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My 54 european deluxe from start to finish
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54bugn
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Joined: April 28, 2005
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Location: Parksville BC, Canada
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PostPosted: Fri Jun 24, 2016 10:43 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Hello all, you gotta love the oil and gas industry! Let's just say I ended up having to move again, it's gotta be the last time.

Living the left coast style now, and finally have started back on the 54.

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Drilling out rusted out bumper mount.

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Looks worse underneath.

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Drilling out the inside shelf. It was rotten in a number of ways.

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With shelf removed. New pieces to go in after clean up.

Thanks for sticking with me.

Cheers, Mike
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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=414940
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54bugn
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PostPosted: Sat Jun 25, 2016 10:44 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Started straightening out and reforming the good metal that is left to repair the area today. Trying to keep as much original as possible.

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Stay tuned for the cleanup and repair.

Thanks,
Mike
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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=414940
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54bugn
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PostPosted: Thu Jun 30, 2016 7:52 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Continuing to fix the left rear bumper mount and frame work.

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Fitting mount, measuring multiple spots compared to original right side.

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Thanks for watching.

Cheers, Mike
_________________
"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=414940
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54bugn
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PostPosted: Mon Jul 04, 2016 6:50 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Another update, more progress on the left rear valance/ bumper mount .

Enjoy,
Mike

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_________________
"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=414940
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54bugn
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PostPosted: Tue Jul 05, 2016 8:33 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

So I got the left rear shelf replaced with a new one. Nice piece from CIP was advertised as original German quality and it was certainly a nice piece only needed some minor trimming.

Original right shelf installed in August 1954.
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New shelf installed July 2016.
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Exterior view afte new shelf and new bumper mount installed. Much stronger assembly now.
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One more repair required to the left rear valance where someone cut it out to fit a later muffler, and the rear end is done. Stand by for that.

Cheers,
Mike
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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
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Zwitterkafer
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PostPosted: Wed Jul 06, 2016 10:28 am    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Nice work there. Is that blue thing an IKEA kitchen trolley? If so, I had the same idea....
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54bugn
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PostPosted: Wed Jul 06, 2016 11:13 am    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Hello Zwitterkafer, thanks for the props. Yes the cart is from Ikea, it has an "almost" look of the old fold up toolboxes, and holds a lot of stuff as well. I highly recommend it.

Cheers,
Mike
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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

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54bugn
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PostPosted: Wed Jul 06, 2016 7:52 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

So I only have a later model replacement valance to steal metal from, so this has to be done in two steps. First step almost complete, now to fill in the hole.

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Stay tuned, Mike
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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

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Basketcase
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PostPosted: Thu Jul 07, 2016 4:35 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

fantastic job! I dunno how you get anything done between work and moving.
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54bugn
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PostPosted: Fri Jul 08, 2016 8:05 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Thanks Basketcase, well now that I have the right job I won't be moving and have more time to work on the 54.

To that end, I made the piece to fit the exhaust cutout that I had to fix. Started out with a thick paper template transferred to flat steel, then massaged it to fit.

Here's the template and early cutout and bend in the flat steel.
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Here's the early inside and outside fitting.
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Here's the final fitting prior to welding.
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And post weld. Stay tuned for the final finished pics.
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Mike
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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
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Joey
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PostPosted: Sat Jul 09, 2016 6:03 am    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

54bug'n wrote:
well now that I have the right job I won't be moving and have more time to work on the 54.


I think I heard that before... Laughing

Nice work - glad to see you back at it!
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‘60 Kombi - '74 Bus - '79 Panel - '65 Beetle
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54bugn
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PostPosted: Sat Jul 09, 2016 8:19 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Thanks Joey, it's great to be back at it. I do have much more time to work on it now.

So the car is now repaired From the rear valance to the heater channels. Will keep working my way forward. For now here are the finished back end pics.

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Cheers, Mike
_________________
"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=414940
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54bugn
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PostPosted: Fri Jul 15, 2016 8:57 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Starting repairs on the front of the 54 bug.

First picture shows quite a few holes in the deck behind the fuel tank, as well on the right side where it welds to the skirt.

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Repairs in this area complete as well as inside the car on the opposite side, in the following two pics.

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Stay tuned more nose repairs to go.

Cheers,
Mike
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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

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54bugn
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PostPosted: Sat Jul 16, 2016 8:19 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Cutting away more rusty metal. Left front lower section cut away, and spare tire well gone. Next up weld in donor metal.

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Stay tuned,
Mike
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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

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54bugn
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PostPosted: Wed Jul 20, 2016 9:34 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Hello all, more repairs on the left front lower support. Pics attached. Also had to replace a piece of the rubber seal channel on the nose and fill some holes. The results are attached. I had to cut the 55's donor piece to fit in two pieces as it was 1/8 of an inch longer than the 54's. So much for direct replacement. Second piece tomorrow.

Enjoy.
Mike

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_________________
"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=414940
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54bugn
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PostPosted: Sun Jul 24, 2016 7:43 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

More progress over the past few days. Got the 2nd part of the 55's replacement piece welded in place, now have a place to attach a new spare tire well. Also repaired some holes in the front left fender well, and repaired a number of holes in the upper hood channel in front of the window, as well as some holes in the lower window channel. Photos below. Also managed to drill out and tap door mount screws that broke off during both door removals. Next up spare tire well.

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Stay tuned, Mike
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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=414940
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54bugn
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PostPosted: Fri Jul 29, 2016 8:57 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Next job replacing the spare tire well. Cutting and fitting the replacement piece, pics attached, welding it in is next.

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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=414940
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54ovsemi
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PostPosted: Sun Jul 31, 2016 12:21 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Nice!!
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54bugn
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PostPosted: Mon Aug 01, 2016 9:37 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Thanks 54ovsemi.

One of the things to watch out for while welding...."do you smell something burning?" (Nothing was hurt in the producing of this picture.....phew!) Rolling Eyes

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Anyway, so much for those shorts. Laughing

Sorry, back to welding. More pics to come.

Cheers, Mike
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"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=414940
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54bugn
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PostPosted: Tue Aug 02, 2016 9:59 pm    Post subject: Re: My 54 european deluxe from start to finish Reply with quote

Hey folks back to repairing the nose from rust damage. The lower spare wheel section is now welded in. Need to do a few touch ups but it's strong and looking good. I still need to repair the front apron lower edge where it mates with the wheel well. Enjoy the pics.

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Stay tuned for the cleanup of the nose repairs.

Cheers,
Mike
_________________
"Schwing wrote:
You either have to be too cheap to hire a pro or determined to do it yourself, but it helps to be both!"

54 European Sedan deluxe
Build thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=414940
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