The country's first CAL Look Baywindow Bus Restoration

PAVAN KADAM · 16th April 2012, 13:39

So, finally the restoration started, The pre-lude to this restoration dates back to the below linked thread. Nilesh

http://www.team-bhp.com/forum/post-w...-microbus.html

Initially the main aim was to make this Bus a trouble free runner, This Bus was not in use for almost over 3 years. So firstly we needed to get the mechanicals right and then go ahead with the cosmetic restoration.

Got my mechanic into action, he was not liking the idea of replacing new parts before restoration as he feared they would go bad with all that water sanding, etching primer, paint, thinner etc., etc., He went about repairing the existing parts like the Brake, replacing new plugs, cleaning the carb, fuel pump, tappets, and general maintenance of few moving mechanical parts. Over 2 days, he completed a quick general service of the Bus and the Bus was Good to go. Though the clutch is gone bad, but he says, we will replace all the mechanicals once the painting and other fitting is done

So here is the Video of the Bus running in top condition. Starts with one single crank.

1980 VW Kombi - YouTube

1980 VW Kombi 2 - YouTube

And below are the pics of full scrape down in process.

PAVAN KADAM · 17th April 2012, 19:51

Work started, and as you can see, there is lots and lots of metal paste on the body surface. The guys are busy with the scrape down since Sunday.

PAVAN KADAM · 18th April 2012, 21:10

Some more on the scraping process.

Too much of metal paste and putty work done on the bus, So scraping taking more time than needed. Just wish the SandBlasting procedure was accessible to me.

samsag12 · 18th April 2012, 21:32

That seems to be more than 10 kilos of metal paste, not to mention the tinker will have to work a lot on those eaten up parts. I am sure it will look far better in the coming few weeks.
BTW the last picture is truly EPIC

nileshdias · 19th April 2012, 02:53

Hi Pavan,

The guys have made good progress in only a few days

It's killing me to see all the rust but it can only get better from here!

We finally have a decision on the color! I feel like i have spent months looking for the right shade. We decided on blue but there seem to be two shades of Sea Blue. Found a thread on thesamba which nicely details the differences. I was still confused but the girls in the pix clinched the deal!

The country's first CAL Look Baywindow Bus Restoration-merawalablue.jpg

Here are the differences between the two sea blue shades.

The country's first CAL Look Baywindow Bus Restoration-bluevsblue2.jpg

Sea Blue 1

The country's first CAL Look Baywindow Bus Restoration-sb1.jpg

Sea Blue 2

The country's first CAL Look Baywindow Bus Restoration-sb2.jpg

I'm looking for a three tone paint with the roof white, pillars black and rest in SB2 above.

Any suggestions welcome!

Nilesh

condor · 19th April 2012, 06:24

Quote:

samsag12

: .. will have to work a lot on those eaten up parts.

@Pavan, what's the plan for the sections that have been eaten up ?

Quote:

nileshdias

: .. I was still confused but the girls in the pix clinched the deal!

@Nilesh, any specific girl there who helped you decide ?

Quote:

nileshdias

: I'm looking for a three tone paint with the roof white, pillars black and rest in SB2 above.

Not using black for the pillars can help make it look a little more classic. Black pillars are more contemporary. I suggest a PS job to review how it will look before you decide between black or no-black on pillars. Else, White & SB2 should be good.

PAVAN KADAM · 19th April 2012, 09:37

Quote:

Originally Posted by nileshdias

Hi Pavan,

The guys have made good progress in only a few days

It's killing me to see all the rust but it can only get better from here!

We finally have a decision on the color! I feel like i have spent months looking for the right shade. We decided on blue but there seem to be two shades of Sea Blue. Found a thread on thesamba which nicely details the differences. I was still confused but the girls in the pix clinched the deal!

Attachment 917547

Here are the differences between the two sea blue shades.
Attachment 917550

Sea Blue 1
Attachment 917548

Sea Blue 2
Attachment 917549

I'm looking for a three tone paint with the roof white, pillars black and rest in SB2 above.

Any suggestions welcome!

Nilesh

Lets see if i can get my friend do a P.S job for the color shade.

Nilesh, you are the limits

Quote:

Originally Posted by condor

@Pavan, what's the plan for the sections that have been eaten up ?

@Nilesh, any specific girl there who helped you decide ?

Not using black for the pillars can help make it look a little more classic. Black pillars are more contemporary. I suggest a PS job to review how it will look before you decide between black or no-black on pillars. Else, White & SB2 should be good.

Sir, sadly importing those panels will prove much more costlier. The rusted panels will be cut open and new panels will go in.

Me too concerned on which of those girls helped Nilesh

The color looks very good. Hatke as they say.

condor · 19th April 2012, 10:25

Quote:

Originally Posted by PAVAN KADAM

Sir, sadly importing those panels will prove much more costlier. The rusted panels will be cut open and new panels will go in.

Will you be getting new panels, or patch the sections which are eaten ?

nileshdias · 19th April 2012, 11:57

Quote:

Originally Posted by condor

@Pavan, what's the plan for the sections that have been eaten up ?

@Nilesh, any specific girl there who helped you decide ?

Not using black for the pillars can help make it look a little more classic. Black pillars are more contemporary. I suggest a PS job to review how it will look before you decide between black or no-black on pillars. Else, White & SB2 should be good.

Condor, any of the girl would clinched the deal, so many of them makes it no-argument!

I will remember that pic every time I see the bus lol!!

We were initially going for a complete black top. I have seen a few in the UK and they cool. Less classic, yes, but that was not our goal. One reason for a three tone job was Mumbai heat, a white top would make it bit bearable.

Pavan,

PS of the three tone would be good but don't stretch too much for it. I had a picture somewhere with a diff colour combo, will try to find it.

Cheers!

nileshdias · 20th April 2012, 04:05

Three tone pixs

The country's first CAL Look Baywindow Bus Restoration-3tone1.jpg

The country's first CAL Look Baywindow Bus Restoration-3tone2.jpg

The country's first CAL Look Baywindow Bus Restoration-3tone3.jpg

The country's first CAL Look Baywindow Bus Restoration-3tone4.jpg

The country's first CAL Look Baywindow Bus Restoration-3tone5.jpg

nileshdias · 21st April 2012, 17:12

Guys, what do you think of above? Will it look good with SB2?

PAVAN KADAM · 23rd April 2012, 20:40

Quote:

Originally Posted by nileshdias

Guys, what do you think of above? Will it look good with SB2?

White Top

Blackened Window pillars

Red Body

That will look soooper HOT!

Well, body scraping is almost done, Waiting for the tinkers quote to start tinkering.

nileshdias · 23rd April 2012, 23:41

Quote:

Originally Posted by PAVAN KADAM

White Top

Blackened Window pillars

Red Body

That will look soooper HOT!

Red does look hot. But had a red BSA cycle, a red Karizma and a red Getz! I need to add some colour to the collection

PAVAN KADAM · 24th April 2012, 18:23

Quote:

Originally Posted by nileshdias

Red does look hot. But had a red BSA cycle, a red Karizma and a red Getz! I need to add some colour to the collection

Alrite Nilesh, we will decide on the color by the time the D-day arrives.

Finally Mr Pinto sent the keys

And i am planning to start tinkering in the coming week. Here are pics of few badly rusted panels.

PAVAN KADAM · 6th May 2012, 14:50

I searched through some old folders on my computer today, It is shocking to know the present condition of the bodywork, as this bus was Re-Stored just recently in 2009

The restoration begins from today and i need to ensure the body shell this time is sealed perfectly so as not to allow corrosion

17th April 2012, 19:51	#2
PAVAN KADAM BANNED Join Date: Jan 2007 Location: NAMMA BENGALURU Posts: 5,602 Thanked: 2,549 Times	re: The country's first CAL Look Baywindow Bus Restoration Work started, and as you can see, there is lots and lots of metal paste on the body surface. The guys are busy with the scrape down since Sunday. Attached Thumbnails
	(5) Thanks

18th April 2012, 21:10	#3
PAVAN KADAM BANNED Join Date: Jan 2007 Location: NAMMA BENGALURU Posts: 5,602 Thanked: 2,549 Times	re: The country's first CAL Look Baywindow Bus Restoration Some more on the scraping process. Too much of metal paste and putty work done on the bus, So scraping taking more time than needed. Just wish the SandBlasting procedure was accessible to me. Attached Thumbnails
	(3) Thanks

18th April 2012, 21:32	#4
samsag12 Senior - BHPian Join Date: Dec 2009 Location: City of Nawaabs Posts: 1,624 Thanked: 242 Times View My Garage	re: The country's first CAL Look Baywindow Bus Restoration That seems to be more than 10 kilos of metal paste, not to mention the tinker will have to work a lot on those eaten up parts. I am sure it will look far better in the coming few weeks. BTW the last picture is truly EPIC
	(1) Thanks

19th April 2012, 02:53	#5
nileshdias BHPian Join Date: Oct 2004 Location: London, UK Posts: 60 Thanked: 58 Times	re: The country's first CAL Look Baywindow Bus Restoration Hi Pavan, The guys have made good progress in only a few days It's killing me to see all the rust but it can only get better from here! We finally have a decision on the color! I feel like i have spent months looking for the right shade. We decided on blue but there seem to be two shades of Sea Blue. Found a thread on thesamba which nicely details the differences. I was still confused but the girls in the pix clinched the deal! Here are the differences between the two sea blue shades. Sea Blue 1 Sea Blue 2 I'm looking for a three tone paint with the roof white, pillars black and rest in SB2 above. Any suggestions welcome! Nilesh
	(1) Thanks

20th April 2012, 04:05	#10
nileshdias BHPian Join Date: Oct 2004 Location: London, UK Posts: 60 Thanked: 58 Times	re: The country's first CAL Look Baywindow Bus Restoration Three tone pixs
	(2) Thanks

21st April 2012, 17:12	#11
nileshdias BHPian Join Date: Oct 2004 Location: London, UK Posts: 60 Thanked: 58 Times	Guys, what do you think of above? Will it look good with SB2?
	() Thanks

6th May 2012, 14:50	#15
PAVAN KADAM BANNED Join Date: Jan 2007 Location: NAMMA BENGALURU Posts: 5,602 Thanked: 2,549 Times	re: The country's first CAL Look Baywindow Bus Restoration I searched through some old folders on my computer today, It is shocking to know the present condition of the bodywork, as this bus was Re-Stored just recently in 2009 The restoration begins from today and i need to ensure the body shell this time is sealed perfectly so as not to allow corrosion Attached Thumbnails
	(1) Thanks