Matilda, 1972 Devon Crossover

[Adamfulwell]

Hi all, welcome to the restoration/modification of my 1972 Devon Crossover, Matilda. Bit of background I've been into VW's for several years, modifying, restoring and building with a mate of mine. Always wanted a bus but been priced out the market. I recently completed my MK1 caddy project and was offered a ridiculous amount of money for it after it picked up a trophy at Retrodubs Suffolk 21. So even though it broke my heart I sold her on to fund a bay window project. Here's the caddy before and after.....

 

[Adamfulwell]

I found my project on T2D swop meet and after exchanging a few pounds and arranging transport she was on her way home....







The only photo I have of them together, the caddy left for its new home shortly after

Here is a picture of Matilda in her heyday when she was part.of the Ipswich air-cooled society...



I'm gonna be keeping her pink but two toning with an off white and toning the pink down massively to a more pastel pink.

 

[Adamfulwell]

So I've set about having a look round and then moving her into the workshop, it's surprisingly solid to be fair. There is some fairly ropey welding that had been done and the cab floors are in a bit of a state, I'm looking to slam her so the arches will be cut and tubbed along with chassis notching etc. Here's a few shots...at this point I'm looking at my old photos of the caddy thinking wtf have I done

 

[Adamfulwell]

So first things first and armed with lots of left over cash from the caddy pot, massive panel order in at Alan Schofield's and sent her off for sandblasting.



Back from the blasters.....

 

[Adamfulwell]

I've decided to prime the whole bus to stop any further rot, then I can set about cutting out all the crap and welding in fresh metal. I've taken the front end panel off as it's not survived well and there is an issue with the front Valence.









Cut the floors out as well so I have better access to the front Valence.

 

[Adamfulwell]

So currently the front end has some hidden rot, to be expected really. With the front panel off set about re building the front. First off the new windscreen panel as the old one was a bit ropey....


Ive then compleatly cut off the front Valence. It was previously replaced and sat about 10mm proud making the front panel not sit correctly. If you like a bit of quality welding this was the state of it when I cut it off



Valence off compleatly, cleaned everywhere up and rust eatered the chassis rails. Then went on to for the new Valence and front lower panel....

 

[Adamfulwell]

Primered.......



At this point couldn't resist a cheeky test fit of the front end



Bit of fettling needed to make it perfect but I think the missis approves

 

[Adamfulwell]

Got on with finishing the front Valence, welder has been playing up massively for a while, turns out the local store sold me the wrong type of gas when my bottle went a few days ago. It was 100% argon instead of Co2 Argon mix.

 

[Adamfulwell]

Next purchase from fbook marketplace was the front bumper, bolted this on to help line everything up....

Put the doors on and made a start on the steps. I have also fitted a full width rock and roll bed just to get the holes in the right place. This will have to be chopped a bit to make way for the new rear tubs...

 

[Adamfulwell]

I've taken the plunge and spent an absolute fortune on a set of Rayvern hydraulics, brand new beam from Matt balls @ Balls'd, and I'm gonna hand the bus over to him in the coming months to fit it all and do the chassis notching. Had to make a few decisions about wheels etc, I've decided to go with a set of GTI Monza's from a Mk5 golf GTi. My missis has the Mk5 golf and I'm a big fan of these wheels. I can only find one example of a bay with these on....



So off on a road trip to pick up a genuine set again from fbook marketplace. A steal at £80



The Monzas have correct PCD of 5x112 however the center bore on these wheels is 57.1mm the bay window hubs I'm using are 66.6mm so off to the machine shop and have them machined out to the correct fitment....



I'm looking at some machined spacers so I can fit the center caps on the wheels and then adjust the offset when the bus goes in to have the suspension fitted and the beam built.

 

[Adamfulwell]

Moving on to the doors these seemed to be ok upon purchase however after stripping them for re-skinning i decided to have them blasted as there was a lot of rot at the bottom.






Some really poor repair work previously, these have turned into a bit of a project themselves. I've made the decision to outsource the doors to a body shop to try and save a bit of time leaving me to concentrate on the main shell of the bus.

 

[mike202]

Nice work you’re doing on your bus. You obviously know what your doing with cutting and welding, but please have a rethink on painting it pink

 

[YellowBay69]

Nice work
Great photos too - interesting to see under panels taken off ( for me anyway )

 

[Adamfulwell]

Nice work you’re doing on your bus. You obviously know what your doing with cutting and welding, but please have a rethink on painting it pink

Everyone has said that so far , I'm set on the pink, but a nice light pink. Similar to this late bay I've seen....

 

[gvee]

There aren't enough pink buses - so it gets my vote!

I think toning it down a touch would be good - the "original" pink is a bit too loud for me.

Great work on the bus so far - look forward to your updates

 

[gninnam]

As everyone says, some great work done so far
I like the toned down pink, good on ya!!

 

[mike202]

The second pic of the toned down pink is a lot better....

 

[sparkywig]

I don't see what the issue is, it's your bus so paint it whatever colour you want.

 

[Adamfulwell]

Had a spare half hour so nipped out and started to tackle some of the ****** bits. The rear quarter was chopped in some years ago, it's straight enough just some new metal needed around the window area.



Chopped out and the new bit in



The profile is nice just needs the welds cleaning up and the lower bit making out of sheet metal

 

[Adamfulwell]

Made a start on the lower panel for the window/side door.



Does anyone have a photo of the side of their bus in the same spot by any chance?