www.dsk.com.au

So here is the project that I have finally got moving on. I could not quite figure out where to begin because the extent of the rust and which direction I wanted to go with it.

Finally decided to make a useable driver out of it, fixing the major rust, replacing all suspension and mechanicals and leaving the outside ratty.

Originally a 62 LHD Single Cab, to be converted to a 54 RHD Single Cab. Not going to the full extent of making it look exactly like a barndoor bus, just the major points.







A few photos to show the extent of some of the rust









Frame horns became weak and rusty and bent when they couldn't hold the bus on the dolly anymore

So I began to cut and replace..trying to make as much solid again before I cut away more and weaken the structure further..

Repaired the left side front frame section











Sourced a rear bus section for the frame horns...









Began final repair on left side inner frame section...











That brings us fairly current. I have a boatload of Gerson metal to install and about 30 days to do it. Trying to make my first Buses By the Bridge in Havasu, AZ Middle of January. Adventurous goal, but I'm going to make a run at it. More to come...

Wow that's rusty!!!!

Nice work saving it

I love seeing some one with your awesome skills bring back to life a bus (or pick up in this case) that for most of us would be considered beyond repairing. As opposed to cringing when I see an amateur do-it-selfer buy a totally rusted out bus and think they can restore it..... Having a go is admirable but not being realistic about the skills needed and cost invested (all those Gerson panels ain't cheap) sees many incompleted or badly welded examples.....

Hats off to you !!!

Have you been following that Austrian dude on his Samba thread also restoring an old pick up? He's got pretty mad skills, too.

Love it!!!!

Wat! Nice Barndoor, how can it be so nice up top and so rusty down under?

I have seen rusty buses, but never anything with rusty trans horns! Good job on getting on 'er!

Thank you sirs! It definitely would most likely not be saved given its condition, but I'm having a go at it...and my labor is free..kinda...

Haven't see the Austrian thread..have a link??

dawerks..you're bus is rusty on the frame, but I'm still amazed at the lower panels. Mine is wasted 10" up from the bottom all around. Get on that creme puff!

Here's the link of the Austrian guys restoration.....

http://www.thesamba.com/vw/forum/viewtopic.php?t=605363

Big job but hey at least you don't need to make or find an engine lid.

KombiMadness wrote:Here's the link of the Austrian guys restoration.....

http://www.thesamba.com/vw/forum/viewtopic.php?t=605363

Cool thread! I love how many of his own panels he makes without significant modern tools..very creative!

Worked some more on the rear frame section





Cut out the damaged section



Fitted the new piece



Welded up the newer outer section..sorry for the blurry pic



Bent up the new inner structure



Burned in the repair panel



Fully welded panel



Worked on the front inner valance as well..getting it all burned in.



More later..hope you enjoyed the pics.