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 Roy's 1965 Deluxe 21-window restoration 
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Location: Mesa, AZ transplant from O'Fallon, MO
Post Roy's 1965 Deluxe 21-window restoration
I bought this bus from a classified add in the St Louis Post Dispatch in January 2006.
Bought it from a nice early 30's couple that were public school teachers in Lebanon, MO.
I worked on it for a bit that spring then it sat...and sat...and sat...until January of 2009.
Keep in mind I bought a left for dead rail in August of 2007 and had it running and titled in 5-weeks.
I also bought my 1973 Westfalia in December of 2007 that had not run since 1987 and had it on the road May 2008.....now back to the long lost '65 Deluxe.

This '65 deluxe had 1979 stickers on the black CA plates. While it spent ~ 15-years in California....the 25 years it spent beside a barn in Lebanon, MO took a heavy toll on her. The teachers dragged it home but quickly realized it was more than they could handle or afford to pay someone else to restore....so that's the story on how I ended up with it.

In my excitement of buying a 21-window bus I too overlooked the depths of rust it had....cargo floor gone...frame was swiss cheese...doglegs crunchy...and on and on...Meanwhile I aquired a '67 deluxe hardtop that was a very solid Colorado bus and a walkthrough....so lets just say my '65 bus now has a very large donor cab & floor section from the '67 hardtop...but I now have very little frame, bulkhead, nose, dogleg and cargo floor rust to deal with. Bonus is I ended up with 2-sets of deluxe trim, pop out windows, and just about everything else to choose from when I reassemble.

I wanted to attack the worst rust in the beginning so my first surgery was replacing the entire passenger side gutter using the '67 hardtops as a donor. Then replace the lower 3" of all four skylight window openings...this was before Klassic Fab (Gerson) metal and I actually made a die to form these parts. I decided to build a rotisserie for ease of restoration in my 20'X20' garage that I also provide my wife Dawn a parking space in. Then I moved to the two rearmost passenger side window openings replacing the lower 3" of them with more '67 donor metal. This was March of 2009 and is where I neglected the deluxe all summer while enjoying the rail and '73 Westfalia.

February of 2010 I got back working on the deluxe and replaced the radio section in the dash...got it fit and tacked in but was not happy with the fit....left it sit all spring and summer. July of 2010 I sold my rail and bought a 1973 Type-181 "Thing" which pretty much entertained me all of autumn and winter.

My 2011 new years resolution was that I would not find any more distractions until I finished this fuggin bus! So in keeping my word this past week I emptied all the crap that I've been storing in the deluxe and started working on it again. I cut loose the area of the radio hole that was pissing me off and realligned it, tacked, welded, ground and primed it....done and on to the next item on my list. The passenger seat back on a walkthrough should have have these brackets that a rubber bumper snaps into but on my bus some asshat decided he needed them more that I did and very brutefully tore them out. A couple of years ago Kevin from Springfield was kind enough to find me some donor brackets and deliver them to Funfest. I smoothed out the carnage and puddle welded these brackets back on yesterday.

At some point in 2008 my computer took a crap and the hard drive died with a bunch of photos of the dissassembly and splicing of the two deluxes as well as the gutter replacement. The only "early" pics I have are some from my photobucket and off my computer at work.

So there you have it...the four year story of my '65 Deluxe. So now I will cronicle the progress on this thread for all to enjoy.


Attachments:
File comment: As found January 2006
65 Deluxe1.jpg
65 Deluxe1.jpg [ 87.53 KiB | Viewed 2812 times ]
File comment: Previous owner...nice teacher lady
65 Deluxe4.jpg
65 Deluxe4.jpg [ 79.36 KiB | Viewed 2812 times ]
File comment: Home
65 Deluxe19.jpg
65 Deluxe19.jpg [ 78.56 KiB | Viewed 2812 times ]
File comment: Deluxes
65 Deluxe21.jpg
65 Deluxe21.jpg [ 80.27 KiB | Viewed 2812 times ]
File comment: Tacked
65 Deluxe 012.jpg
65 Deluxe 012.jpg [ 655.32 KiB | Viewed 2812 times ]
File comment: Primed
65 Deluxe 020.jpg
65 Deluxe 020.jpg [ 419.95 KiB | Viewed 2812 times ]


Last edited by rjonas on Fri Sep 14, 2012 8:35 am, edited 8 times in total.

Mon Jan 17, 2011 1:11 am
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Location: Mesa, AZ transplant from O'Fallon, MO
Post Re: Roy's 65 Deluxe 21-window restoration
Passenger side rear two windows...


Attachments:
File comment: Rotisserie
65 Deluxe 033.jpg
65 Deluxe 033.jpg [ 599.16 KiB | Viewed 2811 times ]
File comment: Rusty, crusty, holy crap!
65 Deluxe 028.jpg
65 Deluxe 028.jpg [ 631.81 KiB | Viewed 2811 times ]
File comment: Donor window sills
65 Deluxe 030.jpg
65 Deluxe 030.jpg [ 666.79 KiB | Viewed 2811 times ]
File comment: Tacked
65 Deluxe 034.jpg
65 Deluxe 034.jpg [ 581.72 KiB | Viewed 2811 times ]
File comment: Ground flush
65 Deluxe 045.jpg
65 Deluxe 045.jpg [ 536.29 KiB | Viewed 2811 times ]
File comment: Primed
65 Deluxe 048.jpg
65 Deluxe 048.jpg [ 525.09 KiB | Viewed 2811 times ]
Mon Jan 17, 2011 1:16 am
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Location: Mesa, AZ transplant from O'Fallon, MO
Post Re: Roy's 65 Deluxe 21-window restoration
Radio hole and passenger seat back bracket shenanigans....


Attachments:
File comment: Radio hole donor
65 Deluxe 058.jpg
65 Deluxe 058.jpg [ 789.11 KiB | Viewed 2811 times ]
File comment: Tacked, cut out and re-tacked
65 Deluxe 065.jpg
65 Deluxe 065.jpg [ 498.79 KiB | Viewed 2811 times ]
File comment: Ground flush
65 Deluxe 071.jpg
65 Deluxe 071.jpg [ 508.39 KiB | Viewed 2811 times ]
File comment: Ta...da!
65 Deluxe 079.jpg
65 Deluxe 079.jpg [ 463.76 KiB | Viewed 2811 times ]
File comment: What brackets?
65 Deluxe 073.jpg
65 Deluxe 073.jpg [ 440.74 KiB | Viewed 2811 times ]
File comment: Brackets done!
65 Deluxe 076.jpg
65 Deluxe 076.jpg [ 456.53 KiB | Viewed 2811 times ]
Mon Jan 17, 2011 1:21 am
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Post Re: Roy's 65 Deluxe 21-window restoration
Looks like your making good progress Roy.


Mon Jan 17, 2011 6:57 am
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Post Re: Roy's 1965 Deluxe 21-window restoration
Roy,

Can't wait to see it this year at BNNTA!


Mon Jan 17, 2011 8:39 am
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Post Re: Roy's 1965 Deluxe 21-window restoration
Very Nice Work!!! :D

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Mon Jan 17, 2011 11:36 am
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Post Re: Roy's 1965 Deluxe 21-window restoration
You are the metal master!

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Mon Jan 17, 2011 12:35 pm
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Post Re: Roy's 1965 Deluxe 21-window restoration
Thanks guys...my goal is to drive it to BNNTA this September and debut it at Bill's show....although I heard 2 other "older" buses plan on making their first appearances there too.

My first bus was a nice 1959 Standard Mango I bought in '04 or '05...that was European delivered so it had blade bumpers. It was a CA bus too that just needed rockers, battery tray and front floors which I now call my "practice" bus. Had all the metalwork done and only needed paint...then for some stupid reason I just had to have a sunroof bus which brought me to where I am now.

Really stoked to be working on the bus again...I welded for a living the first 10 years in the workforce but now I really look forward to making sparks and banging metal after my boring day job estimating. I'll be massaging the tweeked spare tire bucket and installing it tonight. I'll try and update the build using lots o pics when I've scratched another "to do" off my list.


Mon Jan 17, 2011 1:16 pm
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Post Re: Roy's 1965 Deluxe 21-window restoration
Roy man have you ever done some metal work or what. It a skill that I REALLY want to learn myself. Leme know if you need an extra set of hands assembling anything. Told you once before, I would love to say that I had a hand in getting the only 21 window bus in St. Chuck County rolling under it's own power...


Mon Jan 17, 2011 1:51 pm
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Post Re: Roy's 1965 Deluxe 21-window restoration
Thanks for sharing your build with us Roy. You do great work and to know you actually made your own mold for those window areas is beyond cool. I really like the shot of the bus in the rotisserie and your VERY organized garage. A tentative plan of having mine built by BNNTA is on the table as well, but that's a long shot. I'd like to see your welding setup if you could sometime in pics.


Mon Jan 17, 2011 5:36 pm
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Post Re: Roy's 1965 Deluxe 21-window restoration
Sure Mike...I'll be needing lots of help this spring sanding the body for paint and again this summer assembling and bolting stuff on (the exciting part) and I'll for sure be calling in as many favors as possible. But for now the tedious part of fitting and welding the repair panels is something I can't use much help with.

Lyndon...here is a money shot of my welding corner. I have a Miller 180 Syncrowave TIG welder, a Miller 135 MIG welder and a Harbor Freight spot welder (under bench). And...a little tour of my 20'X20' man cave.


Attachments:
File comment: Welding bench
65 Deluxe 011.jpg
65 Deluxe 011.jpg [ 855.3 KiB | Viewed 2710 times ]
File comment: Tools, junk
65 Deluxe 015.jpg
65 Deluxe 015.jpg [ 816.42 KiB | Viewed 2710 times ]
File comment: Fridge, sink, junk, kitchen door
65 Deluxe 014.jpg
65 Deluxe 014.jpg [ 803.21 KiB | Viewed 2710 times ]
File comment: Air tools
65 Deluxe 021.jpg
65 Deluxe 021.jpg [ 696.61 KiB | Viewed 2710 times ]
File comment: Grinders
65 Deluxe 023.jpg
65 Deluxe 023.jpg [ 701.82 KiB | Viewed 2710 times ]
Tue Jan 18, 2011 8:32 am
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Post Re: Roy's 1965 Deluxe 21-window restoration
Spare tire bucket....


Attachments:
File comment: Donor section...looks like someone chewed the old bracket off.
65 Deluxe 005.jpg
65 Deluxe 005.jpg [ 617.55 KiB | Viewed 2707 times ]
File comment: It looks so innocent not knowing what's about to happen to it...
65 Deluxe 010.jpg
65 Deluxe 010.jpg [ 716.6 KiB | Viewed 2710 times ]
File comment: Nice dent and on the corner too...errgh
65 Deluxe 008.jpg
65 Deluxe 008.jpg [ 540.25 KiB | Viewed 2710 times ]
File comment: Massaged the dent out
65 Deluxe 018.jpg
65 Deluxe 018.jpg [ 596.2 KiB | Viewed 2710 times ]
File comment: 5" cut off wheel held deep makes a very starit cut
65 Deluxe 024.jpg
65 Deluxe 024.jpg [ 788.98 KiB | Viewed 2710 times ]


Last edited by rjonas on Wed Jan 19, 2011 8:12 am, edited 1 time in total.

Wed Jan 19, 2011 8:02 am
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Post Re: Roy's 1965 Deluxe 21-window restoration
more spare tire bucket.


Attachments:
File comment: Cleaned up and ready...and it's dinner time.
65 Deluxe 025.jpg
65 Deluxe 025.jpg [ 759.23 KiB | Viewed 2708 times ]
File comment: Reinforcement spot welded on...bracket on too
65 Deluxe 026.jpg
65 Deluxe 026.jpg [ 622.73 KiB | Viewed 2708 times ]
File comment: Primed
65 Deluxe 029.jpg
65 Deluxe 029.jpg [ 627.69 KiB | Viewed 2708 times ]
File comment: Done for the night...a little late to be grinding all those puddle welds at 11pm.
65 Deluxe 031.jpg
65 Deluxe 031.jpg [ 679.35 KiB | Viewed 2708 times ]
Wed Jan 19, 2011 8:06 am
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Post Re: Roy's 1965 Deluxe 21-window restoration
Very nice set up you got Roy. Just shows what can be done with enough organizing in a small area. The quality of work you do shows in the pictures. The selection of tools you have at your disposal would make most fabricators envious. Like one build I follow he always says with his updates "Still going strong" 8)


Love to see this kind of dedication.


Wed Jan 19, 2011 4:54 pm
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Post Re: Roy's 1965 Deluxe 21-window restoration
I LOOOOOOOVE your organization, and use of wall space!!!!!!!!

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