Angel VW Club

1972 BAYWINDOW ROT BOX PROJECT

Thought it was about time I shared a few pics with you all now that I've started on the project again following a 5 month break due to some extensive house DIY...... Grrrrr . . . lol
This is my first Bay window project and a bit of a Baptism Of Fire you could say . . .
I bought it In Sept 2005 from eBay for only £400 and even though it's a complete wreck, I was instantly hooked.
I decided from the start that I'd try to make my own repair panels to make it more of a challenge and so far I've only bought 2 front wheel arches and an inner sliding door section and have managed to complete the front end and passenger side...... Still a long way to go yet though.

I'll let the pictures do the talking....



Quality interior don't you think ?






The least said about this the better. Let's just say most of the vans underside was held together with bean cans stuck down with white bathroom silicone then coated in filler and underseal....NICE

I decided this was as good a place as any to start working on.


Wheel arch offered into place so new chassis section, floor and inner wheel well repair panels could be made up and fitted.




A few more home made sections made up and welded into place.


Everything is fully seam welded, cleaned back, treated with Anti-rust then coated in Zinc primer.




More to follow . . . .

_________________
Darren.
You know your screwed when "Jimmy Saville can't fix it"

www.covin.co.uk
www.vwbaywindow.co.uk
www.durhamdubbers.co.uk

Lot's of chassis repair work has been carried out including cutting out floor section to repair door runner channel.
As you can see the sliding door also required a little bit of work.
Note the 1/2 inch of filler covering a lump of Dexion shelving that has been used for a past repair



Had to buy a lower inside repair panel for the sliding door as It's shape was a little difficult to make....lol
The ground out line halfway up the door is where the old door skin will be cut out ready for new one to be made and fitted.


Managed to make the new outer door skin from a piece of sheet metal, but bending all the edges round to fit correctly was a real pain.


Also had to make some curved sections to fill these holes round window frame inside and out which was tricky.
You can also see the new door runner I made and the new floor section that had to be replaced that's coated in Anti-Rust treatment.


All cleaned up and ready for some anti rust treatment and etch primer.


More to Follow . . . .

_________________
Darren.

You know your screwed when "Jimmy Saville can't fix it"



www.covin.co.uk

www.vwbaywindow.co.uk

www.durhamdubbers.co.uk

nice work Darren! I'm dreading to think what lies beneath the filler on ours when we strip it back!

_________________
in the real world my name is Grant.....

Cheers Grant.
I've found all sorts of stuff under the filler, silicone and bean cans, everything from a bog roll to a section of roller shutter door being used as a sill

_________________
Darren.

You know your screwed when "Jimmy Saville can't fix it"



www.covin.co.uk

www.vwbaywindow.co.uk

www.durhamdubbers.co.uk

Moving on to the inside floor and rear wheel tub area. This was covered in pop riveted bean cans and filler which when removed revealed this nice bit of ROT. . .




Made a new crossmember section out of box section


A few more plates added and more ROT found


Bit more welding up inside to get the structural strength back in


The floor get welded back into place


Moving onto the door slider and rear window frame, not to bad really as it only required a few patches and some new brackets making to mount door slider cover onto.


The finished repairs all treated with anti-rust treatment.


More to follow

_________________
Darren.

You know your screwed when "Jimmy Saville can't fix it"



www.covin.co.uk

www.vwbaywindow.co.uk

www.durhamdubbers.co.uk

Thanks Andy . . . . I don't think there's much interest on here for Resto work to be honest
Here's another update . . .

Could of really done with some new doors but I decided to have a go at making my own internal sections and a home made outer skin.

Here's the door as it was.


New internal structure was made and welded in place, then I started to rebuild the door.
Home made outer skin actually fitted very well and the channel round the door edge fits nicely with even gaps all round It was a bit of a pain to make though.


Off comes the door again for some finishing touches with the welder.


Time to get some primer mixed up and fire up the old compressor.
Door now in primer ready for flattening off before top coat is applied.


More to follow

Next was to give some of the Van a base coat of primer.


Then the first guide coat of paint, this will be flattened right back again to ensure all panels are as smooth as possible for final painting.


Painted the door and sliding door then fitted them in place. I'm quite happy with the fit considering the amount of repair work carried out and mostly home made panels


Front windscreen lower area was a little rusty so I cut this out to make a repair.


Painted the dash top in Satin black and preped up the window area ready for paint.


The front after another coat of paint


A jump forward in time, all paint has been flattened off and finishing coat applied, fitted windscreen with new rubber... That was a bit tight to get in but made easier by boiling the new rubber first
Wish the whole van looked like this . . .lol


Time to start working on the other side next.... Remember that was just the Passenger side and front..... The rest of it still looks like THIS . . . .




That just about brings it up to date as I've now started the drivers side which unfortunatly for me is far worse than the passenger side was

Here's a preview of just what I mean . . . Even the main chassis is shot


More to follow

_________________
Darren.

You know your screwed when "Jimmy Saville can't fix it"



www.covin.co.uk

www.vwbaywindow.co.uk

www.durhamdubbers.co.uk

_________________
in the real world my name is Grant.....

_________________
Darren.

You know your screwed when "Jimmy Saville can't fix it"



www.covin.co.uk

www.vwbaywindow.co.uk

www.durhamdubbers.co.uk

_________________
Darren.

You know your screwed when "Jimmy Saville can't fix it"



www.covin.co.uk

www.vwbaywindow.co.uk

www.durhamdubbers.co.uk

soul destroying stuff, but at the end of the day, you will have taken a dub that was no good for anything....pure scrapper, and turned it into a nice solid van, really nice, and will go on into the future for another 30 plus years judging by the work you`ve done

and just wait till you slide that door shut and climb into your cosy bed for the 1st time, or the old couple putting there shopping in there boot turn round smile and wave.......it will all be worth it mate

alternativly - you can sell it for 5-6k laughing all the way to the bank and start all over again
(there`s nothing wrong in doing that, especially if your doing it right the way you are, its the baked bean tin merchants that should be hung - cant believ that beam, shocking

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T5 on bbs and 2 bugs