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 rusty nail to sow's ear

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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 7:48 pm

I've been asked to post the resto of my shitter bus by your administrators, so blame them.

It all started back in February 2008 when I bought a heap of rust from a man in from Torquay and had it delivered just North of Bristol.
I had forgotten to tell the wife a new addition was due, so when she came home from work this is what was waiting. Laughing

rusty nail to sow's ear Picture001

It doesn't look too bad on the drive, does it?

rusty nail to sow's ear Picture005-1


However, upon closer inspection

Stripped out scabby diy interior and binned that,

rusty nail to sow's ear Picture007

then polystyrene insulation and tinfoil stuck to every panel and the floor.

rusty nail to sow's ear Picture017

Quick tip, if you've got insulation behind your panels, check it once a year or the condensation will rot your van from the inside.

rusty nail to sow's ear Picture043

rusty nail to sow's ear Picture031

That was the better of the front arches
Rear corner and gutter above cargo hatch from inside.

rusty nail to sow's ear Picture013


Rear corner and roof.

rusty nail to sow's ear Picture026

rusty nail to sow's ear Picture033

Fresh air grille just filled over as well!

rusty nail to sow's ear Picture041

If you look carefully you can see van crying with relief 😉


For a few days the only signs of progress was this as the roof leaked like a sieve. It kept the neighbours happy, but little did they realise what was to come.....

rusty nail to sow's ear DSCN0645

Got brake lights, horn, side lights, dip & main beam working and MOT booked, and then started collecting parts.


Last edited by sparkywig on Tue Jan 15, 2013 11:03 pm; edited 2 times in total
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Mr Scoops
DBS Top Tater
DBS Top Tater
Mr Scoops

Male Number of posts : 38007
Age : 45
Location : Weston super Dooper
My Ride(s) : 1991 Vanagon GL Westfalia 2.1: 2011 A3 S-Line
Registration date : 2006-08-19

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 8:57 pm

Keep posting mate, we want the whole thread!! Very Happy

_________________
rusty nail to sow's ear Pbucket
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 9:03 pm

I drove it around like that for a couple of weeks with some Radars fitted, bloody horrible wheels, pita to fit properly.
Still doesn't look too bad, does it, seen worse driving around and at shows. Laughing

rusty nail to sow's ear DSC_0014-2

rusty nail to sow's ear DSC_0012

Got rid of the Radars and acquired some BRMs.
Drove the van down to my mate's workshop to start work on the rusty bits. Very Happy

rusty nail to sow's ear Sideview002

rusty nail to sow's ear Wigs_camper_001

An expensive pile of scrap, sorry, replacement panels.

rusty nail to sow's ear Wigs_camper_011


I thought the chassis was OK, dooooh!

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Custom chassis repair secton

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rusty nail to sow's ear Wigs_camper_015
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 9:08 pm

OSF chassis leg finished.

rusty nail to sow's ear Wigs_camper017


Better see what's lurking behind here.

rusty nail to sow's ear Picture041

Not as bad as I thought.

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rusty nail to sow's ear Picture009-1

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Right then, time to do something about the lack of rear suspension travel.
The po had dropped the rear by three splines and the front to match. This was the reason why the tyres were rubbing on the arches and it was a pain to drive on anything with a surface worse than a snooker table.

From this

rusty nail to sow's ear Sideview004

to this

rusty nail to sow's ear Picture007-1

rusty nail to sow's ear Wigs_camper019



Hmmm, better make a start on those arches I think.....
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Road Rage
DBS Old Timer
DBS Old Timer
Road Rage

Male Number of posts : 4830
Age : 46
Location : Highbridge
My Ride(s) : 1972 Bay; Shitroen C4
Registration date : 2008-04-28

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 9:10 pm

were the 4 holes on the front panel for a badge?

_________________
Sometimes even Volkswagen get it a bit wrong the first time

Even split screens had high indicators Wink

rusty nail to sow's ear B9d2fd24
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 9:12 pm

Road Rage wrote:

were the 4 holes on the front panel for a badge?

Yes, give me chance, I'll get there in about a year.....
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 9:15 pm

August 2008
Rear axle tube repair

rusty nail to sow's ear Wigs_camper_021

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Found some more holes in the OSR chassis leg Sad

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All gone now

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rusty nail to sow's ear Wigs_camper_024
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 9:22 pm

Sept 2008
Thought I would start on the ns arch and footwell today.

rusty nail to sow's ear Wigs_camper_026

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Doesn't look too bad does it.

After 5-6 hours and a couple of cutting and grinding discs.

rusty nail to sow's ear Wigs_camper_032

rusty nail to sow's ear Wigs_camper_030

rusty nail to sow's ear Wigs_camper_031
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 9:43 pm

Work in progress.

rusty nail to sow's ear Wigs_camper_033

rusty nail to sow's ear Wigs_camper_034

Please note the pile of scrap on the ramp.



























































































I mean under the sliding door Wink
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 9:47 pm

OK, on with replacing the iron oxide and filler with some full fat metal.
Seat belt and seat mounting plate

rusty nail to sow's ear Wigs_camper001

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A touch of primer to keep out moisture.

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A view from below after seam sealing.

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Front wheel tub repair sections

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Cab floor repair panel

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rusty nail to sow's ear Wigs_camper_037

I can cut off that rotten arch now there's something to weld too.
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 9:59 pm

This is the gash plate I removed from the passenger footwell, a piece of enamelled sign.

rusty nail to sow's ear Wigs_camper_027


Hooray, one of the sh*tty arches gone Very Happy

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A bit of making good to be done here I think.

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Looks better than it did earlier.

rusty nail to sow's ear Wigs_camper_041


Last edited by sparkywig on Tue Jan 15, 2013 10:12 pm; edited 1 time in total
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:11 pm

One cleaned up rust free front arch ready to fit.

rusty nail to sow's ear Wigs_camper_043


rusty nail to sow's ear Wigs_camper_044

B pillar repair.

rusty nail to sow's ear Wigs_camper_048

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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:15 pm

I do apologise for the quality of some of the pics.

OK, into October 2008 now.

Bit a bit bored recently. What with working late and at weekends, I haven't been able to get down to my van. So I've started on the less urgent bits.
Before

rusty nail to sow's ear Picture011-1


rusty nail to sow's ear Picture009-1

About an hour later

rusty nail to sow's ear Picture012-1

Rustproofed

rusty nail to sow's ear Wigs_camper_042

Primed

rusty nail to sow's ear Wigs_camper_046

rusty nail to sow's ear Colourchips8

Having some topcoat mixed, L345 Lichtgrau, so finishing grille on Sunday.
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:17 pm

A couple of weeks later.

HOORAY! I've got the first arch on Very Happy

 rusty nail to sow's ear Wigs_camper_049

 rusty nail to sow's ear Wigs_camper_053

 rusty nail to sow's ear Wigs_camper_054

 rusty nail to sow's ear Wigs_camper_055

 
Looks so much better Smile

 rusty nail to sow's ear Wigs_camper_056

 Just need to start on the other one now.


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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:20 pm

End of October and into November 2008.


Now onto the off-side arch

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Anyone want an nos arch Laughing

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N/S arch primered and 95% finished, need to rub down the filler and put some topcoat on.

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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:23 pm

Making start on the os front arch now, and get rid of the gash repair in the back.

rusty nail to sow's ear Wigs_camper_068

No wonder they rot, this has collected since the bodged sills were fitted.

rusty nail to sow's ear Wigs_camper_069


Got some topcoat on today to protect the new arch.
What do you think of the colour, going back to the original L345 light grey.

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rusty nail to sow's ear Wigs_camper_071

Bloody weather Laughing
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:26 pm

Nick was busy in the workshop today, so I couldn't get on with what I wanted to.
Started cleaning ns sill to see what it was like. The 7 layers of paint just flaked off the rust that had got through the crappy primer that was on the replacement sill.

rusty nail to sow's ear Wigs_camper_073

Bit of rust preventer painted on, and then started following the loose blue high build primer and matt black underneath with a filling knife

rusty nail to sow's ear Wigs_camper_074

Bit of an improvement don't you think?

rusty nail to sow's ear Wigs_camper_076
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:29 pm

Next installment, remember this?
Need to repair OS cab floor before I can fit the arch.
 
rusty nail to sow's ear Wigs_camper_060
 
Took another two gash repair plates off.
 
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After a bit more cutting,
 
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can you spot where I cut the brake pipe from the fluid reservoir with the grinder? Rolling Eyes
 
rusty nail to sow's ear Wigs_camper_081
 
The bus is a touch lighter now,
 
rusty nail to sow's ear Wigs_camper_083
 
arch cut ready for a bit of fettling and then fitting next weekend.
 
rusty nail to sow's ear Wigs_camper_084
 
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:33 pm

13th December 2008

I'm only on here to report the sh*t day I've had on the bus, mainly due to my stupidity.

Up to the last couple of weekends, I've been using my mate's workshop with his four poster ramp. All OK so far.
Been working on fitting the os front arch cut, but because the A pillar and gutter section is so ripe, I've been careful in how much metal I've been removing.

Today I got to the workshop ready to fit the arch after the last couple of weekends preparing the bus.
Got the arch tacked in two places, after trial fitting the door 6 or 7 times, door fits well, even gaps all the way round. Took the door off, raised the bus on the jack, and welded the arch on.
Lowered the bus, fitted the door, and, bollocks, the door doesn't shut too well, have to lift the rear end to get it to shut. Awful fit.

Tried packing hinges, levering the door by lowering the ramp onto an engine stand. All to no avail. Getting really pissed off by now.

Nearly 1 o'clock, and my mate locks up at 1.30. I only get 4-5 hours a week to work on the bus and it's starting to wear thin now.
Not complaining about my mate, as he lets me use the workshop, and leave the bus there, scot free. Very Happy

 

Anyway, my mate's old man turns up and says "Looks like the roof's dropped at the front"

I'm thinking "Maybe I should have bought a bus with some more metal and structural rigidity in it"

He says "Drop the bus down to the ground"

So we drop the bus down to the ground, and the door still doesn't fit.

I have a fit of pique and get the grinder out and cut the arch off along the welds that I'm rather proud of.
"F*cking rusty heap of shit"

As I cut the welds, BANG, the bus moves, and the door shuts absolutely fab.

Moral of the story, don't weld on a two poster ramp that lifts by supporting the bus on the chassis rails. The front of the bus had dropped by 30mm as soon as it was lifted off the ground.

My mate's old man then says " We sometimes get this problem with some modern cars. As soon as we lift them we can't open the doors"

"We only use the four poster for body repairs"

 
Rolling Eyes
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:36 pm

I'll post some pics this weekend, but from the top of the O/S A pillar backwards, there is no metal. Had a poke about to see why the front dropped so much and the entire section above the cab door fell out.
There's just the gutter left. Laughing

My mate's are starting to call it "Trigger's Brush" 'cos of all the cuts I'm fitting.
I'm only doing this to save another 40 year old classic......

Well, it was cheap to buy.
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:39 pm

Now you can why I was a little worried about structural integrity. Dormobile owners beware!

rusty nail to sow's ear Camper085

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rusty nail to sow's ear Camper089

 
Anyway after last weekend's troubles, the arch is finally fitted, just needs a bit of tidying and I'll put some paint on. Not too impressed with the quality of the arch cut on this side, Cleaned the paint off the step and it's full of pinholes, oh well, can't expect perfection, can you?

rusty nail to sow's ear Camper090

rusty nail to sow's ear Camper091

rusty nail to sow's ear Camper092

rusty nail to sow's ear Camper093

rusty nail to sow's ear Camper094
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:42 pm

Next instalment.

O/S floor plate done.

rusty nail to sow's ear Camper095

rusty nail to sow's ear Camper096

Scraped the white emulsion off of the wheel tub, and there's a nice coat of og paint  Smile , welds cleaned up and a coat of primer to protect.

rusty nail to sow's ear Camper098

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rusty nail to sow's ear Camper101


Door on, seat back in and cleaned mess up.

rusty nail to sow's ear Camper103


I like this pic, 1st coat of body colour on front, progress   Very Happy

rusty nail to sow's ear Camper106

 
I'm going to keep the 40 year old battle scars on the new arch, adds a touch of character otherwise it'll look like it's stuffed full of Botox.
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:44 pm

January 2009

Not too much to report today, removed half shafts from a old gearbox I had lying about. I'll need to fit this before I can drive it about, the original one is well and truly shagged, seals are gone, and whines like a unhappy wife.

Cleaned and seam sealed N/S arch. This side is all done now underneath, looks like new after a coat of underseal.  Very Happy

Sorry about the quality of the pics.

rusty nail to sow's ear Nsarch001

 

rusty nail to sow's ear Nsarch002

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rusty nail to sow's ear Nsarch005

rusty nail to sow's ear Nsarch006

rusty nail to sow's ear Nsarch008

rusty nail to sow's ear Nsarch009
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:47 pm

Right, where did I get too, a couple of weeks off from grinding and welding.
Not too much to report, bit of tidying around the arches, filling, sanding, etc.
Thought I'd start bare metalling the front panel to see what needed doing.

OK then, new lower inner and outer front valance, and headlamp bowls.
Bugger, oh well. At least the airbox and surround is OK. I think I'll get a front panel and cut repair panels out of that.

Camera has stopped working, so new pics will be posted at some point.

Ordered new front panel, inner and outer lower front panels, windscreen inner repair sections, r/h section of cargo floor, gearbox linkages, windscreen wiper spindles, and accelerator pedal linkage kit.

Stop Press: Good News, found a pair of cargo area heater outlets and some genuine window rubbers in my garage stash when I got the door skin out I'd sold, and paid a tenner for a Scat bus shifter  Smile
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sparkywig
DBS Pervert
DBS Pervert
sparkywig

Male Number of posts : 538
Location : mostly here, sometimes there
My Ride(s) : 1969 rusty bay
Registration date : 2013-01-14

rusty nail to sow's ear Empty
PostSubject: Re: rusty nail to sow's ear   rusty nail to sow's ear EmptyTue Jan 15, 2013 10:48 pm

....and £23 for a pair of Porsche tombstones. rusty nail to sow's ear Thumbs


Can't wait to get back to the workshop.
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