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59 11 window Custom Resto

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Special Air Service Chief "Gunna"

1,769 posts · joined Oct 2004 ·

#821062
Al,

Couple of questions re. the fibreglassing.

When you building the stuff like speaker panels etc

What weight matting do you use?

How many layers of matting / glass do you build up?

Do you use waxed or normal un-waxed resin?

Oh yeah, awesome work on this bus, giving every one a few new ideas I reckon.

Cheers

Brendan
Calling all NSW Mid North Coast Veedubbers

Click Below
Mid North Coast VW

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#821144
G'day Brendan, generally I use 450 weight chop mat in areas needing some strength:http://www.fgi.com.au/files/images/stories/pdfs/products/reinforcements/data_sheets/24969-CSMM705Emulsion.pdf

Anywhere from two layers if strength is not needed up to 6 or even 8 in some sub box applications where I can't afford any flex.

I can't recall the exact resin however given it sands fairly easily and doesn't gum up I would say it would be waxed. Will have to check.

This is where I get the f/g products from:
http://www.fgi.com.au/

Cheers
Al
www.dasrestoparts.com.au

matberry Moderator Go hard or go home

8,114 posts · joined Mar 2006 ·

#821151
Waxed goes off on the surface so is'nt sticky to touch but therefore needs sanding between layers if allowed to cure, whereas unwaxed stays sticky and no sanding required for the next layer (supposedly, but I believe at least a scuff is required).

Not trying to be a smart arse tho.

Awesome job Al and the crew at Das Resto Haus.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#821153
Cheers Matt, much appreciated.

Brendan, will check the label tomorrow as I just go in and order the same product (20L at a time) - the rep knows what I use it for and hence gives me the requried stuff 🙂

I figured it wasn't a laminating resin (unwaxed) but haven't used the term waxed before when ordering the resin previously.
Cheers
Al

More pics:














www.dasrestoparts.com.au

wilderness Slammed & Awesome Dubber

88 posts · joined Aug 2009 ·

#821246
👍👍👍
1958 Beetle (currently restoring)
Mk5 Golf Pacific TDi

bugboymatt Custom Title Time!

1,405 posts · joined Aug 2002 ·

#821248
WOW, just looked through this thread. Very very nice.

Great work as ever from Al.
Da Time For The Aircooled Revolution Is Upon US.
Brothers & Sisters Lets Hit The Streets, Roll As One. And Feel The Power Of The Aircooled Storm.

Special Air Service Chief "Gunna"

1,769 posts · joined Oct 2004 ·

#821282
Thanks Al,

Appreciate you taking the time to answer my questions as you go through this build.

Cheers
Brendan
Calling all NSW Mid North Coast Veedubbers

Click Below
Mid North Coast VW

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#822269
5PL1TDCS10N wrote:Are you going to add the fine line around the inside of the curved banner Al?
G'day Wayne, hopefully we'll get the fine line integrated into the CNC cut logo - haven't had a chance to ask why it was omitted on the pictured prototype. Should look very nice polished.

A few more details....
Third brake light was integrated into the engine lid to match the indicators in the bumpers.






A fair bit of time was spent designing and fabricating the LED mounting plate




The extra hole above the number plate will be fore the reversing camera (would be an expensive dent if Armando reversed into something) 🙂


My first prelminary map of wiring for the bus (not including audio system!)
www.dasrestoparts.com.au

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#822272
After a couple rounds of high build primer and block sanding the roof was prepped for paint


The direct gloss (PPG Deltron) white was applied first - sorry these roof pics are a little blurry




This was then guide coated and wet block sanded to flat it out and rectify any imperfections/nibs/dust....then clear coat was applied


A quick shot of the rear bumper during the measurement process to get indicator positions equal


Cheers again
AL
www.dasrestoparts.com.au

Aussie Officially Full-On Dubber

296 posts · joined Sep 2006 ·

#822542
👍 Super straight. Great job

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#822655
A few more photos....first of the fuse holder cover (that will supply power to the two amps) - obviously will be painted


And the EFI relay holder cover


Lots of time wet block sanding the primer




Ready for red
www.dasrestoparts.com.au

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#822656
When I am not going for an "off the gun" finish knowing the paint will be block sanded, I tend to apply it a little dryer to avoid runs - the orange peel cuts out fairly easily when blocked with 800 then 1200 wet.

The PPG Deltron direct gloss red












Al
www.dasrestoparts.com.au

Craig Torrens 6 times Australian, 7 times State Hillclimb Class Champion

8,040 posts · joined Jan 2003 ·

#822667
Yummy👍


Camo Custom Title Time!

1,936 posts · joined Oct 2007 ·

#822675
I've said it before and I will say it again, this is pure artwork and I hope you are going to sign it as all good artist do 👍👍👍👍👍👍👍👍👍👍

Kev
I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#823768
Cheers Craig and Kev 🙂



Bumpers primed


Before the white could be applied, the small area of red on the lower part of the swage line had to be rubbed (the red was taken up to this point and not masked to the cut line as its virtually impossible to get a straight mask on the underside of the swage).




More red on the panels




www.dasrestoparts.com.au

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#823770
The deluxe trim was then reinstalled to ensure the two tone cut line was parallel especially on the nose


White guide coat was to assist with wet rub of red areas prior to clear








Prepped for white direct gloss


White going on








Cheers
Al
www.dasrestoparts.com.au

annosL Officially Full-On Dubber

378 posts · joined Dec 2008 ·

#823808
amazing pics, shows top-drawer skills, thanks for sharing

baghall Ben Hal Outlaw Bushranger

1,021 posts · joined Jan 2010 ·

#823894
OMG. Just got on after a break ans saw this amazing build. Wish I had half the skills you guys had. Love the interior work especially. Thanks for sharing.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#824103
Thanks annosL and baghall 🙂

Demasked and ready for the next process of wet block sanding the entire exterior to flatten the direct gloss colour in preparation for clear


Lots of masking just to paint the inside of the wheel arches - these couldn't be painted when the underside was done as the side panels and doglegs had not been bodyworked yet (shrinking etc required)


The number of times we have sanded this bus is pretty crazy but that is the labour required to achieve a deep show quality gloss - here the nose has been rubbed with 800 then 1200 by hand block (wet)


The bumpers received some white direct gloss as well




www.dasrestoparts.com.au

11CAB If ya got it....Baja it

4,674 posts · joined Aug 2002 ·

#824106
Who wants to open their chrissy pressy??.......

65 Meyers Manx
68 Country Buggy (KO 367)
68 Country Buggy (KO 669)
68 Country Buggy (KO 789)
68 Country Buggy (KO 815)
68 Baja Bug
76 Baja Kombi Twincab

Golde60 Fahrvergnugen

858 posts · joined Aug 2002 ·

#824124
11CAB wrote:Who wants to open their chrissy pressy??.......

I dont think I could afford too!
even though, I think it would be worth every penny!

great job Al

and congrats on the logo - looking good now that I see it in the final form.
...................( O \ l / O ).....................

vwsteve karmann crazy

2,087 posts · joined Jul 2006 ·

#824202
very nice al, i remember painting flockes splitty two tone, sooooooo much work involved isnt it!

bet you are sick of masking up stuff
1 1963 356b porsche coupe
2 1960 karmann ghia cab
1 1965 karmann ghia cab
1 1966 karmann cab
1 1961 split ute
1 1967 split p/van
1 1952 standard bug
1 1963 ragtop
1 1960 ragtop
2 1954 ovals
1 1956 oval baja project
1 1957 oval flying flea

Turbo54 Veteran Volks Folk

2,220 posts · joined Jul 2004 ·

#824352
Killer job Mate,
T54
C'mon kids gather round,
there's a new sensation hitting town,
It's moving straight, low to the ground,
it'll pick you up when your feeling down.

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#824466
Thanks gents. Steve you are right, we have both sanded and masked this bus what feels like a hundred times!

The PPG Deltron D800 clear was applied next - again with a bit of peel to ensure no runs - fairly easy to block out during colour sanding.


The booth lights always make the orange peel look worse than it does in natural light (in the next pic below)




www.dasrestoparts.com.au

Flintstones Custom Title Time!

1,077 posts · joined Aug 2002 ·

#824475
nice work there Al👍👍
that's not the cyclone in the reflection is it❗❓

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#826053
The body before clear:


and after clear was applied:












I intentionally lay the three coats of clear on fairly dry to prevent any runs as the orange peel is much easier to cut out and buff than runs (esp on the edges of all the vents)
www.dasrestoparts.com.au

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 ·

#826055
The colour sanding process is where all the previous year's worth of work is realised and demonstrated - it is a very labour intensive process especially when all the cutting is done by hand (1200, 1500, 2000 grits) rather than by DA sander (I only use 3000 grit Trizact pads on a small orbit DA for the final step before buffing starts) - buffing cuts the scratches out (quite a long process to get right), then swirl remover to remove any holograms....and finally a wax.








Since still photos can often deceive (as I have seen many times in the past when photos are seen of cars vs seeing them in the flesh) so I do a quick walk around on each panel after buffing to ensure the owner (and others) that the panel work is straight (when he is not able to inspect it in person)

Here is a quick vid


Cheers
Al
www.dasrestoparts.com.au

baghall Ben Hal Outlaw Bushranger

1,021 posts · joined Jan 2010 ·

#826064
Looking so good in colour!
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car

squizy Thinking about another dub...maybe

4,082 posts · joined Dec 2002 ·

#826065
Seriously Al you never cease to amaze me. awesome work again. 👍