Milly the 1979 Westfalia Berlin Deluxe Bay Window Camper Van

[chrisradioman]

[chrisradioman]

Tudor managed to get Mike to make some 2 mm phosphor bronze thrust rings for
the tailgate hinges.
He silver soldered them on because braze would have taken too much heat
and silver sollder is just as strong.
This will stop the engine lid moving from side to side & avoid the new paint being damaged:-

[chrisradioman]

I used a special carbon fiber rich filler to go over the rough metal on the lower arch & also a dent that is near on of the fixing holes for the sink overflow cover:-

[chrisradioman]

All the inside masking is now ready for painting:-



I've started cleaning all the wax from the doors ready for prepping:-

[chrisradioman]

A mate of mine posted this picture on facebook:-

[chrisradioman]

I prepped up the engine lid, I painted the inside in 2K I went at it from devery angle concentrating on the inside of the holes I wasn't really concerned if I had runs on the outside as I can flat these down when the paint dry's. As it happens though I think its come out OK:-






Finally the inside is finished & I'm happy with it:-

[chrisradioman]

The run has gone:-


The buddy seat parts have had a second coat:-



The RHS door is already & Gav is on the final prep:-





While Davey is busy texiting, I mean prepping my tailgate:-

[jolas]

That Mike character must be careful that his hair does'nt catch alight Your bus is going to look brand new !

You speak about having applied paint and then primer afterwards (window sills), did you paint directly on top of the metal / lead treatment ?

[chrisradioman]

That Mike character must be careful that his hair does'nt catch alight Your bus is going to look brand new !

You speak about having applied paint and then primer afterwards (window sills), did you paint directly on top of the metal / lead treatment ?

Lol, I etched primed on the lead & then paint straight up on that.

[chrisradioman]

Masking is now off & I'm happy:-




Panel progress:-

[chrisradioman]

I bought a few hazard warning switches which I'm going to modify to operate the spot lights, the heated front screen & the interior light. These will light up dimly in the dark:-

[chrisradioman]

Milly's prep work is nearly ready now:-


The final door is nearly done:-


I've started work on the pop top:-

[chrisradioman]

Been to Custom Classics today, I removed the canvas & all the hardware, some of the gelcoat had come away from the wood due to the staples. I chunked off all the loose stuff & then carbon fibre'd over the wood to make the surface level, stronger & nicer looking:-




Used this tool to pull all the staples off:-



I went over all the surfaces that looked dodgy with an angle grinder, I roughed it all up & the coated it in the carbon fiber stuff:-

[chrisradioman]

I've sanded the carbon glass fibre down & its now OK, the wood is sealed & the strength is back, I just need to paint it now. I'm going to sand the flock off & get it redone so it will look new again:-


All the furniture is now off the roof, the lot just needs sanding filling & painting:-


All of the furniture will need re-galving:-


Tried the engine lid for fit & its spot on, less than 1 mm side to side movement:-


Cleaned the last door jam down:-



Van prep work nearly done, all the paint I put on the sides they had to sand back off, best if I stay away from the body paint Doh!

[chrisradioman]

More prep work today, the boys spent all day yesterday on it & today the three of us spent all day on it, I think its finally ready.
I have put Rivnuts in all the holes were self tappers go as I don't want to cut into my new paint:-