Restoration – T1 Bus Samba Deluxe Sunroof – Brazil 1975 – Ref. S003

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Restoration - T1 Bus Samba Deluxe Sunroof - Brazil 1975 - Ref. S003

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See all the photos on the restoration process of this collector’s kombi in our workshops in Brazil.

Stage 1: Pre-restoration

  The kombi has just arrived in the shop and is ready to undergo an extreme make-over.

Stage 2: Strip and clean (video)

Taking off the outer layer of the kombi, grinding sanding and smoothing out the roof.

Stage 3: Ties, stringers and floors (video)

 With the Kombi gutted, our team works on replacing the  ties and stringers. There’s also a video of our body-worker welding the floor joists together.

Stage 4: Metal work

 As you can see, some bottom panels of the kombis are being cut out and then replaced with new ones. These are the areas most affected by rust and impact.

Stage 4.1: Metal Work: Side Panels

Some of the panels are beyond repair and need to be completely removed and replaced with new ones. We cut them to size and then weld them back into place.

Stage 4.2: Metal Work: Interior

With the side panels changed and smoothed out, the workers can move to the inside and start working on removing the interior layers of paint and smooth out bumps and scrapes.

Stage 4.3: Metal Work: Undercarriage

The Bus is then put on the rollers and flipped around to ease working on its undercarriage. During this phase it is sandblasted and prepared for painting. Also some smaller pieces are welded and adjusted as its much easier to work from this angle.

Stage 5: Pre-Paint Preparation

  After the bodywork has been completed. The bus goes into a pre-paint prep mode, and a coat of polyester fiber filler is applied to the exterior to be later removed step-by-step in an attempt to smooth our the side panels of any imperfections that we there originally on the bus.

  Here you can also see they have made the incisions for the samba windows and the sunroof that will be installed later after painting during the final stage of the project.

 Before painting, the tinsmiths also work to touch up any pending issues in the metalwork such as the window frames where water sits and creates the most amount of rust.

Stage 6.1: Paint – Interior

The painter first paint the entire interior section and allow it to dry. After drying they will seal all door openings and other smaller ports off to prevent the inside from getting a coat of paint from the outside. 

Stage 6.2: Paint – Exterior

Once all the ports are sealed off to prevent paint from mixing with the already painted interior the painters proceed to put an entire paint of white on first. The whit coat is applied first as it is the most neutral color and can be easily covered by another more vibrant color such as red. After the white is applied, the top half is taped of and then the bottom is painted with red and left to dry.

Stage 7: Mechanics

 In the first part of this gallery you can see how the suspension has been stripped rebuilt, and ready to be reinstalled onto the underbelly of the bus. Second you can see the transmission is totally dismounted and taken apart. During this phase all the bearings and gears are replaced with new ones and so are all the screws and pins.


Stage 8: Motor (video)

Here is the new sandblasted motor ready to be installed in the Bus. Head gaskets, the fan and cables and hoses are all new. Watch the video and see the motor running

Stage 9: Interior upholstery

Here are some of the pics of the special upholstery the client chose as well as the design of the logo representing the business of the client. This options are totally tailored by the client.

Stage 10: Exterior Finish

And here you have the final product! Ready for export and any road near you. Send us a message if you are interested in an impeccably restored bus tailored to your dreams.

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