Sorry for the lack of updates but managed to pick up some work so that took priority.

Well the front beams are back together just need to get some one to weld them in place. welding on the bench is one thing welding vertically and up side down is another...


All the repairs I made on the beam I double plated not sure if this is the way to go or not? but gives me more piece of mind.


next took a look at making the front cross member up the original was pass saving
The original measured 45mm x 34mm give or take but I could find nothing that came close so opted for some 40mm box section and copied "Molers" approach


split the box section to make 2 bits and 20mm and 15mm


old

new little heaver gauge.


seem to have lost some photos as the resto police state no proof did not happen
so off to search in the cloud for them...

Good work - nice to see another rhd coming back! When it comes to replacing the nose, I would recommend WW, mine went straight on with no messing. If you pick one up at a show you can also get good discount. I paid full price and saw one two weeks later for 100 quid less....... Always the way!

RHD was a "requirement" but now thinking for the same money could have got a LHD in better condition and converted it oh well live and learn

Not sure on the front yet.The windscreen lower sections have been worked on but there is rot between the dash and the screen so option is buy the expensive panel including the lower window section or the one that fits below the window surround.

Well my first bit of fabrication. The previous owner had used the original inner valance brackets and added strips of angle iron to fix them to the new inner valance.

so cardboard template

Into steel


fitted in place (sorry for the out of focus shot)


Its not perfect the upper return for the front beam should have been longer
but no body is going to see it once the floor is down and it is infinitely better that what was there.

Great work mate. Although it seems a mountain of work and you say it may have been easier getting LHD it will be worth it in the end. And you have the pride of knowing you have done it all yourself.
You also get to know your bus inside out

Andy

Thanks for the words of support.

Yes I keep getting told its "the journey" that counts not how fast you get there,
maybe is should be its the "experience" that counts not how fast you get there or how expensive the getting there is going to be...

Anybody know how accurately busses were built?
Trying to jig up the front beams but struggling to make things right, If I run a straight edge along each beam and set the sections to the straight edge
the two beams do not run parallel to eachother...

So do I set the sections parallel to eachother or so they run straight with the rest of the beam?
we are only talking about 6mm out over 900mm but it is bugging me.

Any thoughts ideas welcome

Send a PM to one of the retorers that post on here, Blastingdiepast has done a bit of a rebuild on this thread:-

viewtopic.php?f=8&t=105730

So guess he knows the answer.

Well got the beams tacked in, found the issue with alignment one side is perfect the other was about 2mm from when I welded on the chassis to the section where the beam bolts up used a ratchet strap to bring it inline
Welder is coming tomorrow to zip up the joints so hopefully I can now make some real progress.



So thought I would make a start on a roll-over jig, kind of winging it on the design but hopfully it will work.
Went with a third of 90deg is 30deg so used that as a start.


so stage 1 is complete.


Had a bit of a brain f*rt (parp) moment wanted to roll it both ways hence the design so far,
but in hind sight could have just built it one-sided and just unbolt it and swap sides.
once the beams are done I can remove the frame work and start stage 2 of the rollover jig.

Well only managed a few hours in the shed on Sunday so finished of the front section of the roll over jig. Not exactly reversible as the bolt holes do not line up, but as I am a cheap skate and did not want to buy more box section I made the upright removable so they can be swaped from one side to the other. (making closing plates for all the open ends was a bit ott but I was in the zone and it's so nice to weld on good thick ish steel as apposed to 50year old body pannels).

Well done that man good work, I hope 'her' is keeping you supplied with tea and cake.
Am watching with admiration keep the updates comming

Well I feel such a slacker have more free time than ever before in my life and zero motivation to work on the bus...
So now that the weather is vaguely acting like winter I decided to do some work on the bus.

Well gave up trying to source a RHD cross plate but managed to order a LHD one.



after a bit of butchery I now have a RHS crossplate (not sure what the additional holes are for though and the returns on the curves go the wrong way but I can live with that.



Found a large hammer and made some adjustment to the handbrake carrier and then gave it a once over with the shotblaster and a lick of primer.



Made up some closing plates for the sides of the toolbox did not even try and reproduce the stiffening pressings opted for a heavier gauge plate.


Need to find a better method of cleaning up my welds looking at getting a finger file and a some 2" 3M roloc disc and a angled die grinder.

The original wheel arches/seat mounting panels were cut out of the bus by the previous owner when he planned to slam it but fortunately they are in the spares pile. They need some/a lot of work the lower sections are shot and along with the seatbelt anchor area, did think about replacing them but opted for just buying the repair panels hopefully they will arrive by the weekend.

one question I have is what is wrong here why does the panel overhang the dogleg lip by about 10mm...
can the dogleg be adjusted? or do I need to cut it out and replace it? (the leg has been butchered cut in several places and re-welded etc)
Also what the is recommendation for fixing back the inner edge the one that is folded over the tool box section. The original fold is still there they were just cut out vertically. seam weld it back in from underneath?

Well done. You're doing a great job and more importantly having a go yourself. From experience I can only tell you what a good feeling it is when someone looks at all your hard work years later (8 in my case!), and says what a nice bus you have.

Keep going, you have the skills and the determination. You will get there and reap the rewards.

Excellent stuff. Hats off to you..

This might be of some help. Go on theSamba....technical...open and search all the schematics on there. It's a bit small but you can expand and read easily..hope this helps.

http://www.thesamba.com/vw/archives/inf ... nsions.php