Project Details
- Vehicle: 1977 Volkswagen Kombi Camper
- Model: VW T2 Bay Window
- Colour: Leuchtorange L20B
- Work Completed:
- Rust removal and welding repairs
- Removal of previous patch repairs
- Body preparation and repaint
- Bullbar structural repair
- New door seals and rubbers
- Replacement lenses and exterior finishing parts
Some Kombis arrive at the workshop with stories written all over them.
This 1977 Kombi camper was one of those buses.
It had clearly lived a full life. The owners had spent many years travelling and enjoying it, and it had become a familiar sight at events like the Old Bar Beach Festival — one of the great gatherings of classic Volkswagens in Australia.
But as with many Kombis that have been loved and used for decades, time had started to catch up with it.
Rust had begun creeping into the body and some of the older repairs from years gone by were starting to show their age. The paint had long since faded and the body needed proper attention.
Eventually the owners decided it was time to give the old bus the restoration it deserved.
Removing Old Repairs
When working on vehicles of this age it’s very common to find older repairs that were done simply to keep the vehicle on the road at the time.
This Kombi was no different.
Several previous patch repairs had been carried out over the years, and while they had served their purpose, rust can often continue slowly developing behind those repairs.
To properly restore the body we removed many of these old patches so we could inspect the metal underneath. As expected, several smaller rust areas were hiding behind them.
Once those were uncovered we could repair them properly.
Proper Rust Repairs
The rusted areas were carefully cut out and fresh metal sections were welded back into place.
This is the correct way to repair rust in a Kombi body. Simply covering rust will only allow it to return later, so removing the affected metal and welding in new steel ensures the repair will last.
Once the welding work was completed the panels were ground back, sealed and prepared for paint.
Rust repair is often the most time-consuming part of restoring an old Volkswagen, but it’s also the most important. When done properly it allows these vehicles to keep travelling for decades.
Keeping classic buses like this on the road often requires sourcing the right VW T2 Baywindow Kombi parts and taking the time to repair things correctly rather than rushing the job.
A Safety Issue Discovered
While working through the vehicle we also discovered that the bullbar had rusted through along the bottom edge.
This is something Kombi owners should check regularly. Bullbars can often appear solid from the outside, but rust frequently develops internally where moisture becomes trapped.
A heavily rusted bullbar can actually become a serious safety hazard, as weakened metal may collapse during an impact and cause more damage than protection.
The rusted sections were repaired so the bullbar was structurally sound again.
A Classic Volkswagen Colour
With the rust repairs complete and the body prepared, it was time for the transformation.
The Kombi was repainted in Leuchtorange (L20B) — a classic Volkswagen colour used on late bay window buses during the 1970s.
The rich burnt orange suits the character of the bus perfectly and pairs beautifully with the white upper body and roof. It gives the Kombi that unmistakable vintage Volkswagen look that makes people smile when they see one driving past.
The difference was dramatic. What had once looked tired and worn now looked vibrant again.
The Finishing Touches
Once the paintwork was complete, the final stage was bringing everything together with the small details.
A number of fresh VW Kombi exterior parts were fitted to complete the look.
New Volkswagen door seals and rubbers were installed along with fresh lenses and trim. These small details make a huge difference to the final appearance of a restoration.
Old hardened seals and faded lenses can make even a freshly painted vehicle look tired, while new parts help bring the whole vehicle back to life.
Ready for the Road Again
Kombis like this were built for road trips, camping weekends and coastal adventures.
After the rust repairs, fresh paint and finishing touches, this 1977 camper is ready to continue doing exactly that.
Another classic Volkswagen saved.
And another reminder that with the right care and attention these vehicles can keep travelling for generations.
If you're restoring your own Kombi and need parts, we stock a wide range of classic Volkswagen parts to help keep these old machines alive and on the road where they belong.