Tales from the Bulli Klinik

[Bulli Klinik]

[quote="srfndoc"]

[Bulli Klinik]

[Bulli Klinik]

I haven't had the Bus delivered, yet. In the meantime, I modified a rack that I made for a Ghia vert into a little nest for the Bulli carcass.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

I also picked up a couple of beams from my friends at http://www.carswcharacter.com/
Unfortunately, the 68/69 beam that I grabbed out of the yard looks to be un-salvageable. I didn't notice all the rust when I picked it up. If it was just the outer skins, that would be OK. But the rust penetrates the tubes. Bummer.

So, still looking for a beam. Locals??? I'm thinking that I would like to go the early Bay route and install the late model spindles and brakes. I'm not especially particular though. Late K&L will work as well.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Manfred58sc]

pm or call me...
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Fat chick owner/operator

[cdollar]

I know Pagosa Springs isn't quite local, but if Manfred doesn't have what you need I have a bay beam with later bay disc setup that I just pulled from my 58 westy (installed a stock LP split bus beam). It's 95% complete, but I know some parts need replacement. I can give you more details if you're interested.

Oh... And I vote custom highroof! I'd love to see you document a build like that here!

[Bulli Klinik]

Thanks for the offer!

I'm leaning towards custom hi-roof too. It would be a lot of work, but it's going to be a keeper for me.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

I build Buses with a little help from my friends!

Big thanks to Manfred for the lead and help in getting a 68 beam for the project! It was a fun day at the secret stash.

I also picked up a set of hubs and spindles for a late, Bay disk brake setup from my friends at Cars with Character.

Slowly but surely getting all the parts I want to use together for this Bus.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

My buddy, Wayne, came out from Florida for the Buses at the Brewery event that we've been hosting for the last 10 years. He's been trimming down his stash of parts due to a move and uber-generously donated some parts to the project.

My Bus now has a face!

He also donated a decklid from his 67 Westy that once caught fire and a parcel tray. Massive thanks, Wayne! I'll be thinking of you every time I'm driving.

I still don't have the Bus back at the shop, but it's coming soon!
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Manfred58sc]

Working on a parts bundle for you as well, if you decide to go later bay I also have the proper frame upgrades (we did that to the MTN. Bus last year). Nice donate on the nose, rock those fried eggs!
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Fat chick owner/operator

[novetti]

[Manfred58sc]

Die,monster,die. That's just awful, it would look better w/o doors than that set up!
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Fat chick owner/operator

[Bulli Klinik]

[Bulli Klinik]

I'm still on the hunt for a small, rear hatch and front doors. I'd really like to hold out for some from a 67, due to the thicker metal used in the frames that year. Did Gerson start making doors, yet?

Question:

What year did they change from the earlier, pointy dash pod, to the later, more rounded design?
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

A journey of a thousand miles begins with a single step...

Though I still don't have the bulk of the Bus at the shop, I figured that I would dig into what I have.

The nose has some pretty serious rust in the lower sections of the skin as well as the structure below. I removed the skin by drilling out the spot welds at the base of the window frame and the A-pillar flanges.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

As the lower flange was rusty and needed replacement, I ground through the flange and cut the lower part of the nose away below the support flange welded below the nose.

Here's the tools I used to remove the nose skin.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

To remove paint, I use this stripper exclusively. It's up to almost $70.00/gallon at my local paint supply store, but it's the most effective stripper I've used. You're wasting money and time with the cheap stuff.

I like to score the surface prior to applying.

This stuff works!

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

I used the back of the panel to pull an accurate template of the V in the lower section of the nose.

Also marked out the location of the side flanges.

This was transferred to some MDF, which I cut to shape with a jigsaw. A little bit of sanding and it was time to run a test panel.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

I blocked the edges in with a re-shaped hammer head as a corking tool and stretched a bit of shape in.

Then I used the template as a guide and stretched the area with my planishing hammer.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

The shape came out nice, so it's on to make the replacement panel.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs