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1954 RHD Barndoor Samba - Back To Stock Restoration
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alex1916v
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Joined: June 22, 2007
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PostPosted: Sat Aug 20, 2016 3:14 pm    Post subject: Re: Barndoor Samba - Back To Stock Restoration Reply with quote
RockStock wrote:
Scotty wrote:


good detail

why are they there?
is it bracing/strengthening for the receptive threads of the beam bolts?


Yes, they are exactly that. On our bus the arc welds were extremely rusty and porous. They needed to be completely repaired and redone. The reason they aren't finished yet is I'm having to borrow an arc welder to replicate the authenticity with 100% accuracy. Not many shops use arc any more including us, so tricky to find! Very Happy


Your thermal dynamic TIG welder will have a setting for stick welding dude, you just need the torch and some carbon/mild steel 2.5mm rods

Cheers
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Air Kraft
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PostPosted: Fri Aug 19, 2016 11:56 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Barndoor Samba update: Reshaping the front doglegs and setting door gaps. At Airkraft we aim for perfect door gaps as a keen(e) eye is immediately drawn to an uneven gap! Here we are part way through setting, cutting, welding and adjusting to achieve our target. A resto is made or broken on how well the panels line up. It's a labourious, often tedious task, but the end result is always worth the effort Wink

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Air Kraft
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PostPosted: Sun Aug 14, 2016 11:41 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Sam busting out the fabbed mini E-wheel and CP planisher to get the green panels to fit...

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wcfvw69 Premium Member
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PostPosted: Fri Aug 12, 2016 7:28 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Um.. WOW.. simply wow..
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Scotty
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PostPosted: Fri Aug 12, 2016 5:19 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Good work Matt!
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Fredrik.S
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PostPosted: Thu Aug 11, 2016 4:34 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
This is porn, love it Very Happy
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ingenbremser
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PostPosted: Thu Aug 11, 2016 10:49 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
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fazeka
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PostPosted: Thu Aug 11, 2016 10:12 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Brilliant! Absolute insanity! Love it!
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Air Kraft
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PostPosted: Thu Aug 11, 2016 9:27 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Wheeling out the imperfections on the original top edge closing panel...
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The finished item (apart from the seat brackets...)

Hope you guys like it!!!

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Air Kraft
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PostPosted: Thu Aug 11, 2016 9:22 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Busting out the oxyacetylene to replicate the factory welds...
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Air Kraft
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PostPosted: Thu Aug 11, 2016 9:20 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
The panel ready for action...
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Checking fit - perfect!
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Yep!
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Spot welding the panel in...
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Air Kraft
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PostPosted: Thu Aug 11, 2016 9:13 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Forming the pressings...
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Getting medieval on the panel's ass...
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Marking out the original body number...
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Tig welding in the body number...
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Air Kraft
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PostPosted: Thu Aug 11, 2016 9:09 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Marking out the panel...
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Preparing for battle...
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Setting up the Pullmax...
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Forming the beads...
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Air Kraft
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PostPosted: Thu Aug 11, 2016 9:05 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
It's been a short while since our last Barndoor Samba update, but, trust me, we've been busy! The challenge this time around was to make a front cab divider/bulkhead. Sadly, the original panel had been repaired so badly that replacement was the only option. This was a massive undertaking, but between Sam and I we've smashed it. I can hear you all asking "why didn't you just buy a green panel?"... well, we tried and tried and tried! Besides, we love a challenge, and this was a good opportunity to show the kind of work we can do at Airkraft. The process was very long, involving casting Pullmax dies from sections cut out of the original panel. We needed no fewer than 3 sets of dies to make the original style pressings and spears. No mean feat! The original body number was in good shape, so we fully documented removing it from the original panel and Tig-welding it into the new panel. Some light planishing dressed it up so that the insertion was pretty much invisible. Now, I must stress that absolutely no body filler has been used on this panel whatsoever. We metal finish all of our panels to the highest standards to reduce the amount of bodyshop work necessary. Anyway, I hope you guys like our new bulkhead - please like our page and share it if you can. Thanks!

First task, make a template out of 3 sections of steel with an exact fit:
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Tig weld the 3 sections together...
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The sections cut from the original panel to create the cast dies...
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Getting ready for battle...
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vdouglu
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PostPosted: Wed Jul 20, 2016 8:20 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Awesome work! Thanks for posting Smile
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vwhelmot
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PostPosted: Tue Jul 19, 2016 11:32 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
:D Good stuff
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Air Kraft
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PostPosted: Tue Jul 19, 2016 7:50 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Hey guys! Been really busy expanding the business and taking on extra space. Some major updates to follow shortly Wink
Cheers, Matt
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Malokin Martin
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PostPosted: Mon Jul 18, 2016 1:46 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
^ second. This was an interesting thread
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vwhelmot
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PostPosted: Fri Jul 08, 2016 2:37 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
Any update Matt?
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brettsvw
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PostPosted: Mon Jun 20, 2016 4:00 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote
You guys have my attention, great job diving in and doing it right.
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