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1954 RHD Barndoor Samba - Back To Stock Restoration
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Air Kraft
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PostPosted: Thu Jun 09, 2016 2:00 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

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!

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Some of the choice repairs on the door...
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Last edited by Air Kraft on Thu Jun 09, 2016 2:12 am; edited 2 times in total
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Air Kraft
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PostPosted: Thu Jun 09, 2016 2:02 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

making the Pullmax dies:

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playing around testing the profile and adjusting the dies...

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Air Kraft
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PostPosted: Thu Jun 09, 2016 2:07 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Making the lower inner skin:

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skin welded in place:

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Air Kraft
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PostPosted: Thu Jun 09, 2016 2:10 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Outer skin wheeled up:

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tig tacked in place:

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Fully tig welded:

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Planishing the panel and correcting the profile to get the panel flowing perfectly:

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wcfvw69 Premium Member
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PostPosted: Thu Jun 09, 2016 6:07 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

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?
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Air Kraft
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PostPosted: Thu Jun 09, 2016 9:06 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

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
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Air Kraft
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PostPosted: Fri Jun 10, 2016 10:02 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

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 Wink

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Bendango
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PostPosted: Sun Jun 12, 2016 7:14 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

wtf
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fazeka
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PostPosted: Mon Jun 13, 2016 3:34 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Yup, that's insane! Great stuff!
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Barndoor Mafia
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PostPosted: Wed Jun 15, 2016 12:19 pm    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Very cool build thread guys. Love the progress and keep up the awesome work!!!
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Air Kraft
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PostPosted: Thu Jun 16, 2016 8:42 am    Post subject: Re: 1954 RHD Barndoor Samba - Back To Stock Restoration Reply with quote

Thank you for your encouragement and kind words guys! 👍
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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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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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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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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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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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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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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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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 9:13 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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