65 Deluxe - build off entry

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65deluxe
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65 Deluxe - build off entry

Postby 65deluxe » Wed May 02, 2012 1:52 pm

So - after a shit finish to 2011 and a similar start to 2012 I have decided to take the bull by the horns .

I am 40 this year and have decided that some things in life are more important than running round like an idiot for 60 hrs a week for a big corporation who dont give a toss about me and making myself ill in the process .

As some of you will know I have had a side line doing VW's for about 3 years and have decided to ditch the job and go full time .......

I have a customer who has a 21 window fresh into the country who wants a good quality resto and I need a shop truck ...

I have had a bit of a shuffle about with my own cars and now have my 21 window , my expensive oval ( zwitter ) and a 1948 chevrolet stepside ( 3600 ) - all of which are long term projects and leave me requiring a run about as I have had to give my company car back.
I have managed to get hold of a 1988 MK1 caddy - or rabbit pickup as its known on your side of the pond .

I plan to work on both pretty hard and get as much done in a month as possible - As JJ once said " you make your own luck " & " the harder I work the luckier I am "

Sounds like a good way to get things started .

So 1st up is the 21 - The white angel

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Ive called it the white angel as it was originally a lotus white on lotus white bus - since had some work and painted yellow ( ish )

The bus is pretty good but has had some fairly dubious repairs in the past and the chassis is shot

Next up is my new shop truck .
Its a 1988 1.6 diesel 5 speed and its shite .
Looks like crap and sounds like a set of sockets being tumbled in an oil drum .

Anyway I like a challenge ......

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As you can see it has had a few bangs and dings and will need quite alot of work to get it sorted .


Plans for samba are a full resto to a high standard and engine being sorted - suspension will probably be red 9 design front IRS and rear Irs .
lowered by about 1 inch all round - OG interior and original white on white color scheme

Caddy will get a total makeover - Looking at very low - Retro color and something tasty on the wheels front - You know I like my wheel porn ...
Last edited by 65deluxe on Thu Jun 07, 2012 10:27 am, edited 2 times in total.
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dcguy
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Location: Canada eh?

Postby dcguy » Wed May 02, 2012 3:47 pm

Very nice bus and project!! =P~

If you have the time, I think anything can be done. Just keep on powering through and put in WORK! I usually do some work, and then post here, that way I can keep track of what I did and what else needs to be done.

Then when I get bored, I log onto KCW and check out what I've done. It helps!! Plus I show my wife and she usually gasps or is amazed that I'm doing all that and that REALLLY HELPS!

And after I come home all dirty and stuff, well, you know.. that helps

Hope you got motivated. GET CRACKING!
jp

carpe diem, one day, one life, no more.

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65deluxe
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Postby 65deluxe » Thu May 03, 2012 12:08 am

May 1st

First job is to strip the samba of glass and interior trim so it doesnt get damaged

Door stripped - both look to be original
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Skylight frames look like they may hold some water

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The worst of the window frames - just a few cheese holes

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Roof lights will need a bit more work

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Some have gone through - koles on right

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Front screen surround is pretty much perfect

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No rust on either side
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Cab floor will need replacement - holes on drivers side

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Seat bed not the best - hole by the seat belt mount

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Spare wheel well solid but full of nut shells

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Passenger seat base much worse

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Passenger A post has had some sort of repair

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Normal holes where the cab floor meets the seat base

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Onto the cargo floor - This looks as if it has had a new floor and then been repaired at the same time !!!!!

The repairs have all been done in the same way with screws and plate and then painted - This is true of all the repairs on the bus .


B post has repair and the floor patched

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Centre section of bulkhead has gone through and the top hat section is shot

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Other side is also rusty and has same repair

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On to the Chassis - By far the biggest job on the vehicle .
Some one has removed the belly pans already and the chassis looks like this

Rear outrigger

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Rear centre section

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Chassis leg

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Front centre section

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Un believably the front and rear sections of the chassis look really good on first inspection .

Bumpers and front belly pan also removed .

I got this far and then spent a load of time ordering parts .

Awaiting the arrival of lots of boxes .......................
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65deluxe
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Postby 65deluxe » Thu May 03, 2012 12:44 am

May 2nd


Ok so I have no illusion that this will get done super quick - I will only be working on it in spare time or when I have to wait for parts - At the end of every day I will have to drive it home until we get a new car for my wife .

As I have to drive it I wanted to get it clean and comfortable inside before much else

As you can see the seats dont look very inviting

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first up is to clean up the inside and get all the mud - dust - cigarette ends and general shite out and then check that its not rotten - These things rot out the sills for fun .

Getting the original rubber mats out the way - I can get to the sills - good so far

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and again

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And again

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no real signs of any water getting in

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Even the front foot wells are solid and dry

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Rear bulkhead again is solid - small amout of staining from water coming through a vent hole

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First change was the steering wheel - Always liked a MK1 GTI wheel - E bay is your friend on these cars - parts are cheep and plentiful

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Nest up were seats - I got some seats from the local breakers yard for next to nothing - I forgot to take a picture of them before fitting so bear with me .

The original VW mounts are triangulated sliders - the new ones have a built in rail - New Mot rules say seats must have adjustment new if the car originally came with adjustment - Surgery required

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After a bit of experimentation with position I worked out the best and easiest way way to make a frame assembly that would sit on top of the original rails

I had some 40 x 20 box so set to work

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I used .8 wire and laid it down thick so I could clean it up and still have strength

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Once cleaned up they dont look too bad

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Rear seat locator is vertical not horizontal - helps out a load when fitting up
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The cross members would need surgery to get the bases low enough to allow movement forwards
Cut the crown off the cross members

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Fitted a bigger and thicker brace inside

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Cover welded in - Lots of curves in this so I guess it will be nice and strong
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Not pretty but plenty of penetration - needs to be strong

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Cleaned up its not bad and will be covered with carpet and soundproofing when trimmed

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Touch of primer

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Both sides done

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Disconnected wiring for Airbags - dont want those bad boys going off

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Speaker mounts integrated into bases

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Just to hold 6 x 9 - dont want to cut OG door cards as they are nice

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Finally mounted in position and ready for seats !!!

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In they go - These are leather seats out of an Alfa Romeo 156 - unusual as they dont have any alfa badges in the leather ... Nice fit and comfy as your momma's breasts
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Oh and they are heated - and thats all wired up and works.
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Last bit is something to run the speakers - in dash DVD screen .
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So thats it for today .
More tomorrow
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Franz
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Postby Franz » Thu May 03, 2012 7:24 am

DO WORK SON!

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65deluxe
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Postby 65deluxe » Fri May 04, 2012 1:21 am

More done

I am waiting for a load of parts for the samba so have carried on with the caddy .

Decided to try and tidy this thing up a bit so turned my attention to the sides at the back - Both doors are not worth repairing as good rustfree ones are plentiful and cheep .
Someone in the past has filled in the trim line and added a large amount of filler
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They also filler in the panel gaps to the roof

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Wire wheel took care of the filler in the gaps and the trim line

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Lots of trim holes and bolt holes to be filled

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Removal if wheel arch trim shows arches to be really good

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Dent being hidden by all that filler

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Pins attached
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And pulled out
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Small skim will sort the rest
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Trim holes all welded up
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Touch of etch - off to the other side
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Welded up trim holes in front wing as well

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Took left side bumper off to get a better look at the damage on the back - tried to persuade it out but not having any of it .

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If you look in the first group of pictures you can see a big unfinished dollop of filler - 1/2 an hour with the wire wheel it began to look like christmas !!
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Putting a straight edge against it shows the extent of the damage
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Lots of pins and a fair bit of pulling and swearing

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Beginning to get there
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A skim of filler and I am almost there - Beginning to lose light by now
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At the point im happy to leave it for a bit - ran out of white primer - DOH !
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Postby 65deluxe » Thu May 24, 2012 1:05 pm

So I think ive got this all wrong - I keep doing the work but am too knackered when I get home to post .
Anyway will have to do better

First off is to sort out the chassis
Old floor

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Coming up
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All old repairs are covered in black stuff
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And are all screwed in place
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Using big headed screws
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Lots of fluff in the sills - guess its from the multiple rodents that called the bus home
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Nearly out
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Rear outrigger and jacking point
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Rust on chassis leg ( black is holes )
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some of the long list of parts
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Chassis legs
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Brace for the bus for when the rails are repaired
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inner sill has a few too many layers

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The solid section of the chassis
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Ready to cut out rot
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New section welded in
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65deluxe
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Postby 65deluxe » Thu May 24, 2012 1:34 pm

a little more
Rotten front section of chassis - where it begins to turn up
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The main chassis rail
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Top of chassis rail below top hat
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I guess the outrigger may have had some " work " in the past
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Having one or 2 extra layers
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Outer chassis repaired
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Looking a bit better - just a bit of a clean up required
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Looking a bit better now
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Inner chassis is slightly porous
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Will need a section made up
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New inner ready to go in
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cookiemonster131
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Postby cookiemonster131 » Thu May 24, 2012 2:19 pm

not sure how i missed this for a month but i love the work so far on the caddy
"With all of those VW's in the parking lot i thought it was a Unitarian Church" Hank Hill

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Woody
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Postby Woody » Thu May 24, 2012 3:25 pm

I lust after your shop truck !
Cheese

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65deluxe
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Postby 65deluxe » Fri May 25, 2012 4:10 pm

Still trying to play catch up

Long side sill shows all the signs of the same repairer
Black shite - screws and multiple plates - This is rear jacking point

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This is the front jacking point on same side - Same repairs present

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Bottom of long panel opened up from outside

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Lower section removed from by the rear jacking point

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About 3/8 filler over the screws originally

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The lower section of the support posts

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The new centre chassis section fitted

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Outrigger offered up and checked to be straight

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Fitted in place

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Top hat spot welded in place

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Welded in place over the main chassis rails

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Cleaned up and ready for protection

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65deluxe
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Postby 65deluxe » Fri May 25, 2012 4:12 pm

cookiemonster131 wrote:not sure how i missed this for a month but i love the work so far on the caddy


Thanks but It doesnt pay the rent so Samba is priority at present .

Caddy will be built on here I promise !!!!
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dcguy
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Postby dcguy » Fri May 25, 2012 7:38 pm

Good job of cutting it up and digging in! Keep on trucking brother! (We're all brothers, those of use who have gone through the same thing. The cutting, grinding, swearing and welding!)

It gets kind of addicting actually, taking off the rusty bent parts, and making them look new again. Keep at'er! \:D/
jp



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Slow Steve
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Postby Slow Steve » Fri May 25, 2012 8:50 pm

Nice work. ... I thought my bus needed some work. Damm, mines a creme puff compared to this. Keep it up. =D>

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65deluxe
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Postby 65deluxe » Wed May 30, 2012 1:12 pm

a bit more of an update - sorry its so picture heavy - nearly month end and all that ....

Base or inner wheel arch after removing previous repair

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Said previous repair - 2 plates screwed in place and covered in black shite

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filler removed the holes for screws are visible

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Viewed from inside the rear

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inner strengthener in place - spot welded

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from the inside

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Front outrigger in place

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ready to start on other chassis leg

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Front of chassis

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Rear chassis and outrigger

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Brace in place

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Front outrigger after removal - screws and black rubbish again

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Outrigger cut out

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cleaned up a bit - not pretty

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Repair section made up

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from the inside

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Chassis leg repaired - long section also done but pictures same as other side

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looking much better

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from above

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