Morrow the Samba's Diary

Dogleg and B Pillar

2011-11-11T19:00:00.001-08:00

Cut this off the walk thru section for possible use on the Deluxe.

New driver's door

2011-11-11T18:58:00.001-08:00

Lower B Pillar Driver's Side

2011-11-09T14:10:00.001-08:00

I can't believe that was how rusty he was

Welding frames together

2011-11-09T14:09:00.000-08:00

Joining roofs

2011-11-09T14:05:00.000-08:00

A Pillar

2011-11-09T13:42:00.000-08:00

'67 rear hatch

2011-11-09T13:40:00.001-08:00

Gear Linkage

2011-11-09T13:27:00.002-08:00

This got cut through when the bus got separated. I welded it back together.

Rear Corner Driver's

2011-11-09T13:27:00.001-08:00

Battery Tray Driver's Side

2011-11-09T13:20:00.001-08:00

Passenger B Pillar

2011-10-30T04:26:00.001-07:00

Door Rubber Channel

2011-10-30T04:22:00.001-07:00

Roof Brace

2011-10-25T15:46:00.001-07:00

Welded in a new piece to complete the roof brace.

Elvis and Morrow

2011-09-17T11:36:00.001-07:00

Dogleg Walk thru Seat and Door Frame

2011-09-09T04:24:00.001-07:00

This section went in fairly easily in one day. I now have a solid B pillar, passenger
dogleg, door frame and walk thru seat back.

B Pillar wheelwell panel

2011-09-09T04:22:00.000-07:00

Cargo Floor seat metal

2011-09-07T13:53:00.000-07:00

There are some pieces of metal that go by the seat anchorage. I'm taking the metal to be recycled so here's photos of where the metal goes in case I forget later.

Dogleg fixed

2011-09-07T13:50:00.001-07:00

This took hours to fit in. If I had the money to buy a new panel I could have saved a lot of time.

Lower Bulkhead repair

2011-09-07T13:49:00.001-07:00

I figure it will be easier to add this now than when I put everything back on the bus.

Torsion bar removal

2011-09-07T13:44:00.001-07:00

Covers come off with 15mm, then trailing arms can be hit to knock out the bars.

Passenger Dogleg

2011-08-29T13:28:00.000-07:00

I have three doglegs and they are all rusty in different places so I should be able to make one good one from the trio.

Passenger Seat and dogleg

2011-08-28T04:33:00.002-07:00

I thought about cutting out the cab section and welding back the whole thing to the frame, but I did that once before and it'd be more trouble than cutting out what I need. I also was going to cut the cab floor from the frame, but there are so many different places they are welded together that I'm just cutting out what I need. Before I put it back on Morrow I'll fix the dogleg and lower wheelwell.

Deluxe trim on walk thru seat

2011-08-28T04:33:00.001-07:00

Passenger seat, pillar and dogleg

2011-08-28T04:27:00.001-07:00

The B pillar is fubar and the passenger seat back bent, so I'm cutting up the walk thru' donor section and using it for Morrow.

Klaus getting wet

2011-08-14T14:00:00.001-07:00

Normally I stop work when it rains, but I wanted to get the rear roof in on Morrow, so Klaus got wet in a thunderstorm.

Rear Roof and Hinge Springs

2011-08-07T16:55:00.000-07:00

Spent the day grinding and cutting and measuring and I am pretty close to fitting the clip back in.

Rear Roof and Hinge Springs

2011-08-06T13:57:00.000-07:00

Rear Roof and Hinge Springs

2011-08-06T13:47:00.000-07:00

The rear roof is rotten so I'm chopping out the crap and welding in a new section. At the seam I am grinding the metal back so it is the correct gap.

Seat belt anchoring brackets

2011-08-06T13:35:00.000-07:00

Engine lid and driver's door from Mike

2011-08-03T11:57:00.000-07:00

They look better in person.

Fixing Passenger Door

2011-07-10T12:41:00.000-07:00

Inside the bottom of the door it ended up having too much rust and if I had just patched it I'm sure rust would come through later.

Passenger's Door

2011-07-09T16:07:00.000-07:00

Next I will be working on the passenger door. I'm going to fix Morrow's old door. It had lots of filler for some unknown reason as it's not too rusty. I'm cutting up the bent Zebra door for donor metal.

Cargo Rocker

2011-07-09T16:00:00.001-07:00

B Pillar

2011-07-09T15:59:00.001-07:00

This comes in several pieces. I welded it together before putting it in place with the rocker.

Cargo Rocker

2011-07-07T14:04:00.001-07:00

The C pillar had to be trimmed a little

to line up with the inner rocker.

Elvis and Morrow

2011-07-05T06:14:00.001-07:00

POR 15

2011-07-05T06:12:00.000-07:00

Side Windows

2011-07-02T04:22:00.001-07:00

Morrow's Side windows and top rail were rotten and while the windows could have been fixed the rail needed to come out completely so I swapped them with some more of the Zebra Bus.

Driver's Rocker

2011-06-28T11:57:00.000-07:00

Gave myself a pat on the back as it ended up fitting very nicely. Lots of trial and grinding and fitting back and forth. The Klasfab panel is a great fit. It goes all the way to the top of the cross strengthener, but I trimmed it down as I wanted the original metal to stay securely in position.

B Pillar

2011-06-28T11:51:00.000-07:00

It took a little figuring out how to line up the panels for the B Pillar. I then welded the new parts together before putting them in their new home.

Driver's Rocker

2011-06-19T13:17:00.000-07:00

First lot of work I've done in several weeks due to having a bad back. Boy was it hot out there today. I'm trimming back the metal for the new rocker panel.

Rear driver's jacking point

2011-06-01T06:19:00.000-07:00

I tested out the Wolfsburg West panels. These look and fit as well as the Klasfab.

Cargo Floor

2011-06-01T06:05:00.000-07:00

The floor has an extra bend in the side edge that goes up against the rear bulkhead. This will be cut of to make the floor fit in properly.

Driver's Rocker

2011-06-01T05:58:00.000-07:00

Next to attack is the driver's rocker. I've left the strengtheners in situ for now so I can keep stuff lined up.

Chassis cross beam

2011-06-01T05:53:00.000-07:00

One of the chassis cross beams was rotten. I still had part of the floor from the Zebra Bus so cut off a piece and welded it onto Morrow.

Driver's side windows

2011-06-01T05:50:00.000-07:00

I am going to cut out the old windows and weld in the good panel from the Zebra.

Front Cab Joining to rear

2011-05-18T07:37:00.001-07:00

Front Pillar lining up

2011-05-18T07:36:00.000-07:00

Forgot to post these before.

Cargo Door adjustable screw plate.

2011-05-14T13:34:00.001-07:00

Some how the screw plate has gone awol and so I cut one out of an old panel, then cut into the side panel and repalced the item.

B Pillar

2011-05-14T13:25:00.000-07:00

I'm cutting out the B Pillar again. It's bent in a little and the hinge holes are 1/2" too far apart.

2011-05-14T13:24:00.001-07:00

The Zebra doors are more solid but the a little bent. I'll probably repair the grey ones and use them.

Parcel Shelf

2011-05-08T04:01:00.000-07:00

Next to fit will be the parcel shelf. This is just a mock up. It will fit in easily, but the piano hinge will need replacing.

Rear Hatch

2011-05-08T03:58:00.000-07:00

This fitted nicely, following extensive pre welding measuring, with factory gaps.

Passenger Rear Quarter

2011-05-08T03:53:00.000-07:00

Greg came over and we spent half a day fitting the side panel on. Everything went smoothly and the bus looks very nice now.

2011-04-21T17:59:00.001-07:00

Not much more work and I'll be able to attach the side panel. It's pretty close, but no cigar yet.

Rear Pillar

2011-04-21T17:54:00.000-07:00

I have a spare left hand pillar but need the right hand side as I don't think I can save the one I cut off.

Engine Apron Mount

2011-04-21T17:49:00.000-07:00

Needs to remedial work and one of the bolts removed.

2011-04-21T17:46:00.001-07:00

The side panel I have is from a Standard bus so I had to save some of the old window and then repair it.

Passenger Side Window

2011-04-21T17:36:00.000-07:00

Originally I was going to just repair the side window with a smaller piece of metal but then opted for a large section.

Rear Passenger Wheelarch

2011-04-21T17:35:00.001-07:00

Short side rocker

2011-04-06T05:32:00.001-07:00

Engine rear pillar

2011-04-06T05:30:00.001-07:00

Gas filler

2011-04-06T05:26:00.000-07:00

Corner tray replacement

2011-03-28T16:39:00.001-07:00

The old tray was easy to cut out and the new one is pretty snug, but needs a lip made. I'm not sure if i'll fix or repair the corner.

More Spare Wheel Well Work

2011-03-23T11:15:00.001-07:00

Gas tank shelf

2011-03-14T13:57:00.000-07:00

Spare Wheel well

2011-03-14T13:51:00.000-07:00

Rust treament then painted so that

black doesn't show through the vents.

Rear Parcel Shelf

2011-02-24T16:50:00.001-08:00

There was enough of the rusty old shelf to use to fix the Zebra shelf.

Rear parcel shelf, wheelwells, etc

2011-02-24T16:46:00.000-08:00

The Westy panels had some damage so I can't just cut away all the rusty stuff and put in the better metal. Also, I have to put in the walk thru spare tire well.

Walk Thru spare tire well

2011-02-19T13:27:00.000-08:00

Cutting away the old metal to make way for the Walk Thru spare tire well.

Gas tank shelf

2011-02-19T13:25:00.000-08:00

is also rusty, imagine that.

Rear parcel shelf next on the chopping block

2011-02-19T13:22:00.000-08:00

Passenger Rear Quarter

2011-02-19T13:16:00.000-08:00

Morrow's panel has accident damage and rust. I have the other panel I bought in Jensen Beach, but I have to leave the rear window as the JB panel is for a Standard model.

Passenger B Pillar

2011-02-19T13:12:00.000-08:00

I tried fitting the door but it rubs. The pillar looks like it is in the correct place so the door hinges may be the problem.

Rear Passenger Jacking Point

2011-02-19T13:11:00.001-08:00

Passenger Door Frame

2011-02-19T13:05:00.000-08:00

The rubber channel around the door was rotten, so I used metal from the Zebra bus to fix it.

Rear Outrigger

2011-02-13T04:26:00.000-08:00

Rear Top Hat

2011-02-06T05:49:00.000-08:00

Made a bottow piece for the rear top hat. Sprayed it before welding it together. I drilled holes to help teh welding, but the welds did not hold, so I had to weld the sides. Cut out where the tubes go through and welded into new home. I applied seam sealer before I welded it back to the frame as I didn't think I would be able to reach some spots later. Seam sealer is flammable!

Rear Top Hat

2011-01-30T09:56:00.001-08:00

Had to stop working on the door channel as the flanger broke. Harbor Freight did not have any more in stock so I mail ordered one, but it hasn't arrived yet.

Door rubber channels

2011-01-20T09:07:00.000-08:00

I saved a lot of the metal when the Zebra bus was chopped up. I am cutting out the rust from Morrow and going to weld in as much as I can from the good metal.

Shifter Bushing problem

2011-01-20T09:06:00.001-08:00

It came back out when I was lining up the frame for welding and now will not go back in fully.

Cab attachment

2011-01-20T09:04:00.000-08:00

Frame is now welded back together and the walk thru cab is attached. He will live!

Welding window pillar

2011-01-14T17:39:00.000-08:00

I'm quite pleased with the outcome. I decided to weld this first before doing the frame as I was having a lot of trouble lining it up. Now I'm having some bother getting the frame lined up, but it's not as far out as the pillar had been.

Red earth

2010-10-14T08:02:00.001-07:00

Just some of the red Arizona earth found in the Zebra bus.

Dogleg

2010-10-14T08:00:00.000-07:00

The Zebra bus had accident damage and filler, so i'll keep some of Morrow's old metal.

Areas to be aligned.

2010-10-10T05:36:00.000-07:00

Front Roof

2010-10-10T05:34:00.000-07:00

The right hand side of the Zebra's

roof and door pillars is dented, so I am having to save that portion on Morrow and try and match it up!

Front cab removal

2010-10-10T05:29:00.000-07:00

There are more photos on H2oneindanke, but here are some of the work taking off the Zebra's front and also Morrow's.

Zebra

2010-10-10T05:27:00.001-07:00

I forgot to post updates. A lot has been doen lately. We got the Zebra bus from Chip and chopped it up to get good metal for Morrow.

Outriggers

2010-06-03T17:30:00.000-07:00

The jacking points weren't made perfectly and the top of them had to be ground down or later on they would be too high to lay the floor on top of. Also I cut a notch out ot the top hat for the jacking point to go through.

Spot welds

2010-04-02T07:02:00.000-07:00

The panels need drilling and cutting so that the cable tubes will fit through and spot welds can be done.

Main Frame Rails now completed.

2010-03-21T16:18:00.001-07:00

Framework

2010-03-10T14:59:00.002-08:00

The driver's side frame had less rustworm than the passenger's. I left the gusset intact so we will hve less fabrication to do.

Move

2010-03-10T14:59:00.001-08:00

We moved Morrow to the other side of the garage so we can work on the other side of the frame.

Engine Lid

2010-03-10T14:52:00.000-08:00

I got fed up with the rotten engine lid falling and hitting me on the head, so I took it off.

Front Seats

2010-02-22T16:41:00.001-08:00

Klasfab

2010-02-22T16:33:00.000-08:00

At Winterjam I got some more repair panels. Jacking points and outriggers, plus B & C pillars.

Gusset

2010-02-22T16:28:00.001-08:00

I kept the frame gusset at the rear, but I needed to make one for the front. I had cut off the end of the frame repair panel and thought it would fit in nicely as a gusset. With a little jigsaw work to make a hole for the wiring and voila one passenger side gusset.

Front Parcel Shelf

2010-02-14T15:07:00.000-08:00

Thanks to Guadalupe for the part. It's nice and rust free with desert dust on it. Thought I'd loosely fit it on Morrow to make him look a little better and to get it out of the way for now.

Valentine's Day

2010-02-14T14:50:00.000-08:00

We welded in the frame, and the welds look good and solid, then ground them flush. Also used the sanding disc which cleans off rust very nicely. There is metal under there! If we keep this up one day I'll be able to change the posting from the "rusty" category.