis
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PostPosted: Sat Jan 27, 2024 4:27 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

That's done.

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sgellis
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PostPosted: Sun Jan 28, 2024 2:06 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Pressed in some ribs today. Much easier and faster than bead rolling.

Last rib I pressed was off 3mm at edge so will need to split and narrow that section. Used the wrong mark. I was a bit annoyed. Smile

Overall I am pleased with how the ribs came out.

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My 54 standard restoration
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Huetti_1989
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PostPosted: Sun Jan 28, 2024 11:56 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Nice work man!!

do you ever thinked about buying a power hammer for a work like this?

The Pullmax is a dream from me, but expensive, heavy and big...

-Christian
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My 1954 Deutsche Bundespost Barndoor:
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My 1961 SO34 Flipseat Westfalia:
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jborregoy2k
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PostPosted: Mon Jan 29, 2024 2:24 am    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Thanks for documenting this project. Feel inspired by your work. I’m almost in the same part you are doing right now, so eagerly waiting for your youtube episode.

Cheers from El Carmen de Viboral, Colombia (South America)

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sgellis
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PostPosted: Mon Jan 29, 2024 5:38 am    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Huetti_1989 wrote:
Nice work man!!

do you ever thinked about buying a power hammer for a work like this?

The Pullmax is a dream from me, but expensive, heavy and big...

-Christian


Thanks

Would love to have a Pullmax but too expensive for me. I am thinking of building a cheep power hammer with an air chisel though. It would do shaping and planishing.

For this part pressing was easier anyway but for the rear floor panels a power hammer with sliding guide would be nice to get the ribs perfect.
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Blue Baron
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PostPosted: Mon Jan 29, 2024 4:21 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

sgellis wrote:

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Next thing you'll be building a Kubelwagen from scratch.
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PostPosted: Tue Jan 30, 2024 1:14 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

amazing!! absolutely amazing!
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sebgi1
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PostPosted: Tue Jan 30, 2024 3:42 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Amazing work!!

Power hammer for cheap…
https://youtu.be/pN4lP-bvNqk?si=SRQQlUjakgI-JGCi
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sgellis
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PostPosted: Wed Jan 31, 2024 4:35 am    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

sebgi1 wrote:
Amazing work!!

Power hammer for cheap…
https://youtu.be/pN4lP-bvNqk?si=SRQQlUjakgI-JGCi


I was thinking of a combination of that and something like this.
https://www.youtube.com/watch?v=ebJxjrXQ1d8&t=16s

Doesn't need as strong a frame as it is impacting and not pressing. Not sure how light it can be made though.
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kadeef 1
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PostPosted: Wed Jan 31, 2024 2:21 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

As always, amazing metalwork. Ivan
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sgellis
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PostPosted: Wed Jan 31, 2024 6:11 pm    Post subject: Re: Nova Scotian 54 standard restoration Reply with quote

Decided I was not going to get this welded properly without a jig. This holds everything in position and will make fitting easy.

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