markp wrote:Cool

What's the name of the colours you used. ..... The top looks black .... But in sun it's looks a black with gold metallic ?
Love the roof ... Look idea
Mark

Hi Mark sorry I didn't see your comment earlier, your right about the paint the top of the van is painted in "Black Gold" its a GM colour some times called Saturn Black. the swirl is the same black gold just with more gold added and the base colour is the black gold without the gold.

So here goes the latest update, I was expecting to have the van rolling 6 months on from paint but it does not always work out how you hope, any way here's the lasted in brief, more detailed info on the blog paulssplit.blogspot.com

So checking out the underside of the van I was not happy with the over spray, this would have been fine if I had sprayed it cream




And some of the filler left behind


there was also stone chip that had lifted and needed cleaning up and rust treating



I covered the fresh paint half with my cover as I ran out of materials

Then covered the engine bay


So I primed the suspension mounting points

I brought a detail suction gun that needed modifying to get into the gaps


And sprayed the whole under side again this time on my back




Also treated and brushed the top of the chassis rails that missed out on paint


I then covered it In lacquer, not sure why, still working out if it was a good idea, what's wrong with Black.


my lead lamp makes it look orange



I later found out I had been using two different reds, due to a cock up from the paint suppliers.
NOT PLEASED, I'm not doing it again.


Taking a break from the paint I made a brake master cylinder spacer




Stripped down my steering box


cut out the sealant holding my quarter light glass and pulled them out the frame using some wire in a vice


I then got back onto the paint work, there were lots of small bit of paint that needed some attention
some of it that will never be seen again.

The top cargo latch had over spray


the lip around the rear hatch I repainted in cream


a area that will probably be covered in a seal but I wanted to sort


both B pillars had paint flaking this was because I wax inside the box sections and it had seeped out, this was the same around a lot of the window frames.



I closed the vent for paint but should have left it open, and touched up the inside tube rather than spray the part that was hidden


after a slight rub down the engine bay needed another coat
so masked up the van again


Its hard to see but some of the low spots were showing primer


I wanted to get into all the tight corners so got out the detail gun


fresh coat of paint in all the right places


while I was painting added a coat to the battery strap


Id pulled some paint off the lip from masking up when painting the red.




the cab door frame top lip needed attention


the lacquer on the air vent and by the sun visor was very mottled, I tried to cut it back to repolish but there was not enough paint there so broke through to the primer


I then used my air brush to touch up the parts that had cut through


Then put a couple of coats of lacquer back on



I really thought I was done with the paint until I found these rust spots under the dash

this is from the dippers not getting primer on there and the painters not getting any paint under the dash either


I cleaned what I could


before I spent time on my back with a cheep dremmel cleaning between the grills


I cut strips of foam to blank the grill


rust treated it all


raided the curtains to masked up the cab


A lot of hard work and I managed to get a coat of paint under the dash




the rear valance needed a touch up to the cream and the red




the engine lid also had some touch-ups to do I got fed up with spraying so got out the paint brush



I spent over 3 months sorting all the small bit of paint with a couple of small bits left to do I had to see some progress, so unboxed my fuel tank


I unpacked my new loom, comparing it to the old one


slid it through the chassis from back to front using a coat hanger


Watched my girlfriend struggle getting the loom up to the dash


then sat pondering for a few hours going colour blind


with some help from an avonic genious tried to work out how to fit a 6V fuel gauge to a 12v system



then striped out the wires in my new loom because I was not happy with the way they were laid up.


Now the engine bay was a bit nicer I stuck one some foam seals


laid in the new engine seals and cut them


trialled the rear valance


I got some front beam bolts back from chemical blacking


went to fit the front beam to find the to steering bush was in the wrong way round, the grove should be facing the grease nipple


made a tool to pull it out



pulled it back in with the same tool and reamed the bushes.


I sorted all the new parts and went through all the bolts and ordered stainless ones.


also picked up my locks from being plated


Hope fully by the next up date I should have some better progress of the build, Its frustrating having all the parts ready to fit but messing around getting things right before I can put the parts back on the bus, just hope I don't miss to much of the summer...

Good update Paul. You have the patience of a saint!

Things have been a bit slow, work and lack of dosh have slowed things down, don't think She'll be rolling this summer. Any way here's the latest.

Got my gearbox from Bears, It has a IRS 4 spider gear super diff
with 1.26 3rd and 0.89 4th gear


Finally got my parts back from the powder coaters
which means I can start fitting stuff.


was going to start with the gear box but noticed they had painted over some of the corrosion,
so decided to clean it up and also clean up the casting on the case


masked up ready for repaint


Fitted some conversion drive flanges for larger CV joints


dressed the rest of the box ready to fit


cleaned out my gear shift tube and lubbed up my shaft


fitted my coupling and wire locked it up


slid in my cable and mounted my box in place trying not to take off any paint.


cleaned out the spring plates this included all the powder coating off the internal parts



Mocked up the IRS A arm


trailed the full Range of movement of the drive shafts


found out I needed to drill through the gator plates to get it to fit


found my air box controls ready for a clean



striped and blasted ready for paint


painted ready for assembly




fitted the front beam while it was not assembled



although I had previously reamed the bushes I could not get this arm in as far as it should have gone


so I cleaned it out with a abrasive flapper wheel


fitted the trailing arms, the reamer was just to remove the paint


made a cup to squese the old king pin bushes out with the vice


Laid out the seals and cover plates for fitting the pins then after after a days of working it out found out you cant fit these if you flip the spindles


made a black nylon bush to replace the previous one Id made


the black replaces the white one that I made in stead of a thrust bearing
that would have replaced the steel bush



Started mocking up the front spindles realising I was missing some parts


after cleaning out all the paint I started fitting the pedals parts




And rebuilt my master cylinder after it got painted


there was a few parts I forgot to give to the powder coaters, that I found after an afternoon search




Also forgot to fit the brake return spring, found it in a box of bits I never throw away, cleaned painted.


found all my gear stick parts



hinge needed cleaning out


Had a problem with a blocked accelerator cable tube, made a twist in a coat hanger to clear it out.
think this may be crap from dipping


nearly all the cab controls in place




I didn't like concept racing mod for the tank straps so I decided to make my own

Started with a strip of Stainless and a rubber cover


Then made some L pieces like the original using a block and punch


spot welded this onto the strip


I wanted to fit the same way as original but the width of the tank and the angle that's needed fot the bracket would not allow


straps made and bent o fit the shape of the tank


strap installed, it tightened up better when tight


All looking pretty


so a few bit fitted now, still finalising the brakes and some other parts looking for and ordering some of the smaller parts before the hubs get a final fit, Really anxious to get it all fitted but don't want to muck up the previous hard work.
Should have it rolling by the next update.

'Er, stunned for words really.

Keep up the excellent work.

Superb

Wow

Amazing work, detail is incredible......

Thanks for the kind words, it's really incouraging.
It's nice to share my progress even though I'm stuck in the garage.
thanks.

wow


Hello


Another amazing update well done ..... your updates and Trints updates are on a pare a real pleasure to read ..... You make me want to restore another bus


I love the way no stone is un-turned ..... a proper job ..... I take my hat off to you sir



Really coming on well ...Keep pushing not too long to go now



Mark

A great update Paul, stunning work

Steve

here's a small update to show off the shiny bits,
Thanks for the help in the technical section, its been a long time since I took these parts apart so the forum has been really helpful.

Made a cap for the spindle was not a fan of the Ali one that T2D fitted


Here's it painted and fitted


fitted the nylon bush between the king pins


measured up my trailing arm gap which didn't help as there was to much paint to get an accurate measurement. eventually got the camber with a digital protractor against the hub


severed a o ring fitting the link pins


fitted the stub axel on its highest fitting, so it can only get lower.


Fitted my steering pin with the spring washer in the wrong place, thanks for the help it the technical section for putting me straight on that one


sorted my steering parts


to find Id been supplied the wrong ball joints large bay ones


brought a couple more only to realise they were two different manufactures



finally got those fitted to find id been given narrowed tie rods that weren't narrow
this is with the wheels straight.


cut an inch of each of these, that was not quite enough


re-tapped the rods, should have just made my own. still need to cut the split in these


Back to the good bits, pulled the bearing out of the Porsche hubs


sand blasted my hubs and fitted the bearing spacers


Baked the hubs 200deg for 20 min, don't tell the misses.


As quick as I could took the inner bearing races out of the freezer and taped then into the hub


once left to cool sprayed with silver high temp paint


dug out my front discs cleaned off the corrosion inhibitor and tapped up the breaking face


Sprayed up the front and rear discs with black high temp paint


had to find some Porsche bearing seals as the VW ones are a little to big


fitted the inner bearing, the spacer behind the bearing is just enough to let the bearing sit on it matting surfaces


laid out all the parts ready to fit


fitted the stub axel, calliper carrier and bolted the disc to the hub


All installed looking pretty



the front calliper's were previously sand blasted to get rid of the corrosion, but needed a quick going over then a coat of wash primer


a light coat of red to match the under side of the van


even the nipples got a tickle


stuck on a couple of decals I got from e bay, think I should have got a stencil so I could paint it cream to match the bus



A coat of lacquer, I was told by the paint shop that thin coats of paint should be OK to dissipate the heat, Lets hope so.


While the lacquer was out I coated the servo


dug out the seal kits I've had sitting around for to long, most of the pistons were shot from the corrosion these were about £80 a calliper plus pads and hoses, so not cheep to restore.


lubed up the piston and seals


cleaned up the plates and fitted them


cleaned the anti squeal pads and fitted the pads and retaining springs


then tried them on



OH and finally got the van rolling since paint, big land mark, heres a look back at some of its restoration history

Arr just tried to preview my update and lost the lot as it asked me to login again, so here we go again... probably in brief


loom in cab mocked up


indicator cleaned up


working out 12v wiper motor connections


made a bracket for 12v flasher


Do let me know if these fuses are wrong?

fettled repro fish eye reflectors to fit


thread was oversize in body so fitted with a nut and bolt.


repaired and polished light switch



repaired horn push


fitted shiny horn with caps and heat shrink on the connections


fuse box area tidy


speedo area will need a few wire remaking to tidy up.


trying to work out the route for the rear loom I cut the bulk head hole bigger to fit the extra wired I had added



fitted my starter


then realised the loom was meant to go along the chassis rail.
so did not need to cut the hole bigger, but did need to strip the insulation to get the loom up the rear lights. still not sure if this is correct


drilled a hole bigger in the gearbox earth strap



wish I had taken more photos of when I pulled it all out.


A bit more messing about with the loom but nearly there.
Next break lines and engine.

Nice build,with interesting pictures.

Henk!!!

Nice bus and great work your doing there, those Porsche callipers look amazing mate.

Nice one for the beam! Had to get out of the car myself as the helper was asleep

Marco

Cheers Marco, could not have been easy moving the beam, good luck with your build, keep us updated on your progress, catch you later.