I was asked to do this job for a customer of a local VW Dealer who had heard I do the odd rusty repair Word soon gets about doesn't it
It's a 1975 Bay that needed a new front end fitting and a few other little jobs.



Small area on the side panel near front arch that also needs some attention


Very bad corrosion round windscreen area




Accident damage to lower passenger side corner which has also bent the door pillar and creased the door so this will need sorting.


Drivers side door pillar looks ok though


Preparation for cutting off front panel


Off it comes. I left the windscreen in place here to enable me to loosen off all the filler from inside rather than risk cracking the screen as it was suck solid to the filler.
Incredibly, the rest of the inner body work is still in very good condition and only needed some surface rust removing before being treated with anti-rust etc


The inner windscreen panel looks to be in poor shape as well.


Hmm, wonder what removing the windscreen will reveal.


Some patching up and a few measurements will be needed here as there's nothing left of the inner lip where front panel is welded onto and also where windscreen sits. This needs to be spot on or the screen won't fit.


Here's a better view of the rusted inner panel.


Quite a few patches later and a good coating of anti-rust treatment has the panel all done and ready to test fit the new front panel




Well what do you know..... It fits
Wasn't easy fitting this on my own I can tell you, but it's amazing what you can do when you shout and swear at things


More to follow

_________________
Darren Parker
Club Technical Advisor & Site Admin
WebSites www.covin.co.uk - - & - - www.vwkd.co.uk - - & - - www.flat4dubs.co.uk


I LOVE RUST ME
Patent Pending "The Ultimate In Rust Remedy"

From 2/11 to 7/11!!!!!! You really attacked it, didn't you mate? Nice one

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Doros
The Car
The Garage
The Award

Have a break (down), have a Kit Car.

Yeah, made a great start, but then the weather turned so couldn't prime or paint it as it was just way to cold

_________________
Darren Parker
Club Technical Advisor & Site Admin
WebSites www.covin.co.uk - - & - - www.vwkd.co.uk - - & - - www.flat4dubs.co.uk


I LOVE RUST ME
Patent Pending "The Ultimate In Rust Remedy"

I always feel a sense of shame watching threads like this


Well done Darren top workmanship...... as usual

_________________
death. the working mans friend.

thats strange i always feel a sense of laughter well done bond you bloody foool

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Covin Owners Club Administrator

looking at that tells me youll do other camper ..Noooo problem Great work darren.Are you on the donor list for some new fingers when yours wear out

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Cheers guys

Here's an update of the rest of the work I did to the front end.

Front panel now all welded in place and ready for prep work before etch primer is applied


Cleaning off the panels protective coating back to bare metal and treating all welds with anti rust.
I also thought it would be a good idea to clean up the dash top as it was very rusty.


Very small amount of filler required to smooth things out then a guide coat of etch primer before sanding again.




Etch primer goes on followed with a light coat of filler primer


Now all primed and ready for final prep before painting


Thought I'd take care of this little patch before any paint was mixed


Turned out to be a bit more crusty than I first thought with lots of filler.


Only one solution here.... Cut it out.


Made a couple of sections for the repair and welded them in then trimmed off to fit.


Light coating of filler and a bit of sanding later... Job done


Primed and sanded


Ready for paint


Time to get some paint on.......First the White




Then the Green




You'll probably notice I've painted the dash top as well. Looks much better now




Quite happy with the joins and all lines look good.


The side repair after paint.


I wouldn't recomend fitting a windscreen on your own, it was a bit of a struggle but got there in the end and finally the Bus is all back together, colour sanded, polished and ready to collect.


I also repared and painted the pasenger door pillar and door but didn't take any pictures of this....oops
Managed to get the door gap back to how it should be though.








The owner was very happy with the results and has booked his Bus in again for Phase 2 this Autum....

_________________
Darren Parker
Club Technical Advisor & Site Admin
WebSites www.covin.co.uk - - & - - www.vwkd.co.uk - - & - - www.flat4dubs.co.uk


I LOVE RUST ME
Patent Pending "The Ultimate In Rust Remedy"

Cracking job matey.i would be happy if it was mine

_________________

great job as always bond, looks like a million dollars, shame you put that peice of crap wheel on it though . you done well mate, for the time of year is the ice biting your nees yet. ooopps forgot antifreeze. i hope this one pays dividents for future garage extension mate

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Covin Owners Club Administrator

Cheers guys Your right about putting that horrible wheel on the front. Fancy having to put that onto a brand new painted front panel Still, it's what the guy wanted so can't argue with that.

_________________
Darren Parker
Club Technical Advisor & Site Admin
WebSites www.covin.co.uk - - & - - www.vwkd.co.uk - - & - - www.flat4dubs.co.uk


I LOVE RUST ME
Patent Pending "The Ultimate In Rust Remedy"

Nice job darren, I know where to bring any of my cars should I need any work doing

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"Bikes are for speed and Covins are for posing"

yep join the que mate

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Covin Owners Club Administrator