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Micheal's Bent Bus


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Posted (edited)

This is why I would personally never buy a classic without the view of restoring it. At least he has C.A.R on the job. A lot of other shops would just end up putting makeup on a pig, whereas Locky does it to last.

Edited by Wags
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  • 3 weeks later...
  • 2 weeks later...
Posted (edited)

Onto the LH floor - I worked out the cost for new KFVintageJDM floor pans + freight + installation,
and the figures said it was going to be cheaper to fabricate & install patch repair panels:

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2U438tPG9rbA6hATOu1ZxghTXW532p_vEpS7Fb-6

uj5Sy-XmRtIv6qOsARWhm-1HKHojvjHWOc0e1xQt

LeIegpfk1iDy1OHMY_Wxnx3RAD-3XkFH0X_GOzf3

Xu7Q_5EH6dOUx02u_xwlNE40pkRWsRuzahd8RSzw

I'm not taking credit for this - it's Graeme's handywork.

Edited by C.A.R.
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  • 2 weeks later...
Posted (edited)

The back of the RH floorpan - under the rear seats - was rusted out, so the section was cut, rust treated, then new sections were fabricated and welded into place.
Then the RH rail assembly could be installed.

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sqHWRY8Z-zSFpzigldfDPWVqcNYFyaYXdTEMrgkB

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Hw3bX0TH9aPNVEU4-NO3AD6SpWE0NeMbFVcPO5GE

WVPR_Mw2qFiVg68Y-aaahG6ibWt0jlOAzJV6Jy-A

The RH door hinges also came back from Leon - they've been been re-pinned and re-bushed, along with a new roller and leaver:

WiD-9bFYn1y6MUmReFhTLlwbqjJUcS9llYcpvENg

Edited by C.A.R.
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  • 3 weeks later...

A section of quarter panel below the LH quarter glass had rusted out, so I fabricated a replacement section, cut the old section out & welded in the new patch:

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uYo19HrHV0PEMGBas_FqzH5o712nX545T2MG7-rA

8RvBQPwEhMz0yTK487njgC9AywUp1leCWsR17juv

It just needs a little tapping about to smooth it up, so I'll come back to it in due course.

The LH sill was rusted out at the front and back, along with accident damage.
We decided to remove it & replace it with a new one, but as it was a Bus, it's not that simple...

Cut off, de-rusted and KBS'd:

FMKQCOMMZOnPNXj1UNyI_W_EMwRU1OeEhFRvjohR

I bought a 260Z/280Z LH sill from @kfvintagejdm, then cut the end off and fabricated an extension.
This was then KBS'd inside and welded into position:

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z2-1fwiyObGMzv9x32BAX4SmIzSS0VyFE7Fk5BnE

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  • 1 month later...

Due to me taking a little holiday & the workshop being busy, I haven't had time to update this thread.
Suffice to say we are done &  Michael is collecting the bodyshell shortly. Here comes the photo dump:

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61sBdBViPnUXx-6JKwh4p5gkPVC6A3rPGmCJ-fNz

MOyl76wzGcPPYMdNBZd6hzv9CUpeKbGl1PCV_WWH

V0axExQPGCAvBOBfjK7jjx_MsnlzKGm8tt7SYlcD

PXfGVkFre_pGJ8uOrrj7AYOiOwQQ902ElyBTiG1t

uZXFwjnbjV3G8jxVZSSamGU0_XFVSXOJR80skIhM

AwTKWtTYbMyPKEN5CTXkIH_0iORP9YDB3DxaXox9

tx8uUY4tZ8G9b-5FNwC4ZaBufvsoQC-9z4l1Ijk_

s2d3Ljl4eHTqrQj4YS1uukIfUbD34Jrl3_xA5H2G

LDnuB6_gYLhwvjMLrWXYzeSlFehJP1JGPc4gx5Qe

RW11sumpH2CfcOhxiua1xoOvRpm9GoaOh1cjTBLI

XXX0T1x-0y8Q8Sj6cYS0sw6RWi5G1Qeuh-OaAh7e

4Qrern-3-Cq63RNscYGINQ3lvG4eMAkOXxipy2H-

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Yes, I made a new rear valance:

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8Gvfx26R0Njo5nNv2JR0YM0PmbfAgESM2nYYDUi0

Hot Tip: RS30 and GRS30 rear tail light panels ARE NOT the same. They are deeper (not wider as generally thought).

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Finally the 'piste de resistance'.
The RH door skin was stuffed - dented to the moon & rust holes everywhere.
I couldn't get a decent rust / damage free Bus door locally, so I repaired frame which only needed a small section at the top & bottom...

...then made a new door skin from scratch. I'm not taking full credit - my employee Paul did 75% of the fabrication.

Taking a paper pattern off the old skin:

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Cut out some 1mm cold rolled steel:

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Wheeling & folding up the new skin:

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'Blocking' in the handle recess:

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CQc1Q9MagK6HamlZZGbwPLuyCvST52jHADQIZZxyTi

And fitting the skin to the frame:

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O5kgIYQZhJko4nOs5cOEVZfEmCmcdE1Q8Na9jqfz

7D3l7xj4O7oT07F3rT4F-Hl2cQBSkN24zo1-8XQE

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