I posted recently about the rust I discovered on the back window. It turned out to be pretty bad so I opted to cut out the rust and purchase a new window which is on order.

My main objective was to remove the rust, make a new frame with window cut-out, sealing and then sand and coat ready for final spray coat.

This is what I have done so far, to see how I cut out the rust, you can read my first How To: Cutting out rust

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Here you see the metal glued, sealed and riverted into the finished place.

If you look closely, you will notice that the bottom metal sheeting has a few cuts. The reason for this was due to the fact that the original frame has a sill.

This was part of the buses original design which curved out across the back.

There was no way I could bend the frame to this shape so several cuts were needed to cover up the original sill.

I have allowed about 20 millimeters with the new metal to cover over the old bus frame.

It was then glued and riverted which is something I have done from the beginning of this project. The riverts are approximately 80 millimeters apart, I put plenty of them in for extra strength.
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Using my grinder, I roughed up the metal surface and ground a little bit off the heads of the riverts (not all though).

I also took the old paint off at the top above the new metal and the bottom so I can get a good finish when I bog it all up.

DSCF1138_3.jpg This is some more rust I found on the side up at the roof sill. I will cut it out as before and fix.
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This is the first coat of bog and covers all the metal and riverts.

When dry, it is sanded back. You need to rough it up to ensure the next coat takes properly.

A second and third coat is applied with sanding done each time.
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This is the final product.

It needs one more sand and I will then use a spray on under coat.

I know it doesn’t look much but once the bus is painted, it will look brand new!
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