This page was last up-dated 07 March 2006

Bodywork Restoration and Paintwork

 This camper has recently had bodywork, paintwork and mechanical restoration. The first task was to get the engine started. A new starter motor was fitted, and as any good Volkswagen should, fired up first turn of the key.

After starting the engine............ the next job was to remove it !

This was to enable us to access the bodywork that needed repairing and to work on the engine itself.

The first panel to be replaced was the N/S lower quarter panel, then the outer & inner wheel arch  was removed, corrosion was found around the rear suspension/body mounting, which was removed and the hole in the chassis leg welded. The seatbelt mounting area was badly corroded, this required the wheel housing tub to be replaced.

Then round to the other side for the same again, corrosion was worse around the seatbelt area on this side, so a larger area was cut away & replaced.

While the bodywork was being worked on some panels were to the sandblasters, once back they were checked for dents, filled where necessary then primed.

 

The next stage of the bodywork restoration was the fitment of  the NOS (new old stock) genuine front wheel arches. After cutting the old arches off, the inner arch cleaned up ready for spot welding and MIG welding the new arch in place.

Genuine NOS front arches were chosen over pattern parts because of the quality of the fitment. Although more expensive, the panels fit much better than the cheaper pattern panels.

Because of the corrosion to the front axle it was decided that a used axle would replace the original, and once removed the extent of corrosion became apparent.

 The new (used ) axle has been cleaned and had a new top ball joint fitted in place of the worn N/S one, new brake discs, callipers and brake pads fitted and generally checked over before bolting in place.

A propex heater has been fitted under the rear seat and connected  into the heater pipe to boost the original system.

Next on the agenda was the mechanical work to the engine, consisting of a routine engine service and carburettor overhaul, renewal of the heat exchangers, new lower tin-ware ( due to corrosion ) a new clutch and a flywheel oil seal. The upper tin-ware was treated to a coat of paint, completing the new look.

Before we could fit the engine back into place the engine bay was seam sealed where necessary and painted in L31H Chianti Red. Also the wheel arches were sprayed with a rubber based stone guard then topcoated.

Meanwhile, body filler was applied over the welded and glued joints and seams, sanded until flat and smooth then sprayed with a polyester spray filler. This was then dry sanded with 180 grade sandpaper, then 2K primer was sprayed over the entire bodyshell. Further dry sanding with 320 grade paper then wet flatted with 1000 grade ensures an excellent base for the Standox 2K topcoat.

First the red was applied, then baked at 80 degrees centigrade, then the interior was masked off and painted white, again this was baked hard, after unmasking the top half was wet flatted and the lower half and door-shuts were masked off, and the top painted in L90D Pastel White.

A new alarm system was the next item on the agenda, fitted in place while all the internal trims were removed, so that it could be hidden away neatly.

The last parts to be painted were the bumpers, the sliding door trim panels below the rear windows and the wheels. While these were being prepped and painted the interior was cleaned and replaced, also the underside and internal cavities were coated with Wax-oyle.

Finished.

Body Panels Bought to Date: