- Stage 1: Arrival
- Stage 2: Sandblasting
- Stage 3: Chassis Reinforcement (video)
- Stage 4: Chassis Paint Preparation
- Stage 5: Side Metal Work
- Stage 6: Window Frames
- Stage 7: Front Doors (Video)
- Stage 8: Floor
- Stage 9: Samba Walkthrough
- Stage 10: Metalwork Finition
- Stage 11: Paint Preparation
Stage 1: Arrival
This 1964 beat up school bus is going to undergo one of the most prominent and profound transformations in automotive history, but there is plenty of work to do yet!
Stage 2: Sandblasting & Stripping
The hull is separated from the chassis because of necessary structural work, and sandblasted to remove all the paint and filler.
Stage 3: Chassis Reinforcement (video)
Two major modification have to be done to the undercarriage of this bus to accommodate the power and weight of a 2.0lt engine.
1. First the back axle is swapped out for a much sturdier T2 axle that will provide the structure to hold the weight of the 2 liter engine.
2. The chassis itself must be reinforced. All the power and energy travels through the chassis and up to the front wheels. A normal 1500cc engine holds its own without a hitch, but the power applied by a 2000cc engine would twist and wrench a normal T1 chassis when going around a corner.
Stage 4: Chassis Paint Preparation
Since the Chassis is already completely separated from the body, we will prep it for painting and coat it before installing the cab back. This way any parts touching the cab will also be protected from rusting over time.
Stage 5: Side Metal Work
In the Meanwhile, specialists prepare the body that will be fitted onto the reinforced Chassis at a later date.
Stage 6: Window Frames
Here we meticulously work on the window frames, restoring and strengthening them. This is one of the most time consuming steps in a restoration as window frames are not readily available.
Stage 7: Front and side doors (Video)
This work requires a lot of attention and time. In this case even more so since this bus will get a much more powerful motor.