Step-up my game..

I've had this VW Bus for 1 year now.  I really need to step-up my game. By summer, I promise to have it in painting mode.  Thank god for having this blog, it helps me keep track of time.

Nose Clip Repair Plan

I have it traced out where I am going to remove the damaged area.  Before, this was filled in with filler and I tried pulling it out with a stud hammer. Because the area has a rather complex cure, the metal is not very malleable. None of the stud hammering pulled any part of it out. I will cut this part out and patch in a replacement.

I found this rather crude organ downer online. It was cheap, because it is pretty rusty, but the part I need is OK. I wish under the eye wasn't so jacked up as I would have liked to pull the who area, but once I have the cut open, I'll be able to work on the other part with a hammer and dolly.  I'll also have to pull out a small 5"x5" patch on the passenger's side.  It is not shown in the above picture, but there is a small rust hole there.

 I've also found online a nose clip that I can replace the smashed up nose area of the bus. This will handle the bang in the front.  This project will begin when I close up the side. I'll start cleaning up the downer part when I have a moment before, As I want to reduce the big elements in my garage. So I am going to do most of the cutting this weekend.

The inner rockers are permanently welded in. I had to remove them and straighten back out the metal, as I welded it too forward the first time. I was going to order a new one, but I thought it would be a better exercise if I fixed what I destroyed to help keep my cost down and save time waiting for the new part to come in.  Also, I've welded in the b-pillar post cover that I also had to re-work.  Hey!  I'm learning the hard way, but it is learning indeed.   I still have a question posted on a forum on how to handle the tab down on the bottom left.I believe it has to be bent over and weld closed. If I don't get a response, I'll take a look at the other side

Here is the outer rocker mating up to the B-pillar post that I fabricated. I'll have to grind down some of the arch, as it doesn't allow for my tack-weld holes to line up.  These wholes were made with a flange tool. The reverse side allows you to punch holes into sheet metal like paper. It works with a compressor. Please see the photo at the very end.

Along the top side panel, I'll have to grind down some of the ridges that doesn't allow the outer rocker to mate evenly to the bottom. This doesn't allow the weld holes punched in the bottom to mate to the inner rocker.  This will be fixed on my next visit to the garage.

Here is how the side rocker panel looks when mated up. As you can see, this will look pretty good once welded in. This will start next weekend.  I got an immunization shot on Saturday that made me feel pretty sick, so I had to stop.

Fixing the front B pillar post

 After trying to weld the beotch to non-weldable primer, I finally got it straightened out. This piece was fabricated in-house, as no suppler carries the B pillar cover.

 Not the best looking welds in the world but they are holding after I removed the primer and tack welded the plate in.  I've wire brushed the welds and the next photo will show it in primer.

Next I'll just have to grind down the welds so that I can close up the side rocker panel. I primed it up so it doesn't rust over the week, until my next time in the show next weekend. This is weldable primer, so that any touch ups can just be cleaned and welded.

Before and after

This picture, I was finished trying to repair the inner rocker. As you can see, after trying to weld in some metal over rusted parts, I cutaway a piece because I realized it should be completely replaced.

Here is the inner rocker being size up for welding. The small weld holes have been drilled in (not in this picture) and ready for welding in.  I just need to make sure the side by the dog leg can be closed up right.

My 58 VW Bug

Thought I should post a picture of my 1958 VW Bug that was in the Gov Island Show in 2013.  I missed the show this year.  I now this is off topic, but often I forget that I have this car because I am working on the Bus so often.

Labor Day Week-end with the Bus.

I've partially installed the new jack port under the drivers'side rear.  This is weld-thru primer, so that it would not rust while I am tackling other small jobs. I am sort of running low on argon/CO2.

 This is the inner wheel well that I am patching in. The original one was rusted and it is easier to replace complete, rather than trying to cut out a lot of small little patch sections. The piece is tacked in, secured and ready for full welding on the next weekend.

 Here is the side view of the work to be done.

 Again, making sure the inner rocker fits well before I progress to the next stage.  I'll just need to remove the rust under the cargo floor and pop in some spot weld holes on the top of the inner rockers.

 I have the replacement (driver's side) B-pillar welded in on the driver's side. So far, this all looks good.  I'm looking for a way to deal with the A-Pillar before I work on the dog legs.