OK Here we go again... my '69 Early Bay Camper project

[CockneyPlayboy]

Following this...

http://www.ssvc.org.uk/phpbb/viewtopic.php?f=8&t=3986" onclick="window.open(this.href);return false;

I have now embarked on my next project... My newly purchased 1969 Early Bay.

I intend to follow the same restoration route as I did with the Splitty, pretty much gutting the van out and painting it throughout and going something with the interior, not sure what just yet but I do want to retain its camping ability so the stove, sink and a R&R bed will defo feature.

Lets start with some pics of how it currently stands 11/08/2009

 

[CockneyPlayboy]

As you can see, the van is pretty straight...

Belly pans still in tact... these'll be coming off to investigate further then re-coat...

I am looking to replace the rear hatch as it is slightly warped/out of shape and will not line up flush with the body.... the engine lid as there is substantial rust on the inside of the frame.....and will have to look at one of the cab doors as it simply will not align properly although in pretty good all round condition and relatively heavy rust free... maybe some more patience and some more attempts to get it closing as it should, flush with the bodywork.

I know the pics make it look a shiny bus but in fact it looks like a very poor quality celulose job to tidy it up. The van is pretty solid which is very good, and a nice starting point for a project being as it is already MOT'd till next year and so it can be used. The pop-top is appauling and needs tearing off and the job doing properly. This I am actually happy about as I had a 6ft raggie in my Split and really want one in this bus also. I'll fit a proper Paris Beetles kit to it.

I am not sure what happened with the headlining... but the pimps boudior padded black is coming straight out and a nice standard white/cream one going back in its place. Door handles back to chrome, Empi's going (good condition with good tyres so I'll stick them up for sale soon).

I intend giving the paint job a go myself on this bus, as I have now completed my vehicle restoration course/quals so if i dont try...I'll never know! I have been painting water-based and 2k paint, metalics, flat base and pearls so time to practice on the bigger canvas. Hey if I fook it up that bad i can always hand it over to my friend who usually does my paintwork which I'd have got to do it anyway so I cant really lose! Nearly secured my workshop and started assembling my tools.

I paid £4500 for an MOT'd on the road and mechanically sorted RHD walkthrough early bay so I think thats pretty fair money.

I'll update the thread as I progress through the project. It'll be a biggie, I have proper plans for this van so dont expect it done in a month or two but when finished hopefully it'll be another bus to be proud of. My aim is for a fresh looking but classy mild custom....nicely dropped.

Wish me luck! Here I go...........

 

[lard]

Best of luck! Will enjoy watching the progression with interest - I love full resto threads

 

[CockneyPlayboy]

SO..... now the workshop is up and running I started stripping the bus out to see what we have to work with...

Biggest problem seems to be the sliding door. Whilst in great condition it appears whoever welded the bottom half repair panel on it has welded it slightly too far to the right thus not closing snug against the wheel arch (which also appears to be slightly on the wonk!!!) creating a gap.

Now Im not sure what to do about this... pretty pain in the arse time if I have to cut it off and re-do it, panel beating MIGHT make it a fair bit better but wont know till I try.... or the other alternative is sourcing another door which is hard enough as it is, expensive and no guarantee it'll be any better than the one I have!

Someone has also 'tin-opened' two sections of the rear bed apparently in an attempt to repair the fuel sender so that'll need attention. I intend cutting a proper panel out, refitting a new sender unit as precaution and then fitting a new section of metal in its place.

The rest doesnt look too bad. Not sure on what to do about the interior. Seems too good to rip out (and it'd need just that, its so built into it that it'd never come apart nicely!) but on the other hand I think I migh tlike to try doing my own custom one...... what do you guys think? (see pics above)

Ive booked a week off work next week so I'll update with loads of pictures.

 

[gninnam]

Looks like a good base for a project 8)

You now have loads of room to work on your van too you lucky b@gger

 

[CockneyPlayboy]

Started my 5 day 'holiday' from work by stripping the van out totally and I decided to first of all turn my attention to a 'bubble line' which consists of a line of bubbling paint approximately half a foot from the bottom of the bus. I had initially thought someone had welded the repair panels in place but not ground them down or filled them properly.....HOWEVER..... :shock:

Even Pudney's kind etched words cant hide my anger at the fact that the previous repairer has actually slapped the repair panel BEHIND the existing panel and secured it with a few stretched tacks and blobs!!!

He hadnt even seam sealed behind it so water was regressing down the two panels... hence the bubbling. Check this beauty out...

God only knows what he was thinking of here! A 'strip' added and not even trimmed the same length! Appauling workmanship... and more for me to repair!

We tried paint stripper/remover on the sliding door but to no avain... the crap on there was so caked on thick that it just made the mess worse....

SO.... I took a break...

....and contemplated giving up..... lol

 

[CockneyPlayboy]

...but decided to persevere and with a good few hours work.... BARE METAL!

Now I could see what I was dealing with. Metal very good but unfortunately very ripply and warped, probably due to heat from the previous welding and repairs perhaps.

Here's another piece that'll need some fresh metal welding in...

Moving inside and we see another substandard bit of filling on the passenger bulkhead....

The drivers one not the cleanest either!

Still, at least the cargo floor is in fab condition!

...but hang on... WHATS THIS??!!

Looks like a botched attempt at creating an opening hatch to repair a fuel sender if I had to guess... not done very well!

Standing up through my 6ft hole where the Dormie roof used to once live, I can see the front metal lip that I'll need to cut off if I want to fit my 6ft Rag-top sunroof...

Here it is started... once cut it'll need further grinding down.

And the final straw... this really takes the buscuit...
Imagine if you will, you have fitted the front and two sides of the canvas rag-top skin... then you realise you've either mounted it too far forward or had it cut too short!!! THIS PREVIOUS REPAIRER MUST HAVE BEEN A TOTAL COCK and I'm sorry but I dont care if he is reading this... it has to be said!
LOOK! He's even mounted the studs on the sodding lip rather than on the roof like on the rest of it!!! Unbelievable, but at the same time believable after all the other crap I've found!

SO.. . it looks like I will have my work cut out after all. A much bigger project than I previously envisaged but then again, its a solid bus, just shoddily repaired and it is a RHD walkthrough and of course an Early Bay so time to get my head down and GET ON WITH IT...

More to follow as I progress.....

 

[BigG]

Looks like you have a fair bit of work there fella but if your split is anything to go by its gonna look ace

Im off to my garage later today with my grinder to investigate some suspicious areas and im dreading finding someone elses bodges :?

Good thing is there are alot of busses on this gallery which are being 'redone' properly and that can only be a good thing, good luck with this one :mrgreen:

 

[rockandrollcamper]

Looks like your gonna be getting a good return on that resto course and your workshop! - keep up the good work and progress reports

 

[CockneyPlayboy]

Couple more pics.....

Here I am cutting the rear lip off of the dormie roof remains so that the rag-top will sit nicely..

and here is a nicely smoothed and filed down ex-lip! :lol:

Now all I have to do is smooth it with the actual roof and it'll be finished. (I know you wont see it under where the rag top starts but I'LL know its there! (grin)

....for now I masked the interior up as still undecided whether I am going to sell it or not... it'll be coming out eitherway shortly.

I always say you know when a VW bus project has started when the front badge comes off... ha ha

Next time one adornes that space it'll be finished because its always the last thing I add!

 

[CockneyPlayboy]

DAY 5 of my marathon resto session!! (back to work tomorrow!)

OK, so last night and today I concentrated on the cab doors and the front panel.

On the whole I was very happy with the cab doors, one being worse than the other but only due to one long bit of rust eaten metal at the bottom of the front skin. The rest of the doors, underside etc all very good and Ive certainly seen A LOT worse! This can all be rectified by cutting out and replacing with fresh metal.....

before... (if you see this forming on your dub beware.....)

(....it usually means underneath the paint is this.....)

The worst bit...

All have since been ground/cut out and the repair has been given lashings of Kurust to kill any remaining rust and chemically change it before leaving it protected for the future......longevity, THATS what we like!

Anywhere that metal will come into contact with metal (such as this handle recess) also got the 'strip back to bare metal and rust protected' treatment!

More shocking quality welds and finishing appeared on the base of teh front panel (bumper level) so I knew what I had to do....

......back to bare metal, clean the welds and rustproof protect... ready for further repair work...

Here is the cab looking very empty.... now also devoid of seats (in preparation for the TUBBING!!!)

FINALLY... it was time to call it a day after 5 days and nights (one night till 1am!) the van had been through hell and it was time for me to go home and chill out.

More updates to come as I complete them!

 

[easy]

Nice work sir 8)

 

[aircult]

Nice work man. :shock:
How many hours do you spend for that???

 

[CockneyPlayboy]

TOO many ! lol

I work around 60 hours a week as it is so it leaves me precious little to do the van. I took a few days off though to really get stuck into it as you can see! From now on progress will be a little more steady.

If I can at least have it painted and ready for reassembly by end of spring next year I'll be happy

 

[dandaz]

Are you keeping the red handles ? they look cool... 8)


69 is a good year... 8)

 

[sparkywig]

69 is a good year... 8)

Certainly is, but they're full of rot.
At least you've no filler foam yet...

 

[gninnam]

Good work so far - got love these old VW's - every bubble has a story to tell :shock:

 

[De8oy]

Looking good!

Cant wait to see it on the road mate.

Del

 

[CockneyPlayboy]

SO....not posted for a few weeks so thought I'd update you all on my progress with the bus...

The misery hasnt stopped with the last post I'm afraid. We analyzed the state of the roof and decided to poly-primer it to give us a bit of depth to play with bearing in the surface looks like the surface of the moon! BUT of course you have to take off all the old paint so painstakingly I started grinding and sanding all the existing paint off to bare metal to see what horror stories lurked beneath.... I didnt have to wait long.....

Absolutely filled with pug... which of course doesnt do the job at all! It was standard filler too! Not even a bridging compound such as P40 fibreglass..... See below the square filler patch... that was to fill the depth left by a plate welded on the INSIDE of the roof!!!

Here it is looking a little blacker but that is due to the coat of KURUST rust killer and protectant that was applied to ensure all was dead before proceeding.

LASHINGS of the stuff was applied....

OK, so with the crap that i found that had been pugged with filler on the roof i figured that everywhere else i saw an imperfection there was a similar story and I wasnt disappointed as I worked my way around the van...

Plenty of cutting, welding and bridging to be getting along with there!

 

[CockneyPlayboy]

........so whilst i cracked on with the holes, my mate Dan made a start on the DA'ing of the panels to get them nice and level and as straight as possible which thankfully SO FAR hasnt turned out to be too difficult...

(by the way if you are wondering why we havent removed teh headlights, indicators and windscreen yet its because we can still move the ol' girl about semi-legally! lol)

Thats it for a couple of weeks now as Christmas period far too busy with my work... more updates in the new year!