The country's first CAL Look Baywindow Bus Restoration

PAVAN KADAM · 17th October 2012, 23:41

Off-late due to multiple restorations and hectic office schedules i have not been frequently visiting the workshop, its become 4 visits in a week as compared to daily

The painter is working slowly, but steadily on the body shell prepping, the tinker is still busy tapping out the undulated surfaces and by the day. And as we complete some major sheet metal work, there are those tiny one's that surface

2 more weeks is the goal set to finish off with the Body-filler job, and looks like its going in the right direction, after which its just a few steps to finish the paint job, but considering the size of the Bus, its understandable that it will take twice the days a regular car should take.

14000rpm · 19th October 2012, 10:07

Hey Pavan, as usual, one more awesome restoration.
You've done so many restorations. you should actually get them all together for a drive or a meet up etc.

vijaycool · 22nd October 2012, 12:12

Hi Pavan,
In the post# 37, last two pics, looks like some oil is sprayed on the panels. May I know what is that. Regarding rust protection I couldnt get it sorry. I may also missed/ wrongly put few steps
1. zinc primer spray
2. sheet metal work
3. epoxy spray
4. sanding down and body tapping (why its sanded down to bare metal again and removing earlier epoxy coat)
5. Bondo
6. Epoxy coating
7. Sanding (I am not sure this step is involved)
8. Primer

Regards,
Vijay

PAVAN KADAM · 26th October 2012, 19:10

Quote:

Originally Posted by vijaycool

Hi Pavan,
In the post# 37, last two pics, looks like some oil is sprayed on the panels. May I know what is that. Regarding rust protection I couldnt get it sorry. I may also missed/ wrongly put few steps
1. zinc primer spray
2. sheet metal work
3. epoxy spray
4. sanding down and body tapping (why its sanded down to bare metal again and removing earlier epoxy coat)
5. Bondo
6. Epoxy coating
7. Sanding (I am not sure this step is involved)
8. Primer

Regards,
Vijay

Vijay, keep going through this thread, you will understand the process

Well, the Front and the RHS are almost there. They are good for the Final Surfacer

Work on the rear and the LHS begins from Monday, and hopefully will end in the next 7 days, later which the most difficult portion - THE TOP... That should alone take a week to be fully prepared.

Some pics

nileshdias · 2nd November 2012, 01:17

Hi Pavan,

This is the trim beading picture we spoke abt today. Found it in vwheritage catalogue and quite liked it

What do you think? I am not sure how it is fitted.

Name: ForumRunner_20121101_194622.png
Views: 1917
Size: 568.4 KB

Cheers
Nilesh

nileshdias · 24th November 2012, 16:49

Received few items from vwheritage last week!

The country's first CAL Look Baywindow Bus Restoration-image1694346014.jpg

And inevitably one of the mirrors had broken in transit. They were very quick to send a replacement however!

The country's first CAL Look Baywindow Bus Restoration-image1665256970.jpg

Still waiting for few more items before we travel to Mumbai in 10 days. Hoping they will arrive in time.

PAVAN KADAM · 26th November 2012, 23:34

Quote:

Originally Posted by nileshdias

Received few items from vwheritage last week!

Attachment 1017969

And inevitably one of the mirrors had broken in transit. They were very quick to send a replacement however!

Attachment 1017970

Still waiting for few more items before we travel to Mumbai in 10 days. Hoping they will arrive in time.

We were supposed to have received the original mirrors from Papa rick, lord knows where they vanished

Last bits of work attended today, Surfacer work should complete in a couple of days. The most difficult part is, the Bus consists of Straight panels and box sections on the inside, making body tapping very difficult

very little undulations shows up only after the surfacer is sprayed, There are few undulations and hopeful to finish it in a couple of days.

nileshdias · 1st December 2012, 02:18

The wheels arrived today!!! However no black wheels in stock Pavan :(

The country's first CAL Look Baywindow Bus Restoration-image3156976065.jpg

PAVAN KADAM · 13th December 2012, 22:03

Quote:

Originally Posted by nileshdias

The wheels arrived today!!! However no black wheels in stock Pavan :(

Attachment 1020502

So finally Nilesh flies down to Bangalore from UK, and yesterday had a field day, tagged Bulletboy ( pankaj - Jalopyshop ) too

Went over to the workshop -Saw the Bus.

Went to the Paint shop - Selected the Paint shade

Met the upholsterer - Selected the interior shades

A productive day for Nilesh, hopefully the Kombi must be Painted by Christmas, Work in full swing as of now, will keep u guys updated.

PAVAN KADAM · 2nd January 2013, 18:59

Last 20 days had been really hectic, The Kombi though was assumed Ready showed up lot more flaws than what we expected.

Again we sanded down a few more microns of the body filler, (There were barely none) Some more putty work and few more coats of surfacer.

PAVAN KADAM · 2nd January 2013, 19:48

Updates as on today.

After 3 coats of Surfacer, The Final Surfacer is sprayed, but a day before the Final coats of paint we plan to do one more coat of the Glasurit Surfacer.

Its so nice to see the way the boys have turned it around, when the project started, i had lots of doubts regarding arresting rust. Many of my friends too quoted me Mad, but glad with the way things have turned around

Now just a couple of weeks to wait..

PAVAN KADAM · 19th January 2013, 02:07

The weather has been kind and with no rains, the Bus has dried up perfectly.

Finaly coat of surfacer was sprayed 5 days ago and now the surface looks exactly as expected

without wasting time, we decided we will finish spraying the insides of the bus as we have a much bigger job ahead of us with the THREE TONE PAINT JOB

PAVAN KADAM · 20th January 2013, 16:01

After an overnight the Interiors are neatly dried up and looking awesome

What say Nilesh..?

Also, today morning starts the most difficult task of 3 way Masking, The roof has got its 3 coats of Final White, the window panes will get its 3 coats of BLACK. The last coat of white and Black will be sprayed in the Booth, just before the BLUE on the body.

Plans to drive the Bus to GT Tuners- paint booth on Thursday.

vw splitscreen · 20th January 2013, 22:22

I Like this Pavan ,looking really good,glad you have managed the progress well to get to this stage good work.

nileshdias · 21st January 2013, 04:14

Quote:

Originally Posted by PAVAN KADAM

After an overnight the Interiors are neatly dried up and looking awesome

What say Nilesh..?

Also, today morning starts the most difficult task of 3 way Masking, The roof has got its 3 coats of Final White, the window panes will get its 3 coats of BLACK. The last coat of white and Black will be sprayed in the Booth, just before the BLUE on the body.

Plans to drive the Bus to GT Tuners- paint booth on Thursday.

It's looking great Pavan! Can't wait for Thursday now

Did you paint the top already?

17th October 2012, 23:41	#61
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 Off-late due to multiple restorations and hectic office schedules i have not been frequently visiting the workshop, its become 4 visits in a week as compared to daily The painter is working slowly, but steadily on the body shell prepping, the tinker is still busy tapping out the undulated surfaces and by the day. And as we complete some major sheet metal work, there are those tiny one's that surface 2 more weeks is the goal set to finish off with the Body-filler job, and looks like its going in the right direction, after which its just a few steps to finish the paint job, but considering the size of the Bus, its understandable that it will take twice the days a regular car should take. Attached Thumbnails
	(2) Thanks

19th October 2012, 10:07	#62
14000rpm Senior - BHPian Join Date: Dec 2007 Location: Helsinki Posts: 2,340 Thanked: 5,557 Times View My Garage	re: The country's first CAL Look Baywindow Bus Restoration Hey Pavan, as usual, one more awesome restoration. You've done so many restorations. you should actually get them all together for a drive or a meet up etc.
	(1) Thanks

22nd October 2012, 12:12	#63
vijaycool BHPian Join Date: Aug 2006 Location: chennai Posts: 309 Thanked: 111 Times	re: The country's first CAL Look Baywindow Bus Restoration Hi Pavan, In the post# 37, last two pics, looks like some oil is sprayed on the panels. May I know what is that. Regarding rust protection I couldnt get it sorry. I may also missed/ wrongly put few steps 1. zinc primer spray 2. sheet metal work 3. epoxy spray 4. sanding down and body tapping (why its sanded down to bare metal again and removing earlier epoxy coat) 5. Bondo 6. Epoxy coating 7. Sanding (I am not sure this step is involved) 8. Primer Regards, Vijay
	(1) Thanks

2nd November 2012, 01:17	#65
nileshdias BHPian Join Date: Oct 2004 Location: London, UK Posts: 60 Thanked: 58 Times	Hi Pavan, This is the trim beading picture we spoke abt today. Found it in vwheritage catalogue and quite liked it What do you think? I am not sure how it is fitted. Cheers Nilesh
	() Thanks

24th November 2012, 16:49	#66
nileshdias BHPian Join Date: Oct 2004 Location: London, UK Posts: 60 Thanked: 58 Times	Received few items from vwheritage last week! And inevitably one of the mirrors had broken in transit. They were very quick to send a replacement however! Still waiting for few more items before we travel to Mumbai in 10 days. Hoping they will arrive in time. Last edited by karlosdeville : 25th November 2012 at 09:23. Reason: Fixing attachments
	(1) Thanks

1st December 2012, 02:18	#68
nileshdias BHPian Join Date: Oct 2004 Location: London, UK Posts: 60 Thanked: 58 Times	The wheels arrived today!!! However no black wheels in stock Pavan :( Last edited by nileshdias : 1st December 2012 at 02:24.
	(2) Thanks

2nd January 2013, 18:59	#70
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 Last 20 days had been really hectic, The Kombi though was assumed Ready showed up lot more flaws than what we expected. Again we sanded down a few more microns of the body filler, (There were barely none) Some more putty work and few more coats of surfacer. Attached Thumbnails
	(1) Thanks

2nd January 2013, 19:48	#71
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 Updates as on today. After 3 coats of Surfacer, The Final Surfacer is sprayed, but a day before the Final coats of paint we plan to do one more coat of the Glasurit Surfacer. Its so nice to see the way the boys have turned it around, when the project started, i had lots of doubts regarding arresting rust. Many of my friends too quoted me Mad, but glad with the way things have turned around Now just a couple of weeks to wait.. Attached Thumbnails
	(1) Thanks

19th January 2013, 02:07	#72
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 The weather has been kind and with no rains, the Bus has dried up perfectly. Finaly coat of surfacer was sprayed 5 days ago and now the surface looks exactly as expected without wasting time, we decided we will finish spraying the insides of the bus as we have a much bigger job ahead of us with the THREE TONE PAINT JOB Attached Thumbnails
	(2) Thanks

20th January 2013, 16:01	#73
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 After an overnight the Interiors are neatly dried up and looking awesome What say Nilesh..? Also, today morning starts the most difficult task of 3 way Masking, The roof has got its 3 coats of Final White, the window panes will get its 3 coats of BLACK. The last coat of white and Black will be sprayed in the Booth, just before the BLUE on the body. Plans to drive the Bus to GT Tuners- paint booth on Thursday. Attached Thumbnails
	(1) Thanks

20th January 2013, 22:22	#74
vw splitscreen BHPian Join Date: Jul 2008 Location: Goa/UK Posts: 153 Thanked: 28 Times View My Garage	re: The country's first CAL Look Baywindow Bus Restoration I Like this Pavan ,looking really good,glad you have managed the progress well to get to this stage good work.
	(1) Thanks