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 12/10/2010 4:31 PM
 
 Modified By johnchurn  on 2/19/2011 12:33:56 PM

The good is they are fun and keep you young. The bad is they are constant care to keep them looking new. Our VW Bus is 34 years old now.

We have had the bus for 4 years. It took us about a year and a half to find one that wasn't totally rusted out. We we bought it in Ft Lauderdale Florida. I crawled under it to make sure all the frame rails and important frame parts did not have any rust. It was very clean under neath and had the original factory undercoat still in tact . I knew I could keep the rest of the body looking good, even though it has rust in some of the exterior panels. It had been painted 3 or 4 years earlier and looked as if it didn't have a lot of previous repair on it. This turned out not to be true. In the first two years I replaced all the panels that I could see at the time that had rust thru on them. They are still holding good.

This year all the other patch work started showing it's age. I started getting a lot of rust thru on the fender corners. The rocker panel under the sliding door was extremely rusted and had to be totally replaced. This project was to identify all the areas that were totally rusted thru and to cut new metal and replace that area, do the body work and repaint.

Here I am starting with the rear fenders.


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 12/10/2010 4:33 PM
 
 Modified By johnchurn  on 2/23/2011 4:04:27 PM

The panel on the left is one I replaced earlier last year and seems to be holding up well.


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 12/10/2010 4:34 PM
 
 Modified By johnchurn  on 2/23/2011 4:05:11 PM

The doors are going fast and I have been looking for replacements. They are hard to find and very expensive to buy and ship.

I am still keeping them looking good.


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 12/10/2010 4:36 PM
 
 Modified By johnchurn  on 2/23/2011 4:06:08 PM

Any where the metal is rusting thru, I am replaceing with new metal.


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 12/10/2010 4:36 PM
 
 Modified By johnchurn  on 2/23/2011 4:06:50 PM


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 12/10/2010 4:36 PM
 
 Modified By johnchurn  on 2/23/2011 4:07:23 PM


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 12/10/2010 4:38 PM
 
 Modified By johnchurn  on 2/23/2011 4:07:58 PM

This was the worst area on the whole bus and I have been dreading replacing it. It's the rocker panel under the sliding door. I bought a new factory rocker panel to replace the whole area.


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 12/10/2010 4:45 PM
 
 Modified By johnchurn  on 2/23/2011 4:08:32 PM

I sprayed the whole area with OSHPO a rust killing chemical and let it dry before I installed the new panel. This was like putting a puzzle together to make it fit. It has to be exact for it to look professional when painted.

What makes this more difficult than normal is it's supposed to be cut out entirely and welded back in.

A friend of mine who used to be in the body business , now retired, gave me a tool that shoots body panel glue that is as strong as welding. It takes a lot more skill to do it this way than welding, but you don't have to take out all the interior and such as to not set it on fire when welding. It did great.


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 12/10/2010 4:47 PM
 
 Modified By johnchurn  on 2/23/2011 4:09:04 PM

New replacement panel. I had to do some trimming and fitting before putting it in place.


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 12/10/2010 4:48 PM
 
 Modified By johnchurn  on 2/23/2011 4:09:41 PM

Cleaned up and drying, ready fo the new panel.


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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