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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Thu Jun 09, 2016 2:00 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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A little update: The cab door lowers had been previously repaired to a poor standard, so it was necessary to completely redo the repairs. We templated the door and then set about patterning and then transferring the pattern to sheet steel. As the outer door skin is a varying compound curve, it's very a very tricky panel to make. Luckily we have several English Wheels, so we wheeled up a lower skin to exact standards.
The inner door skins are really tricky to make correctly. The profile is almost a 'P' shape on the pressing, which people mistake to be a simple bead. To overcome this, we made a pair of Pullmax dies to exactly replicate the pressing. All panels were tig-welded then fully planished.
Hope you like the update - doors are now pretty spiffing!
Some of the choice repairs on the door...
_________________ www.air-kraft.com
Last edited by Air Kraft on Thu Jun 09, 2016 2:12 am; edited 2 times in total |
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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Thu Jun 09, 2016 2:02 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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making the Pullmax dies:
playing around testing the profile and adjusting the dies...
_________________ www.air-kraft.com |
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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Thu Jun 09, 2016 2:07 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Making the lower inner skin:
skin welded in place:
_________________ www.air-kraft.com |
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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Thu Jun 09, 2016 2:10 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Outer skin wheeled up:
tig tacked in place:
Fully tig welded:
Planishing the panel and correcting the profile to get the panel flowing perfectly:
_________________ www.air-kraft.com |
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wcfvw69 Samba Purist
Joined: June 10, 2004 Posts: 13385 Location: Arizona
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Posted: Thu Jun 09, 2016 6:07 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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I love this thread and the incredible attention to detail. I have to confess though and wonder how many hours went into fix that door to such a high standard and the costs associated with it?
Question, what tool do you use to peel the pinch seam open? Basically, where the door skin meets the inner panel? _________________ Contact me at [email protected]
Follow me on instagram @sparxwerksllc
Decades of VW and VW parts restoration experience.
The Samba member since 2004.
**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours** |
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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Thu Jun 09, 2016 9:06 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Hey Bill. Thanks for the compliments!
Totally agree on time scale to do such work, but it's not as bad as you think. As this is a stock resto, we are keen to keep all the OG panels to keep the Bus as "matching numbers" as possible. Besides, Barndoor cab doors don't grow on trees these days, so finding a good replacement pair is pretty much impossible.
And... We love a challenge!!! 😄👍
Cheers, Matt _________________ www.air-kraft.com |
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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Fri Jun 10, 2016 10:02 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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As the engine lid has been repaired so badly in the past, we decided to make one from scratch. Here's the very beginning; blocking out the shape for the number plate recess. Obviously a long way to go yet
_________________ www.air-kraft.com |
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Bendango Samba Member
Joined: September 04, 2005 Posts: 593
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Posted: Sun Jun 12, 2016 7:14 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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wtf _________________ I want a real garage.
WANTED - [WTB] 55-62 Bus Thin Lip Package Tray SWR
Getting Used - SWR 60 westy copy built by vw ( apparently )
http://www.thesamba.com/vw/forum/viewtopic.php?t=320866
Braukuche wrote: |
Where did you find the elephant dick? |
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fazeka Samba Member
Joined: July 09, 2005 Posts: 93
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Posted: Mon Jun 13, 2016 3:34 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Yup, that's insane! Great stuff! |
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Barndoor Mafia Il Capo
Joined: August 23, 2001 Posts: 6194 Location: EUSKAL HERRIA
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Posted: Wed Jun 15, 2016 12:19 pm Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Very cool build thread guys. Love the progress and keep up the awesome work!!! |
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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Thu Jun 16, 2016 8:42 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Thank you for your encouragement and kind words guys! 👍 _________________ www.air-kraft.com |
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brettsvw Samba Member
Joined: November 22, 2007 Posts: 2145 Location: Florida
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vwhelmot Samba Member
Joined: May 04, 2006 Posts: 617 Location: united kingdom
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Posted: Fri Jul 08, 2016 2:37 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Any update Matt? |
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Malokin Martin Samba Member
Joined: August 19, 2007 Posts: 3093 Location: E-burg
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Posted: Mon Jul 18, 2016 1:46 pm Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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^ second. This was an interesting thread |
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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Tue Jul 19, 2016 7:50 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Hey guys! Been really busy expanding the business and taking on extra space. Some major updates to follow shortly
Cheers, Matt _________________ www.air-kraft.com |
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vwhelmot Samba Member
Joined: May 04, 2006 Posts: 617 Location: united kingdom
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Posted: Tue Jul 19, 2016 11:32 pm Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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:D Good stuff |
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vdouglu Samba Member
Joined: December 12, 2001 Posts: 278
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Posted: Wed Jul 20, 2016 8:20 pm Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Awesome work! Thanks for posting |
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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Thu Aug 11, 2016 9:05 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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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:
Tig weld the 3 sections together...
The sections cut from the original panel to create the cast dies...
Getting ready for battle...
_________________ www.air-kraft.com |
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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Thu Aug 11, 2016 9:09 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Marking out the panel...
Preparing for battle...
Setting up the Pullmax...
Forming the beads...
_________________ www.air-kraft.com |
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Air Kraft Samba Member
Joined: October 04, 2008 Posts: 62
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Posted: Thu Aug 11, 2016 9:13 am Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration |
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Forming the pressings...
Getting medieval on the panel's ass...
Marking out the original body number...
Tig welding in the body number...
_________________ www.air-kraft.com |
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