In Part 5 of the “Restoring a 1973 VW Campervan” series, Snowdonia Classic Campers take you through the process of preparing their 1973 VW camper van, Nell, for the 2020 hire season. The video begins with the host explaining the steps they will take to replace the windscreen in a support and create a brace to keep the posts in place. They then proceed to remove panels, clean surfaces, and treat areas with rust preventer before fabricating new sections for repair. After much effort and finetuning, they successfully fit the repaired sections, ensuring they are strong and safe, and preparing to apply primer and wax oil before the new front panel is installed.
Throughout the video, the host shares their progress, challenges, and plans, offering viewers insight and inspiration for their own restoration projects. Stay tuned for Part 6, where they will begin welding the pieces back together to complete Nell’s transformation.
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Restoring a 1973 VW Campervan: Part 5 – Windscreen Replacement
Introduction to Windscreen Replacement
The windscreen is a crucial component of a vehicle, providing structural support and protecting the occupants from external elements. As part of the restoration process for a 1973 VW Campervan, it is essential to replace the windscreen to ensure the vehicle’s safety and integrity. This article will guide you through the process of windscreen replacement, highlighting the necessary tools, techniques, and considerations involved.
Tools and Equipment Required
Before embarking on the windscreen replacement, it is imperative to gather the necessary tools and equipment. Some of the tools required for this task include a socket set, screwdrivers, pry bars, a rubber mallet, a scraper, and a wire brush. Additionally, you will need a windshield removal tool or piano wire for older models that may have a rubber seal holding the windscreen in place. Safety equipment such as gloves, safety glasses, and a mask should also be worn to protect yourself from any potential hazards during the process.
Removing Old Windscreen Support
To begin the windscreen replacement, you must first locate and access the windscreen support. Carefully remove any panels or flanges that may obstruct your access to the windscreen. Inspect the support for any signs of rust or damage, as this may require additional attention before proceeding with the replacement. Use appropriate techniques to safely remove the old windscreen support, taking care not to cause any further damage to the surrounding areas.
Preparing Surfaces for Replacement
Before installing the new windscreen, it is crucial to prepare the surfaces for replacement. Start by cleaning the surfaces thoroughly, removing any dirt or debris. Next, use a wire brush to remove any rust or corrosion from the metal surfaces. To prevent further rusting, apply a rust preventer or converter to the affected areas. Once the surfaces are clean and rust-free, coat them with a suitable paint to provide protection against future corrosion.
Treating Rust and Applying Paint
As you prepare the surfaces for the windscreen replacement, it is essential to address any existing rust issues. Assess the extent of the rust and determine the appropriate course of action. If the rust is minimal, applying a rust treatment product can effectively halt its progress. However, for more severe cases, you may need to remove the affected metal and replace it with a fabricated repair section, which we will discuss in further detail later. Once the rust has been treated, choose a high-quality automotive paint that matches the original color of the vehicle and apply it evenly to the surfaces.
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Creating a Cardboard Template for Repair
To ensure a precise and accurate repair section, it is advisable to create a cardboard template. This template will serve as a guide for fabricating the metal repair section and ensure a seamless fit. Measure the area that requires repair and transfer the measurements onto a piece of cardboard. Cut out the template and test fit it on the vehicle to ensure proper alignment and size.
Fabricating a Metal Repair Section
Using the cardboard template as a guide, fabricate a metal repair section. Select a suitable metal material that matches the original structure of the vehicle. Begin by cutting the metal sheet according to the dimensions of the template, using appropriate cutting tools such as shears or a metal cutting saw. Shape and bend the metal to match the contours of the damaged area, ensuring a precise fit. Test fit the repair section on the vehicle to verify its accuracy.
Fitting and Welding the Repair Section
Once you have fabricated the repair section, it is time to fit and weld it in place. Before welding, prepare the surfaces by cleaning them thoroughly and removing any paint or coating that may hinder the welding process. Secure the repair section in position using clamps or welding magnets, ensuring a tight and secure fit. Use welding techniques appropriate for the type of metal being used, such as MIG or TIG welding. Take necessary safety precautions during the welding process, such as wearing appropriate protective gear and working in a well-ventilated area. Once the welding is complete, verify the fitment and alignment of the repair section.
Finishing Touches and Priming
To complete the windscreen replacement, add the finishing touches to ensure a polished look and long-lasting durability. Treat the welded and surrounding areas with a rust preventer or converter to provide additional protection. Once the treatment has dried, apply a primer to the repaired section and surrounding areas. This will create a suitable surface for the application of the final paint and enhance the overall appearance of the vehicle.
Repeating the Process on the Other Side
After successfully replacing the windscreen and completing all necessary repairs on one side of the vehicle, it is essential to repeat the entire process on the other side. This ensures uniformity and consistency in the restoration project. Follow the same steps outlined earlier, from removing the old windscreen support to fitting and welding the repair section. Pay close attention to alignment and fitment to maintain the integrity of the vehicle’s structure.
Bracing the Bottoms of the A-Posts
To further strengthen the windscreen area and prevent future issues, consider bracing the bottoms of the A-posts. The A-posts are the vertical pillars located on either side of the windscreen. They play a vital role in supporting the windscreen and roof structure. By fabricating and installing metal braces or reinforcing plates at the bottoms of the A-posts, you can enhance the structural integrity and reduce the risk of future damage or deformation.
Cutting Off Remaining Panels
As part of the windscreen replacement process, it may be necessary to cut off remaining panels that obstruct access to the windscreen. Carefully identify the panels that need to be removed and mark them accordingly. Use appropriate cutting tools such as a reciprocating saw or an angle grinder with a cutting disc to remove the panels. Take precautionary measures to protect surrounding areas from any potential damage during the cutting process.
Repairing the Bottoms of the A-Posts
While working on the windscreen replacement, it is crucial to inspect the bottoms of the A-posts for any rust or damage. If necessary, cut out the rusted or damaged sections and replace them with fabricated repair sections, following the same techniques and procedures discussed earlier. Ensure a proper fit and alignment to maintain the structural integrity of the A-posts.
Removing the Steering Box
In some cases, it may be necessary to remove the steering box to gain better access to the windscreen area, especially if extensive repairs or modifications are required. Consult the vehicle’s service manual or seek professional advice before attempting to remove the steering box. Take necessary precautions such as disconnecting the battery, draining the power steering fluid, and supporting the vehicle securely to avoid any accidents or damage.
Conclusion
Replacing the windscreen of a 1973 VW Campervan is a crucial part of the restoration process. By following the steps outlined in this article, you can ensure a successful windscreen replacement that enhances the safety, structural integrity, and overall appearance of the vehicle. Proper tools, techniques, and attention to detail are essential to achieve the desired results. Remember to prioritize safety throughout the process and consult professional help if needed. With careful execution and proper restoration techniques, your campervan will be one step closer to its former glory.
