'63 11 Window

GarryA
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Re: '63 11 Window

Postby GarryA » Wed Mar 02, 2016 8:39 am

It takes a Binz owner or luster to notice such things.

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tlambert
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Re: '63 11 Window

Postby tlambert » Wed Mar 02, 2016 10:29 am

Not really. Smile
Tim

john jones wrote:Sanding sucks balls, My balls have been about sucked off..:-#


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Mid West Dubber
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Re: '63 11 Window

Postby Mid West Dubber » Wed Mar 09, 2016 10:52 pm

Front door hinge pin repair - Part 1

I attempted to remove the left hand side front door pin using one of these Bob Drake hinge pin tools. Unfortunately I had no success and the shortest push rod from the tool snapped clean off and didn’t budge the pin.
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The driver’s side (RHS) mirror stalk had been snapped off years ago so I decided to try the method of drilling the door pin out and then reaming to suit the oversize mirror stalks or hinge pin.
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To make the drilling process easier I decided to remove the hinge from the door. The first step to remove the hinge was to drill out the factory rivets until the heads broke free and the rivet could be removed. I started off with a small hole and went up in size until the rivet head broke loose.
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Mid West Dubber
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Re: '63 11 Window

Postby Mid West Dubber » Wed Mar 09, 2016 10:55 pm

Front door hinge pin repair - Part 2

Pic of the rivets removed from the door…
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The next step was to mark out and cut two sections which would allow the hinge to be removed from the door. I used a small cut-off wheel in a Dremel to make the cuts. The sheet metal was then carefully peeled back and the hinge removed…
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Mid West Dubber
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Re: '63 11 Window

Postby Mid West Dubber » Wed Mar 09, 2016 11:00 pm

Front door hinge pin repair – Part 3

I ground the top and bottom of the existing pin almost flush with the hinge surface then centre punched both ends so the drill bit would locate.
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I then drilled out the pin, size by size until there was just a small layer of the pin remaining inside the shaft.
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This pic shows the thin layer remaining inside the shaft…
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This step is where the dremel came in handy again. This time with a small tip grinding tool.
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I used this little grinding tool to carefully grind out a small section of the remaining layer of the pin. This released the pressure from the pin and broke the rusted seal.
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I could then use a small flat punch to drive out the remainder of the pin and leave the shaft inside the hinge untouched and undamaged.
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Mid West Dubber
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Re: '63 11 Window

Postby Mid West Dubber » Wed Mar 09, 2016 11:02 pm

Front door hinge pin repair – Part 4

A 5/16 drill bit was used to open the hole in both parts of the hinge…
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The 5/16 drill bit allowed the .3220” reamer (Purchased from Wolfsburg West) to accurately remove the remaining material and create a hole which would be spot on for the new oversize hinge pins/ mirror stalks.
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Using the reamer in the drill press at a low speed…
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The new pin fitted through both parts of the hinge and was firm and moving freely. I used counter-sunk bolts and nyloc nuts to re-attach the hinge to the door. The hinge will soon be removed so I can sand blast and paint the cavity behind the hinge. The hinge can then be re-installed and the cuts I made can be welded and ground back.
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Mid West Dubber
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Re: '63 11 Window

Postby Mid West Dubber » Tue Nov 01, 2016 5:01 am

Spent a little bit of time messing around with the tail lights for the bus today.

I've always been a fan of tail lights with a chrome bezel but I couldn't seem to find any apart from the all red US spec ones. I wasn't really all that keen on running the stock Red and Amber lenses with the painted silver style bezel built into the plastic.

So, I decided I would just fit the chrome bezel over the lenses.... But when I had all of the parts, I realised it wasn't going to be that simple.

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As you can see from this pic, the Hella lense is too large for the chrome bezel...

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and the screw hole sticks out the back of the lense too far, not allowing it to sit flush...

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I started by using the bezel as a guide and marking out how much plastic I needed to remove from the outside edge to ensure the bezel will fit over...

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Having ground off the excess from the edges it was now time to remove the bulk of the screw hole so the lense would sit flush at the base...

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The bezel now fits around the outside...

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Mid West Dubber
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Re: '63 11 Window

Postby Mid West Dubber » Tue Nov 01, 2016 5:02 am

The next step was to counter sink the screw holes on the lense due to the counter sink on the bezel...

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Because I had to grind so much off the edges of the lenses, I now had to space the lense back out to tack up the slack from the removed plastic. So I made up a spacer from a piece of alloy...

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All screw together and satisfied with the result. Much nicer then the silver paint on the inside of the plastic. Plan on getting the second one finished off this coming weekend...

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tlambert
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Re: '63 11 Window

Postby tlambert » Tue Nov 01, 2016 5:27 am

Nice great job. =D>
Tim

john jones wrote:Sanding sucks balls, My balls have been about sucked off..:-#


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john jones
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Re: '63 11 Window

Postby john jones » Tue Nov 01, 2016 6:05 am

bus upper hinge pins can be a whore!@!!!!!!!! a torch is almost always needed.... Smile Smile Smile Smile Smile Smile

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vwfool
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Re: '63 11 Window

Postby vwfool » Tue Nov 01, 2016 6:37 am

Nice work on those tail lights

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rustabus
Livin' the retired life
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Re: '63 11 Window

Postby rustabus » Tue Nov 01, 2016 7:06 am

No Kidding!!! Making it happen!!! =D> =D> =D>

Mid West Dubber
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Re: '63 11 Window

Postby Mid West Dubber » Sun Nov 06, 2016 3:01 am

Got the tail lights finished off this weekend. I think they have turned out not too bad..

Spacer made..
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Mid West Dubber
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Re: '63 11 Window

Postby Mid West Dubber » Mon Nov 28, 2016 4:49 am

Bought a pile of rusty pop-out frames from the DOVW swap meet the other weekend as I would rather try repair originals then buy repo frames. Some would have looked at these frames and thought they were all beyond repair. Just proves that one mans trash is another's treasure...

After studying the many rusted frames, I came up with an idea on how I could make these work for me. I will let the pics do the talking. Pretty happy with how the repairs are turning out.

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Mid West Dubber
Posts: 57
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Re: '63 11 Window

Postby Mid West Dubber » Mon Nov 28, 2016 4:50 am

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