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Joined: 3/16/2009
Posts: 9405
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When we bought the Bus it was hard to find one that had no rust, so we found the best we could find for the money. The under bed of the Bus is in perfect condition but some of the body panels had their issues. When I did this project last time, Akers another old time car buff, indicated the work was only temporary, without replacing the metal. I agreed but wanted to see what I had and how long it would last over time with a temporary fix. About a year and one half.
I didn't want to buy a mig to do the work because this is probably the last project I will take on. A friend of mine who is in the body business and I were talking and he said what about using panel bond. I had never heard of it.
I decided that was the way I wanted to go and ordered all the necessary panels for the bus. More on my friend Jim later in the post. He saved the day.
Here was the main problem area. I'll explain later what causes this.
There is nothing worse than pulling up in an area with a shiney new bus with AC and have a few panels smiling and laughing at you with a rusty mouth.
 Big Bad John & Runaround Sue & Paris Hammock,Florida 97 Dutch Star Diesel 76 VW Bay Window Bus
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Joined: 3/16/2009
Posts: 9405
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The new rear fender section. It covers from the rear deck lid to the front 1st rear section joint.
 Big Bad John & Runaround Sue & Paris Hammock,Florida 97 Dutch Star Diesel 76 VW Bay Window Bus
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Joined: 3/16/2009
Posts: 9405
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They never fit perfect, so you have to trim and fit.
 Big Bad John & Runaround Sue & Paris Hammock,Florida 97 Dutch Star Diesel 76 VW Bay Window Bus
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Joined: 3/16/2009
Posts: 9405
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Initial fitting, screws will keep it in the right place when the panel adhesive is applied.
 Big Bad John & Runaround Sue & Paris Hammock,Florida 97 Dutch Star Diesel 76 VW Bay Window Bus
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Joined: 3/16/2009
Posts: 9405
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Notice the body line. if you just installed the panel as is, the original body line would not line up and be at an angle. I tried several ways to line it up, but it would only fit properly where it is. I will cut it on the line and make it match the next panel.
Big Bad John & Runaround Sue & Paris Hammock,Florida 97 Dutch Star Diesel 76 VW Bay Window Bus This message was edited by johnchurn on 4-13-08 @ 10:19 PM
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Joined: 3/16/2009
Posts: 9405
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This area was the worst. It was caused by the battery being enclosed on the other side of the panel. It is a flooded lead acid battery, which emits fumes and acid while charging and they in turn react with the metal panels inside.
I just replaced the battery with a gel cell which is fully enclosed. This will eliminate the problem with the flooded cells emitting fumes, and causing corrosion on the inside panels inside the panels.
 Big Bad John & Runaround Sue & Paris Hammock,Florida 97 Dutch Star Diesel 76 VW Bay Window Bus
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Joined: 3/16/2009
Posts: 9405
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To fix the rusted rear fender I had to buy the whole quarter section all the way to the sliding door. All the metal was good except for the area next to the rear fender. I decided to cutoff the section I needed which saved me a lot of work.
You still have to cutoff all the inner panel bends, because all you need is the top surface for an over lay.
Here's the main panel.
 Big Bad John & Runaround Sue & Paris Hammock,Florida 97 Dutch Star Diesel 76 VW Bay Window Bus
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Joined: 3/16/2009
Posts: 9405
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This was all I needed.
 Big Bad John & Runaround Sue & Paris Hammock,Florida 97 Dutch Star Diesel 76 VW Bay Window Bus
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Joined: 3/16/2009
Posts: 9405
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Again all the screws are for the initial line up. After all the new panels are fit, I have to take them off and grind the contact area's to metal so the new panel will bond to the old surface.
I drew an outline on the panels so I would know exactly where to grind
Notice I have cut the two panels to align with the original body line.
 Big Bad John & Runaround Sue & Paris Hammock,Florida 97 Dutch Star Diesel 76 VW Bay Window Bus
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Joined: 3/16/2009
Posts: 9405
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I ground off the bad rusty area. They say you can leave it open behind the new panel but I know from past experience that wet dirt will accumulate behind the new panel and it would be rusted out in no time.
I filled the gap with a product called Mar-glass. It's a fiberglass product that is waterproof. It will help to keep the water and moisture off the new panel.
 Big Bad John & Runaround Sue & Paris Hammock,Florida 97 Dutch Star Diesel 76 VW Bay Window Bus
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