Another VW bus restoration, a 1968 VW Bay Window Bus for the same customer we did the 70 Westy for.  This project is a 1968 VW bus restoration project with original paint and in great shape, apart from front end damage from a spare tire that was mounted to the front.

Our duties were to perform a partial VW Bus restoration, which included the front end repairs, general rust repairs/dents/gouges , trim restoration, swap out the Jalousie windows for the original factory configuration, custom made aluminum front vent housing to replace the plastic one, and new weather stripping/seals all around.  Lastly, a new, custom made, two-tone interior, by TMI to match the original German factory look.

As the VW bus was in original paint and there were too many external repairs to just ‘blend in’ new paint to the original, we decided to ‘buzz’ down the original paint, seal, featherfill and prime, followed by a coat of the original 1968 beige and clear coat.

Follow the pictures and captions that unfold the story of bringing this 68 VW Bus back to its factory glory.

Condition Before VW Bus Restoration

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Here are three overall pictures of when the 68 VW Bus came to us. First thing to notice is the front end damage from the spare tire that was previously fitted.  The nice thing is 80% of the body is original factory paint.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Various creases and isolated dents are apparent on this VW Bus.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Close up of the front end damage.

 

VW Bus Restoration: Metal Work on the Bay Window

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Surgery begins. The panel is removed and straightened out on the bench.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

The repaired panel is now grafted back onto the bus.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Patterning from side to side for symmetrical profiling.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Unfortunately early bay window front floors aren’t available, so a section had to be hand made and grafted in.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Floor being grafted in.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

In primer.

 

VW Bus Restoration: Fresh Air Vent Restoration

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Original vent housing was in poor shape and easily deteriorates over time, being plastic.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

A jig is made and an aluminum replacement is in progress.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

First stage complete.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Painted and bug mesh added.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

New vent installed. We can make these for your VW restoration, email to ask.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

New interior trim to match the original factory colors and style.

 

Completed 68 VW Bus Restoration from outside

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Rear view with restored original trim, new seals, lens, and body paint, and freshly painted ‘cloud white’ bumpers.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

German made hubcaps were hand painted in the work shop.  And wheels were powder coated.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Clean look.

 

VW Bus Restoration: Restoration Of 1968 Volkswagen Bay Windows Bus at The Metal Surgeon

Thanks for checking out this VW Bus restoration!

One Response

  1. Carl Foster

    I bought this in June 2015 – love it. You guys did a great job on the body.

    Reply

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