59 Split 11 Window - Resto

chillax · Post by **chillax** » Mon Nov 10, 2008 8:48 pm

hahaha

Longimanus is sniffing a barny's bum

chillax · Post by **chillax** » Wed Nov 12, 2008 6:37 pm

The rust in the side windows was repaired today

Holes were drilled in the outer repair section so it could be plug welded to the inner repair section once in place

All three inner frames had similar problems to this which required repair

So tonight they were all done - unfortunately still more rust to fix though! One repair at a time

Onto the cargo door repairs then including pulling out some dents

The lap joint of new skin was filled after treating the entire panel with deoxidine ot condition the bare metal. More work to come after the doors are primed.

chillax · Post by **chillax** » Thu Nov 13, 2008 9:35 pm

Creative Safaris went in today

The slightly bigger seal was used from Clark Rubber ("pinchweld small" Clark product code is 19899 manufacture code is 322077, thanks Kanaka) to hopefully make sure there are no leaks.

The centre bracket had to be cut down the middle then welded on individually (each side) to get the fit right

Safaris will be removed and frames painted to match body colour

Jack

frenzix · Post by **frenzix** » Thu Nov 13, 2008 9:40 pm

looking lovely, are you using the seals that came in the kit for the safaris?

chillax · Post by **chillax** » Sun Nov 16, 2008 8:43 pm

The seals used for the safaris are a seal brought from clark rubber (supposed to be better quality and slightly bigger profile).
The seal is called "pinchweld small" Clark product code is 19899 manufacture code is 322077.

A little bit more primer to report

The cargo doors and rear panel were prepped and primed - looking better slowly but surely

Still waiting on the lower b-pillar, once that arrived the left dogleg can go in

Engine tinwear was sanded and primed ready for some colour soon (waiting on the alternator backing plate and rear firewall tin)

Jack

shark · Post by **shark** » Sun Nov 16, 2008 8:52 pm

Looking good Jack I think Al ised the same seals for my Safari's which were only put in last week.

Dasdubber · Post by **Dasdubber** » Sun Nov 16, 2008 9:16 pm

shark wrote:Looking good Jack I think Al ised the same seals for my Safari's which were only put in last week.

Yep, both buses will run the clark rubber seals - we (well mostly Steve) took a lot of care in doing trial fits during bracket and catch plate positioning to ensure an even seal/pressure around the entire frame especially bottom corners. I will have my fingers crossed neither will leak!
Al

greenbus · Post by **greenbus** » Mon Nov 17, 2008 12:07 pm

Great work guys!

Love following the progress...

chillax · Post by **chillax** » Tue Nov 18, 2008 8:58 pm

The time has come to tackle the long side so it was stripped back to bare metal - half of the side (front) has been treated with deoxidine - the rear half followed

The right dogleg was also sanded back and some imperfections filled - lots of sanding with the longboard ahead!

chillax · Post by **chillax** » Sat Nov 29, 2008 6:24 pm

The rusty bent up section where the popout hinge mounts to needed replacing

After being cut out, it was replaced with fresh steel, butt welded in and dressed smooth

Had to drill the holes in the nose for the VW badge so trial fitted one in place

After three days of beating, shrinking, beating, sanding, filling, sanding, filling and more sanding, the long side is finally in primer!

The nose was re-primed after its first gudie coat/block sand....time for another round now!

Light guide coat will reveal low spots during torture board sanding!

muzza72 · Post by **muzza72** » Sat Nov 29, 2008 7:18 pm

coming along very nicely well done fella's

cheers muzza

splitbus07 · Post by **splitbus07** » Sat Nov 29, 2008 8:03 pm

nailed the long side.

very nice. thanks for the pics.

chillax · Post by **chillax** » Wed Dec 03, 2008 12:16 am

ive got some more pics!

B-pillar finally arrived after a long wait

The inner hinge plate had to be adjusted again for clearance (would have been nice to have had the b-pillar section when the cargo doors were aligned!)...ah well

Steve then got onto installing the inner dogleg

After hanging the cab door, both top and bottom hinges had to be straightened out to try and get the door to fit (more work tomorrow)

Will be nice to have the dogleg on!

The last of the engine tinwear arrived today so it was sanded, prepped, primed and painted in beige grey tonight.

Engine can start to come together slowly but surely now!

After trying to get the original buckled passenger door to fit for more than enough hours, a decision was made to use another donor door to make the process easier - so far a much better fit

chillax · Post by **chillax** » Sat Dec 13, 2008 12:00 am

Getting closer

Lots of dents and dings in the cab door which required pulling and shrinking

More rust in the inner corner of cab door that needed repairing

New sections welded in and ground smooth

Masking tape was out today in readiness for some paint detailing of engine components.

FrankenCab · Post by **FrankenCab** » Sat Dec 13, 2008 7:59 am

damn thats alot work , all nicely done . glad to see headlight buckets were rust free, bugger to fix.