Itinerant Air-Cooled

When I pulled my windshield to primer paint my bus, it was apparent that I had not been spared the rusty channel syndrome. A PO had done a pretty decent fiberglass repair job that was not noticeable unless the gasket was lifted. When we got into it, this is what we discovered.

Yikes! Rust never sleeps.

After much checking around, I found a guy named Jerry, only a mile or so away from my home, who has experience welding in replacement channels. I got the metal from Gerson, who shipped it in from South America, where he has his stuff manufactured. http://Www.klassicfab.com . Jerry has cut the bad metal out here.

That is not a fun repair and check for more rust below at the bottom of the front panel.

Thanks. We're doing that, and Osphoing along the way.

Jivermo wrote:Thanks. We're doing that, and Osphoing along the way.

Maybe we should do a consolidation of our experiences into a Procedure Write-Up. That is a serious bit of tinworm you got there, jivermo. I have now done six or seven rescues using rust catalyzing primer and bondo on structurally sufficient swiss cheese channels. One of these days, I will be confronted with something like yours and will have to bow out. I am so crazy about proper dimensions that I recommend using your windshield as a template to make sure that the rubber surround is neither too tight nor too loose.
My '77 has rust trails coming out from under the windshield rubber, seal has been ordered, I may do an on-the-road repair godhelpmeiftheglasscracks.
Colin

Who makes the best seal?

Jivermo wrote:Who makes the best seal?

I don't know all the manufacturers, but I try to shoot for German seals and Wolfsburg West seems to do OK. I have never purchased a straight black seal no trim, but it is on its way, I will let you know.
Colin

Regarding the proper dimensions on the windshield, I asked Jerry how he intended doing that. He said that he has proper length rods that he tacks to the top of the windshield (roof top), that come down to meet up with the new channel, and he lines it up that way. At least that's the picture I got. We'll soon see.

Ready for the new metal.

Coating everything we can reach with this stuff.

Lining up the channel prior to the weld. Measured stick is to get the distance and the angle correct.

Okay, let's get this going.

Jivermo wrote:Okay, let's get this going.

Is that a butt-joint or an overlap? Looking good, I can't wait to see your bus come together.

I am hoping to weld my Naranja battery tray replacement at The Law Firm after visiting Homosassa if Homosassa has enough work for me to afford to go to Pensacola. Where did you get that Right now, I am hung on a surprise back-order of the critical components needed to do the exhaust.
Colin

Butt joint. Where did who get what?