Hi Folks .
I have been building this rare all white 21 window for a customer , have all but finished the metalwork now and its soon off to paint .

Looks like it may be ready for Volksworld Show 2013 so you can get a look at all the work that has gone into this bus .

The bus was dropped off at the workshop and I get to have a look for the first time in the flesh , Someone has repainted the bottom half in the States years ago but the M codes state its an original all white bus .
The belly pans are missing and the chassis is in a bad way.

The unmistakable front end that we all wish to see as we open the garage door

Bus is very complete with all its samba bits - those removed are in good shape and the interior is in fantastic condition - This has already been removed - doors show some sign of rust

Back end looks straight - some bubbling on the tailgate

Long panel shows some signs of rust at bottom

Cab floor will need some work - Drivers seat was still in - You get the idea with the condition of the interior

Sills show signs of rust as does the long panel where it meets the floor in the cargo area

Roof windows show signs of rust so will no doubt need some love

Cargo door shows signs of a previous repair - Black under seal painted at bottom

Floor also shows signs of repair - you may just see a screw head in the bottom right corner on the silver bulkhead

Window surrounds look ok on first look - we will see !!

great looking bus Good luck with it

A look underneath revealed a bit of work required

Main chassis rail


centre chassis cross member at back


rear outrigger


Next thing is to remove the floor to have a look at what its really like


I get to see the repairs done in the past - New metal covered in black underseal then screwed together .


This was the section where the cargo doors shut


Floor out


Top hat - bulkhead and the centre cross member at front are way beyond repair


The main chassis rail on the left side - The dark bits are holes


Removed the remains of the belly pans from the rails

Cleaning the rail a bit to try to find the solid metal
You can also see the bracing I put in above the rails


Just a few of the panels required for the bottom bits


New chassis rails - All panels from Auto craft


Lower section of chassis rail


Main rail section


More holes below the top hat section


Replaced by new metal


You can see repair below the top hat on the left
Also the bracing


The bit that curves up also needed repair - this has been done here and the rail cleaned up


Rail cleaned and ready for some protection

That looks like a great project very dry and solid bus .

A little more
Inner chassis is slightly porous

Will need a section made up

New inner ready to go in


Long side sill shows all the signs of the same repairer
Black ****e - screws and multiple plates - This is rear jacking point



This is the front jacking point on same side - Same repairs present



Bottom of long panel opened up from outside



Lower section removed from by the rear jacking point



About 3/8 filler over the screws originally



The lower section of the support posts



The new centre chassis section fitted

A little more for you .

Lining up the rear outrigger to make sure its straight



Welded in place , again making sure its straight



Top hat spot welded in place



Welded to the chassis rail - to add extra strength.



Back to the chassis rails - this is the offside at the front by the outrigger



This is the rear outrigger on the offside



A section of angle iron to add some strength whilst work is done on chassis



A cross section of the front outrigger - showing previous repairs inside



Out rigger roughly cut out



Cleaned up a bit to find the solid metal

Coming on nicely well done

Some good skills on show too so hats off too you mate

Mark

Thanks Mark - Been looking at yours , getting stuck in as well .

Nice job Jon ... BUT ...






















You should be working on YOUR bus!!! ...

Scott - I will be getting my bus down from the roof of the build up room as soon as I have the space - I want it MOT'd and registered , even if its not finished .

Too be honest - I do 6 or 7 days a week at the moment and am getting stuff done at a good rate - When I get the bus down its going to be fun to get back into it

Its currently in the position of the split bug upstairs - not the best for welding or access



And that picture is why I love going to work every single day

And that's why I didn't go with you the other morning! I'd be perving for hours!

Good work though mate.... You do know that white Sambas are sooooo last year!

I did here all white was out for 2013 .
Blue is the new black and all that .

Oh and you may wish to explain the first line - its a long time since someone I went with was perving for hours - Try about 5 minutes !!!!!

Many "screws" on this one...

Great job you are doing there... "Dejá vú" for me...

Keep the good work!

Thanks for the kind words - Glad you like it so far