Wednesday, March 18, 2015

Think, then Do

Quick post. I cleaned the garage and started exposing the interior of the bus. Today goes through some of that.

Think Once
I hadn't realized just how much think time I waste on some projects. Take cleaning the garage as an example. Usually, I'll just start at one end picking things up and putting them away until I'm either done or sick or doing it. Then, I'll sweep whatever I find and call it good. Net-net, its a crappy job of cleaning, but it looks better than before, so I'll call it clean. This takes a long time. I realized this past weekend why, I think. For each item I pick up, I have to think about where it goes or should go. I'll take it over to that spot, and then have to figure out whether there's room, etc. Lots of standing there thinking time. This weekend I tried a different approach: think once.

I went into my garage with no intention of starting anything cleaning-ish. I had my coffee in my hands and wool socks on my feet. I just surveyed. Sports equipment over there. Christmas decorations over there and there. Skateboards and snow equipment in little piles. And, of course, lots of bus parts. I took mental notes of what needed to go where and considered what-would-fit-where all at once.

Then Do
Like anything else, once a plan is set, just execute the plan. All this sounds simple and obvious, I'm sure, but I'd never gone after cleaning a garage that way. I had it organized in half the time. Following a quick sweep, I was able to shift focus onto the bus. First, there was the not-so-small matter of all the exterior parts. Since I'd planned for where all those parts were going to go, it took 15 minutes to empty the bus of stuff. Then, I simply removed the rest of the interior of the bus.

Removing the Interior
interior strip in progress
I started with the wall panel. It popped off with light tugging with my fingers. Choosing to use standard fasteners rather than bolts pays off in the removal step here. Once the MDF is covered with thin foam and vinyl, it will appear as an even better decision.
The Vanagon middle sliding bench that I installed a couple of years ago is held in place with 4 13mm bolts. Remove them and the seat easily slides out. So I don't lose the bolts, I fingered them back into their original holes.
I discovered that the refer cabinet that I converted into a storage cabinet (see: From Fridge to Storage) is not actually held down. Neat. The cabinet pulled out very easily (obviously), but I'll have to consider how to actually mount it to the bus. There is a bolt that should pass between it and the rock'n'roll bed that is missing. That's a start, but it will need something else at one end or the other... or both.
Next is the rock'n'roll bed. It is held to the bus with 4 different fasteners. Two are obvious: they are the 2 Phillips head bolts holding the upper back to the section on top of the fuel tank. One the right side (facing forward), under the seat there are 2 small (8mm) nuts which hold the folding bracket to the right wheel well. Last, there is a 13mm bolt under the front-center of the seat, bolting the floor of the seat to the floor of the bus.
Last, I removed some of the thin sections of the wood floor that is used to keep the floor level. I chose not to remove everything just yet. I left the middle seat rails, the rock'n'roll bed and some of the wood in place at this point. I'm not sure if I need to paint the steel floor, but I'd like to at least inspect it for rust. Frankly, if I'm going that far, I might as well fill any little holes and paint it too.

Rear Window
Great movie, not a good seal. I replaced the rear (as in the window pointing to the rear) window seal a few years ago with a BusDepot seal. Usually their seals are pretty good, but this one separated at the upper right corner a while ago. I should have replaced it when that happened, but there's lots of shoulda's out there. Anyway, I had rust under the old seal, but when I cut this seal off, there was water under it. Since the bus has been in the garage for quite some time, that water was quite alarming. Once I had the seal off and the window out (don't forget to unplug the defroster wires from your window before you start cutting your seal), I could see some new rust. Drat. More to fix. I'll just add that to the list of rust repairs I need to make before I paint anything. That list isn't too bad, but it is growing...

That's it for today. One last thing: I taped a piece of paper to the side of the bus for me to write down any parts that I need to replace. The list is too long for just having a pile of "replace these" parts. When many of the parts are seals that I need to cut off, there's nothing to throw into the pile that I could reference anyway. This week, when there's time, I'll be repairing small holes in the interior and getting the rock'n'roll bed and wood floor out so I can make steel floor decisions.

Thanks for following along...

Monday, March 16, 2015

Inside Out or Outside In?

The bus-painting saga has really bloomed. This all started with getting the paint on the nose near the washer nozzles a little better. Now, the front 1/3 of the interior is removed, the windscreen and half the windows are out and I'm trying to figure out how much farther this goes before it starts looking more done than undone. Today is a rough plan.

I stood and looked at the bus last night, wrapping my head around how I should eat the elephant. I hadn't planned on painting any part of the inside when I started. But now, that seems like the right place to begin. Half of the windows are out, including the windshield, both fronts and one of the big rear ones. If I finish the front 1/3, I can use the partitions as the clean cut-off line with rust repair and paint.

playing around with colors
Option 1 - Inside Out
One option after getting the front 1/3 done is to complete the rest of the interior. I'll have the right paint color, and any over-spray or tape failures would appear on the inside (outside paint second -> unintended over-spray lands on finished interior color) rather than the outside. So this option is do the whole interior then do the whole exterior as 2 major steps.
Upside(s): when the inside is done, it's done. Once I've started on the interior, I can do it all at once, so it might be faster overall.
Downside(s): the rear 2/3 of the bus is currently where I'm storing all of the body bits, so I'd need to find them a new home. That makes for a bigger mess before it gets smaller. In order to really do the rear 2/3, the other big window needs to come out, as does the rear window, so, again, the mess grows.

Option 2 - Outside In
Another option is to just do the front 1/3 and then switch to the exterior that I'd started with in the first place. I'd come back around to the rest of the interior later.
Upside(s): I get the exterior done sooner. The stuff that's stored in the rear 2/3 wouldn't be there after the exterior is done, so getting after the interior later would just require removing the seats and cabinet.
Downside(s): I may not get back to the rear 2/3 of the interior for a while, so it would look crappy in between. If I re-install the removed windows because of delays or wanting to actually drive the bus once, I would have to re-remove them to do the interior or there would be a section of not-freshened paint under the inner side of the seals.

Its funny how just writing things down make a choice all the more obvious. While I will need to clean up the garage a little bit to fit the stuff from the back, it totally makes more sense to just do the whole interior at once. I found a bunch of rust under the front seats, making this decision all the more powerful. The exterior of the bus doesn't have much rust, but the rust that't there needs attention. At least one of the spots is a hole that I'll need to also treat from the inside, so, again, it makes sense to do the inside entirely first. Of course, that makes this a great deal more work. Better get crackin'!

To keep track of things, I'm playing with "a dark shade of cyan-blue" similar to that which appeared on the squareback in 1972 for the lower 2/3 of the exterior and a flat light/medium grey for the interior. Pantone detail for the similar blue follows. The pantone detail for the Enzian or gentian blue that matches the squareback blue is here.

R,G,B=0, 48, 92
CMY=cyan: 100 (1), magenta: 81 (0.8118), yellow: 64 (0.6392)
CMYK= cyan: 100 (1), magenta: 48 (0.4783), yellow: 0 (0), key: 64 (0.6392)

As always, thanks for following along...

Friday, March 13, 2015

Hopping and Skipping through SF

NO BUS CONTENT today. Instead, I'm going to cover a whirlwind trip to the San Francisco Bay area. In some ways, this may feel like a re-tread of HNY from 2013 (link here). That's not just a coincidence; we tried to eek out a little honeymoon flashback out of this trip. This got really long. Sorry. While I recognize this is public, in a way this is how I record things for my own memory, so, details are important. :)

In looking back through my posts from last year, I realized that I never posted about a trip I took last Winter to San Diego. My sister and her family were thinking about moving to SF from SD, so Boo and I thought we ought to go visit and help them decide while soaking up some needed sun. Last Winter was a typical dreary, but less snow on the mountain than usual (but still more than this year), so we were in need of an adventure. Unlike our trip to SF described in the link above, the departure to SD was very smooth. The exodus from Oregon to SF was almost equally smooth this past week. Rather than a crack-of-dawn departure, we flew out around 7, so we both ducked out of work a little early and cut across town catching rush-hour traffic heading east out of Portland. It wasn't nearly as bad as it might have been, though. Even after missing the economy lot on the first try, we still had time to nab a sit-down bite to eat after cruising through security before our plane boarded.

BART It On Down the Line
SFO BART entrance
We picked SFO rather than Oakland because of the direct integration with the BART. Apparently, Oakland now has a $6 one-way people-mover from the airport to the totally-doesn't-feel-safe stadium BART stop. Yeah... even with the people-mover, standing on that platform at 10 o'clock at night sounds awfully, uh... exposed. I'll take the direct step-onto-the-train deal at SFO, though the walk to the station was quite long. Our flight terminal'd about as far away from the main terminal as seemed possible. Maybe it was having full day-packs on our backs that made it feel so long. Maybe it was just the drain from flight. Regardless, SFO has all kinds of interesting things to look at, and I don't mean the people. Newark Airport is best for that. SFO has museum pieces strewn about in display clusters throughout the airport. We looked at a couple which had just concert posters from the 60's and 70's for venues in the Bay Area. Very cool. BART was a key component through our 4-day stay in the Bay Area. We love BART.

No Renoir and that's no Monet
The place we had honeymooned (Renoir Hotel) has been shut down for a while. Maybe that issue with not having heat during the cold snap did it. Maybe it was just time to renovate. Boo and I walked by it on our first full day in SF, and it has been gutted. It looks like they removed every bit of reusable material, from the marble to the chandeliers and the wood trim on the windows, it has been picked clean. The first floor has been stripped to studs. We wondered if the building was going to get razed, and replaced with some fancy new tower like the Twitter headquarters down the street. That would be very sad. Based on internet news, it looks like it there was a plan to go boutique and then there was a fire. Not sure what the plan is now.

5th floor hallway mirror selfie
Since they weren't open for business, we got a one-night room at the Hotel Whitcomb just down the street. With out late arrival time, we ducked into the bar before last call for a quick taste before checking in. The bar-tender was really annoying, acting the braggart buffoon to maximize tips from better dressed patrons, leaving we travel worn to fend for ourselves. At least he didn't hassle us like the others, so maybe we got off with the better experience. One short pour and an unsatisfying bottled beer later, Boo and I left unimpressed. The front clerk was efficient, and we were checked-in and in our 5th floor room quickly. The room was small, but effective. No coffee maker nor mini-fridge, but we were just looking for a safe bed. The fact that we were the room at the end of the hall next to the fire escape (the homicide room) wasn't lost on me, but I kept the "homicide" part to myself.

Thai Re-try
We didn't stay in the room very long. We were both more interested in getting some food and a better drink, so we hit the streets of Tenderloin. After a little walking about, we found Lers Ros again. Like the first time, it was sooo tasty. The management had added more tables, and the place was much busier than the last time, but the food and service was just as memorable. We'll go there every time we visit SF, so long as they're open.

5 Mile
The following day, we re-traced some other steps we had taken 2 years earlier after checking out. We visited some old Grateful Dead haunts (the Bill Graham, Warfield Theater, Great American Music Hall and the Fillmore), hit JapanTown for some incense and then BART'd to Berkeley to meet up with my brothers, sisters, their families and my folks at a rented house to celebrate my parents 50th wedding anniversary. All told, we clocked over 6 miles with 20 pounds of day-pack on our backs. Bed, when it came, was welcomed. In a stark difference from the last time we walked through Tenderloin 2 years ago, the city smelled different. Two years ago, it was during a cold snap, and the homeless were in shelters, leaving just the skunky smell of cannabis. This time, it was sunny, warm and smelled of old urine. It was so bad that it clung to our clothes and we had to throw everything we were wearing into an immediate wash cycle at the rental house. Yuck.

50 Years
Friday was anniversary day. 50 years. We celebrated with a renewing of vows, led by my brother-in-law. There's a ton of back story on him, but for now, let's just say he's an Episcopal minister working with the SF youth through his Braid Mission. Through his contacts, we were granted access to Grace Cathedral on top of Nob Hill for the vow renewal.

Now, old couples are cute. They just are. When you put them in a big cathedral, surrounded by family while they repeat wedding vows, its all the cuter. The ceremony was little-kid-friendly short, creating time for the little kids to play on the playground in the park across the street (see picture). We picnic'd and then hit China Town. I had expected more culture and less kitsch, but it was nice to walk the street with my brother and sister. We joined the mass quitting-time exodus from downtown SF across the Bay via BART. The underground station and packed train were very different from the trips we'd had thus far, but everyone was polite, and went about their business.

Ca me plaƮt
My brother-in-law and sister hired a French chef to cater a celebration dinner at their house in Berkeley. Having never really had French food, I didn't really know what to expect. Wow. I've been ruined for red meat now. I don't know what it was called or how it was prepared, but we were cutting through rare steak with butter knives, the flavor popping and the meat melting in our mouths. Absolutely incredible. It was paired with simple vegetables and tiny potatoes, seeming almost like a simple country dish. Fantastique!

After eating far too well the night before, Boo and I chose to double-down and hit a local brunch place for breakfast the following morning. Unlike all of the storefronts along Market Street, none the handful of cafe's along Solano Avenue in Albany CA claimed to have the city's best breakfast. Yelp led to Bistro 1491 and Sunny Side Up. The Bistro didn't seem casual enough, so we slid into a window-side table at Sunny Side Up. We could have split a single breakfast, the portions were so big, but they were good. It felt very Portland; very chill and real with a mix of folks ranging in age and demographic. We routed my out-of-town sister and brother to go the following morning and they loved it too. Boo and I spent the rest of our final full day in the Bay walking the shops along Solano Ave, enjoying the sunshine and the sense of real free time.

Our final day started with a flurry of get-out-of-the-house activity. With so many folks sharing one house, it was actually less chaotic than it could have been. Still, we had time for 3 pots of coffee, and conversation before we checked out. We ended our stay back at my sister's house on her sunny back deck listening to the birds before grabbing a final ice cream at iScream. Yummy.

The drive to SFO was longer and more heavily traffic'd than expected, including the "departure" curb at the airport. So, we arrived at the terminal a little more stressed than we'd like. Unlike the flight down, Boo and I were helping my folks get home too, so that added some pressure too. Once their bags were checked and my mom in an airport-approved wheelchair, they whistled through security. Boo and I made it through okay, but not nearly as easily as our last few flights. We dashed for the gate and bought some plastic-sealed sandwiches for dinner on the flight home.

PDX airport was its typical smooth go. We left the folks at baggage claim while we shuttled to the economy lot. By the time we got back, they had their bags and were ready at the curb. Home bound within 30 minutes after the plane touched down and walking in our front door 60 minutes later (after routing through the close-in East side) was way better than I could have expected. Overall, it was a great trip. Boo and I are already planning our next one, but it may happen before the Hootenanny.

That's it for today. Thanks for following along. More sanding and paint-related tales next time-

Friday, March 6, 2015

Pop the Dash... and more Sanding

After I pulled the windshield, I started rooting around for evidence of rust. Like I indicated in my last post, there wasn't much difference since the last time I pulled the windshield, but I hadn't pulled the dashboard top panel either. Today covers that fun adventure.

Plastic Hats
the screw under the plastic hat
I'd always wondered why the top panel / steel sheet on my bus had been such a bright white. The rest of the bus was that slight off-white, but that panel had been bright bright white. It is so bright, in fact, that I cut carpet to set on top of it so the glare on the windshield wouldn't impair my ability to drive on sunny days. At the front-most point of that panel, close to where it meets the windshield, there are 8 little black plastic "hats". Once the windshield was off, and I looked at the rust, it occurred to me that those must by covers. After popping one off, I found Phillips head screws. Neat. I pulled the hats and the screws, and popped them into a "dashboard" ziplock baggie.

10mm Nuts
Once the Phillips head screws at the front are removed, there are 6 nuts/washer combinations at the rear of the top sheet which holds it to the pad. It is easier to get at these nuts if the glove box and dashpod are out of the way, but that's not entirely necessary. The glove box is freed by simply loosening the steel retainer (Phillips head bolt along the bottom facing rear-ward). Once removed, the nuts and washers pop into the same ziplock baggie, and the dashpad comes right off.

Panel Off
what's German for spaghetti?
With the dashpad out of the way and the front-edge screws out, the panel is no longer a-fixed. It may, however, be difficult to extract without some wrangling. I'll have to protect the painted areas on re-install, or I'll scratch up the new paint. I found that the panel was very light, once it was out, and it had been repaired before. There are small rust holes and rough sections under the white paint that leads me to believe that there was a half-assed rust abatement effort conducted once before. Why someone would go so far as remove the sheet and then not fill the rust holes, I don't know. I will.... and I'll paint it a more mellow color and sheen so it doesn't blind me on a sunny day.

I thought about buying a replacement panel, but I have had a hard time finding a new one. Since this is the panel with the VIN plate, it is possible that new panels aren't generally sold. I set the panel in the clean-up pile and decided I'll keep looking for a new one. The rust isn't too bad, but since it'll take me over an hour to rust treat it, much less paint it, it's probably worth looking for a rust-free new one.

That's it for today. Like I said before, I'm running out of things to remove before the next phase starts. That next phase should be rust repair. Then hole repairs, final rough sanding, priming, more sanding, painting, more sanding...
Thanks for following along-

Thursday, February 26, 2015

Windscreen Removal

Well, the prep for painting has really gotten underway now. Today's brief post is about removing the windscreen and what lies beneath. Depending on your windscreen, you may be removing it to replace it. If that's the case, you may not need to take as much care as I did. My glass was perfect, but I needed to get a look at the metal surrounding it as well as get the paint underneath it. One more seal is worth the rust containment.

multiple passes
For tools, you only really need a box-cutter / X-Acto. Extend the blade halfway. Approach the bus from the front and go to the top corner of the passenger side first. Slide the side of the knife blade against the windscreen with the sharp side pointing down. Cut the rubber seal from top to bottom by sliding the side of the blade against the windscreen. It will resist, so that's why we're only using half of the blade edge. Don't press too hard; let the knife to the work. The harder you fight it, the more likely you will scratch your windscreen. Extend the blade to 3/4 length and run the same seal edge top to bottom. Extend the blade to full length and repeat. This time, you should hear that satisfying noise of the knife against the A-pillar. The rubber should separate from the glass and just hang there. If not, gently run the knife along the A-pillar being careful not to disturb the paint. It is possible a previous owner painted the seal on, ran caulk to try to stop a leak or glued it in. Glue is not necessary for this seal. Nor is caulk, but I've seen some crazy road-side repairs go untouched for years, and caulk is definitely one of them.

Repeat the cuts for the driver side and then the top. By now, there should be rubber hanging off the bus, or sitting in strips by your feet. Nicely done. If its an old seal, some of those cuts were very difficult. If it was anything like my first seal replacement on my bus, there were a few spots where I was able to cut right through very easily. I discovered that those spots also aligned with rust. When I cut off the seal the other day, it was only a few years old, and held very well. I'll be getting another Bus-Depot seal for the re-install later.

Bottom Cut Last
Pulled away a little bit
The best is saved for last. When I did my first seal, I had to be careful while I cut the last section. It wasn't holding very well, so I had to keep one hand holding the windscreen while I finished the cut. The newer seal, though, held strong even after I cut off the bottom. The windscreen held to the bus. It held very firm, actually. Your experience may differ, and you may want a buddy around when you make your last cut (as I did a few years ago).

Pop It Out
Old seals don't hold well, so the windscreen may just fall out once you've made your last cut. In my case, I reached one hand through the front door and pushed towards the front while catching the edge out front. This freed the sides, but the center still held. I had to grip the windscreen from the bottom near first the driver side then the passenger side and gently pull forward. Slowly, the seal gave in and handed me my windscreen. I carefully set it where it wouldn't get scratched and pulled out the remains of the seal. If yours was glued in, this could take some time. You want to get back down to smooth metal.

Now What?
glass out. rust inspection
I looked at the rust treatment I did years ago with some POR15. I was impressed. From my memory, the rust had not meaningfully advanced. Still, I needed to sand the whole opening to make sure. It looked pretty good, so I decided I would just expose the rust (read: sand and Dremel) and re-treat it. Then, I'll just handle it like any other metal panel: prime and paint with lots of sanding mixed in. Since it lives under a seal, there's no point in adding Bondo to the rust pits except as practice for visible spots I need to do later. Still, I'm going to skip Bondo'ing here.

As always seems to happen, this small painting effort has grown into a pretty big deal. Next up, removing the dash-top, more rust inspecting and sanding. Apart from deciding how far to go with paint on the interior, I think I'm almost done with the initial prep work. I still have lots of sanding and such to do, though. Unfortunately, that doesn't lend itself to print very well, so it might be a little while before my next few posts appear after this. Thanks for following along.

Tuesday, February 24, 2015

Removing the Slider

Continuing down my path, today's post is about removing the sliding door. Sure, the Bentley has a section about it (5.11), but like the front-door window removal, there's always a little something to clarify.

Getting at It
We start with the splash guard that covers the rail running underneath the rear window. The Bentley (section 5.10) is right in that there are 3 fasteners to concern yourself with, but at least in my case, one of the Phillips-head screws in the Bentley picture is actually a bolt and nut. The first 2 are obvious. They are Phillips head screws and come from below the guard at the rear and just front of the middle. Depending on your individual case, you may need to hit these with PB Blaster to get them to come free.

rear catch
At the front, there is a difficult-to-access nut. This is not shown in the picture in the Bentley. At least on my 1972, there is a Phillips head bolt head inside the bus that threads through to a 10mm nut where the Phillips head screw is in the Bentley picture. If you put a 10MM crescent or box-end wrench on the nut, you can remove the bolt from inside using a Phillips head screwdriver. This is not in the Bentley instructions.

Once the fasteners are removed, tap on the underside of the cover with a rubber mallet. It should free relatively easily. Within the instructions in the Bentley, a cinch-down bolt and bar is pictured. It has a Phillips head, and should be loosened first. In my case, no amount of PB-Blaster would free the cinch-down bar before I got the cover removed.

There is a simple seal between the cover and the side of the bus body. When the cover comes free, this seal will come free with it. The existing one looks fair, but a pair of replacements would be $15 at BusDepot (see here). I tossed it into the keep pile, delaying the decision until the other end of the painting effort.

Door Off
Once the splash guard is off, removing the door is actually pretty easy, but you need a buddy. Again, though, the Bentley falls just a little short. Maybe it's my reading of it (section 5.11). Before you start pulling the door off, there is one step the Bentley forgets: removing the rear catch. If you slide the door all the way open, the inner handle catches on a bracket. That bracket needs to be removed before you try to remove the door. It is held on with 3 thick Phillips-head screws.

rear support in the channel
Now, like the book says, open the door halfway. There is a break in the channel in which the rear support runs. The rear support slips through that opening. Have your buddy hold that end of the slider, taking care to keep the rear support from banging against the side of the bus. The two of you now roll the door all the way to the rear. While holding the rear-end of the sliding door (and facing the side), have your buddy take a single step back away from the bus. Then, while you hold the front edge, your buddy lifts upward, tilting the door. Keep tilting until the front top roller can slip out of the upper channel. Hold the door firmly now and pop the bottom roller out through the gap in the bottom channel (picture 5-37 might help). Set the door on something stable that won't scratch it. I used the passenger seat I'd removed and set against the side of the bus.

Inspect and Prep
With the slider fully removed, you can see all of the little rust spots which were barely visible before you removed it. The bottom edge of my door had a fair amount of surface rust, but no holes. The edge of the body, however, wasn't quite as fortunate. The front corner of the door, under the seal, has some rust spots and a few tiny holes. Some work with a Dremel got the rust removed and the holes clarified, but I need to think about how I can contain the inner side of the rust hole so the rust doesn't spread. Something I'll have to figure out soon.

I removed the door workings to make sure no rust had appeared underneath them. Other than the bottom edge, the door looks clean. I scuffed the paint and got after the rust. More work is needed there before the door is ready.

workings removed
The lower roller channel was filthy. 40 years of mud, oil and grease had made quite a mess. Using a putty knife, I scraped the bulk of it off. Then, with Goop-Off, I scrubbed it clean enough to sand without grime gunking up the sandpaper. Happy to see there wasn't any rust (just patina), I lightly sanded the lower roller channel.

Last, the body panel under the door had some caked on grey gunk that looked like concrete. Neat. After chiseling off the worst of it, I sanded the rest and roughed up the paint. The drip rail on the bottom had some surface rust, but no holes, and nothing remotely structural. A moderate sanding effort later, that area is ready for priming and painting. I removed and sanded the cinch-down bar, concluding that it will need paint to keep it from being patient 0 for the next round of rust in the slider area. I'm not sure it will work as well with paint on it, so I will look for a new replacement.

That's it for today. I still have to finish the rust sanding on the slider, but otherwise the door and door opening are ready for the next step. As always, thanks for following along.

Sunday, February 15, 2015

Stripping Doors

As you may have surmised from my last post about paint prep, I couldn't just stop at the nose. We'll see how far this goes.  For today, I'm focusing on getting the front doors ready. I do feel compelled to explain why I'm going for the paint this winter. Most of the recent years, I've spent my wintertime spare time on Mt. Hood, playing in the snow. El Nino or some other weather condition has hit the Pacific NorthWest with spring-like weather for most of January and, so far, all of February. Tulips and Daffodils are sprouting while our beloved SkiBowl looks more ready for mountain biking than downhill skiing. Sadness. So, I'm taking the opportunity to focus on getting the bus cleaned up and shiny for music-festival season. Onward!

Insides First
inside stripped,
sanded and taped
This seems obvious, but first, the inner door controls and door card need to be removed. The door latch and door pull are simple Phillips head bolts. Pop them into a ziplock bag marked for their respective door. The window should be lowered all the way and then the winder removed, but keep it handy. Then, carefully pull the door card with a tongue depressor (or something similarly harmless) popping the clips out of their rubber homes. Your door should have a plastic sheet behind the card. Peel this sheet off and stow it with the rest of the door bits, preferably labeling the heap in a way that's meaningful to you. As you can see in the picture to the right, here, I put everything into a plastic bag for the door, and put that bag into the hole in the door. Won't get lost that way :) Now you can get after the window trim.

The Bentley does a fine job of explaining how to remove the window, vent wing and trim in section 5.9 of the first chapter. I wouldn't want to misdirect, but there are some opportunities for clarity in their process. The book describes removing 2 window-track bolts, and the picture shows where the front one is. The "back" one is in the middle of the window track, but below the lowest point where the window might travel. There's a picture a few pages back (figure 5-14), though the narrative in section 5.9 doesn't reference it. They are both 10mm bolts.
The book also says to remove the Phillips head bolt from the vent wing housing after removing the felt from the top of the roll-up window channel. What it doesn't say is that you need to bent the little tang on the vent wing housing downward so you can tilt the housing back to the rear on removal. But, don't do that yet. There is a missing, but helpful, step right here after the removal of the felt strips and inner scraper: removing the window glass. Remove the 2 10mm bolts which hold the bottom of the window pane to the window winder assembly. The roll-up window will now float freely in the door. With one hand, lift the window up and catch it with your other hand above the door sill, leaning the window towards the inside. It should lift right out. Once the window pane is out and you've bent the little tang downward, the vent-wing housing easily tilts back and can be removed. These steps augment steps 6 & 7 of section 5.9. Last, remove the outer scraper and chrome-y surround trim.

Outsides Last
outside stripped and sanded
The outer door handle is held on with 2 Allen head bolts (Bentley section 5.5). These can be reached much more easily now that the window is gone. If you left your window pane in, roll it all the way up so you can get to the Allen-head bolts. Once removed, pull the handle off the door and thread the bolts right back in again. Set the handle with the door-specific heap you had from the "Insides First" steps above. The strike plate could be removed at this point, or it may be taped off. User's choice. I removed one, but the other was so tightly attached, I chose to tape it rather than strip the Allen head bolts. The same decision could be made for the latch assembly. I left mine in-place and taped them for the same reason I left the strike-plates: strip fear. I also removed the pin from the door-check (Bentley 5.4), but left the unit in place. For getting at some areas with sandpaper, it proved useful to have the door able to open more widely. I looked at removing the doors, but, like the strike plates, the Allen head bolts seem paint-sealed, and I didn't want to strip them. I still might attack them with an EZ-out so I can make sure I've gotten all of the rust traces dealt with. We'll see.

The front reflector comes off with a Phillips head screwdriver. Beneath mine, I found surface rust, but that easily dusted off. You can see the rust scar in the picture. I've thought about replacing the reflectors with operable lights that key off the turn signals on the front. More thought needed there. I'm not sure it would do much for improving visibility, but its not a new idea. Scroll down to post #12 here.

Last, we have the mirrors. I closed the passenger door hard once a few years ago and the mirror glass popped out. I have had a devil of a time finding replacement glass. All that the online vendors want to sell you are the crappy Chinese-tin full mirror replacements. Boo. So, I've been driving without a passenger-side mirror for a while. I may just break down and buy the more spendy (Brazil or German made) pair of complete replacements. Anyway, the mirrors are threaded into a nut that is welded to the door on the inside. So, it just screws in and out. You may need to break the seal with PB Blaster or a pair of pliers.

Like the prior post, everything that you intend to reuse needs to be tagged and bagged. Anything you intend to replace needs to be collected together and documented. This is a great opportunity to replace ancient fasteners, and one you should definitely take, but be careful how many fasteners you put in a "replace" baggy without any labeling. You could find yourself with a vehicular jigsaw puzzle trying to figure out which fastener was for which assembly. Ask me how I know :) Keep general assemblies together. A ziplock baggy costs a few cents. Hours of trial and error later can cost you a hairline, or just some sanity. Either way, the few cents is cheaper.

That's it for today. Thanks for following along. The tear-down continues next time-