Rust repairs on a Diesel 75 VW T2 bus

[GoceKU]

This VW T2 belongs to a good friend and has been looking for restoring it for years now. But finding a good shop to do it is impossible, i visited his work place to get couple bords cut down he seen the 409 and all the work i've done to it and ask me if i can help. Now i'm busier than ever, i work 2 full jobs and have 2 more side jobs but i decided to have a look. When i've seen the state it was in and the new panels he bought, i know it will end in a scrapyard if i don't help. We work out a deal and couple of weeks later he bring it over on a tow truck. The vehicle is too unique to die, this bus has been converted to run a 1,6 diesel engine from the newer vw T3 van in the early 80s and it's been on the road in macedonia its entire life. The conversion its been done a bit crude, it has a big radiator up front and hydraulic hoses running under it. But its been working everyday for 40 years like that, i'm sure this will change once i get it structural in shape, now is flexible like a sponge form all the rust and the bondo repairs it had in the last nearly 50 years. Another project i hope someone finds it interesting, this one will go a bit slow because of my other jobs but it will be done right up to the point of body work, i'm not going to do the body work and paint prep, i just don't have the time.

 

[GoceKU]

With the bus in the big garage, i started assessing the work more closely. It has good bones but its had many weld repairs done poorly. All the panels from the wheels done have been work on and done badly and rusted again. One thing i like about it it has real thick steel, that i can weld on and make it solid again. The replacement panels are actually repair panels made in serbia, not bad in quality, the silver ones are a bit worse than the black ones. This is all outside sheet metal, when i made the deal to work on it, we agreed on to get the inners seals also and couple more to make it structurally solid and replace the outer sheet metal. Its going to be a lot of work but the vehicle is too unique to die, also the owner had a big connection wit it and wants it done right.

 

[wachuko]

Looking forward to the updates!

That radiator in the front takes so much away from the looks of that VW Bus…

 

[GoceKU]

With the bus in the garage i got started on the passenger side corner, this is where the battery is located and is very rusty. First i wasted couple of paint stores and bought me 4" wire brash for a grainder to take the paint off, some chassis paint, etching primer, seam sealer and some body wox. Took the paint off the corner it had some body filler and previous repairs that has rotted again. I cut them out and continue cutting and chasing the rust inside at the battery tray. The rust continued at the wheel arch, so i cut it also. I did take couple of measurement and offer up the new wheel arch but it doesn't look right. I'll be attending a beetle car show soon and i'll take my tape measure there. At this stage i stopped, i need to buy some thicker steel and some rust converting acid. Its going to be more work than my niva, but this van seems to have the spirit never to die just to keep going like my niva.

 

[Dinsen]

I own an electric id.buzz, a very popular car around here. VW gave your classic a new incarnation, IMO, but the original will always be special. You have yourself a fantastic project. I've been restoring a 1982 Matra Murena for 8 years. The chassis is galvanized and body panels are epoxy, so challenges are different. But all old cars give their challenges, but also good zen-like moments when things come together. I'm loooking forward to following your project

Edit: Noticed in your picture, I have the same impact wrench as you. One of the best tool investments I've made!

 

[matthewsx]

Looking forward to the updates!

That radiator in the front takes so much away from the looks of that VW Bus…

Radiator should go on the roof....

 

[GoceKU]

Yeah, battery impact gun is the way to go, i recently bought its bigger brother 500Nm from the sister company total.

 

[Dinsen]

Yeah, battery impact gun is the way to go, i recently bought its bigger brother 500Nm from the sister company total.

That’s a serious kit. Should be enough to undo stuck and big nuts and bolts for a whole day!

I haven’t seen Total around here. Worx could be the original manufacturer but as with a lot of other power tools, branding is all over the place Around here, people are ready to pay high premiums to get the old brands