... And so it begins.

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Fathermarc
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Re: ... And so it begins.

Post by Fathermarc »

Cam,
from the underside of the wheel tub to where the step in begins is 28mm and to the end of the shut off piece is exactly 385mm.
Let me know if you want a template making up.

There you goes big noes.
---------
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Cam Biscuit
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Re: ... And so it begins.

Post by Cam Biscuit »

Thanks mate much appreciated!
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Fathermarc
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Re: ... And so it begins.

Post by Fathermarc »

The past few weeks have been a little hectic. We move home and work has been a little chaotic. So the kombi was put on the back burner. Today was the first day back on the spannera. Thought I'd fit twin carburetors to the wifes bugster. Swapping the empi kit off the kombi and replace it with the cb performance kit which came the webbers I ordered. Didn't take long and the larger filters look much better in the kombi engine bay. Fired her up and dial ed them in.
I Was surprised to hear a tap. Then a tap tap. What the hell was that. Switch ed the engine off straitht away. My first thought was had I accidentally knocked a washer into the engine. I stripped the carburetors off the engine again and then the manifolds. Taped a magnet to a length of filler wire and pocked it blindly into the engine. Nothing.
I rebuild the carbs back onto the engine and fired it up again. This time it was ratta tatta tatta and it seemed to be coming from no. 4 cylinder. I flipped rhe valve covers off and reset the clearances on all four cylinders and fired the engine up again
Still slapping away. I'M starting to think that it may be a valve seat but as I m new to all this to tell you the real trueth I can only guess.
It was a horrible day and what should have been a nice way to break myself into the resto was the sinking realisation that this resto was becoming more of a complete rebuild. It was fine to have a running kombi to work on but now it feels like the rug has been pulled from under my feet.
So if any of you guys have any advise then I could really do with some right now.
M
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Fathermarc
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Re: ... And so it begins.

Post by Fathermarc »

131201 - Resto

Just a quick update. The past few weeks have been distracting and time under the Kombi took a back seat. I think the last thread I dropped a washer in the intake manifold and into the the heads. That ended with me cursing and swearing. I talked to Wayne Penrose who happens to be a top fella. He convinced me to take out the motor and open her up. If you could have seen my face when I found it. It was as though i found a shiny gold nugget stuck up in the head. :D Gave me time to inspect the inside and everything's brand new.

But now the engines out I thought I'd take a closer look around in there. :roll: It's all alright but up inside the vent chambers was a layer of surface rust that need a damn good seeing to. Difficult spot to get too but it' can't stay there. So I researched and looked around and eventually plummed for a small but pretty good sandblaster. It plugs straight into the compressor nothing to it, just pored in some fine abrasive and set the feed rate and pressure. Done. It took me a bout 3 hours to get the engine bay looking brand new. Amazing.... Dusty but amazing.

I think I'll prime her and give her a blast of Dove Blue.

Now the engine is out :idea: it's got me thinking about fitting the IRS.

That's for another post. Notice the rear quarters slowly coming back iinto shape.
Attachments
Those reduction boxes are going in a box somewhere.
Those reduction boxes are going in a box somewhere.
No-motor_Engine compartment.jpg (41.66 KiB) Viewed 3026 times
I'm going to take off the number plate and re black it now.
I'm going to take off the number plate and re black it now.
No-motor_Engine compartment 2.jpg (56.35 KiB) Viewed 3026 times
RHS - Great!
RHS - Great!
No-motor_Engine compartment 3.jpg (41.99 KiB) Viewed 3026 times
Left hand side 2
Left hand side 2
No-motor_Engine compartment 4.jpg (48.31 KiB) Viewed 3026 times
left hand side all brand new
left hand side all brand new
No-motor_Engine compartment 2.jpg (56.35 KiB) Viewed 3026 times
Got me thinking bout the IRS
Got me thinking bout the IRS
No-motor_Gear box.jpg (55.05 KiB) Viewed 3026 times
With the engine out. Notice the rear corner is slowly being tapped out.
With the engine out. Notice the rear corner is slowly being tapped out.
No Motor - Rear.jpg (44.23 KiB) Viewed 3026 times
---------
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Re: ... And so it begins.

Post by Fathermarc »

:) 131207 - Resto

This weekend I managed to get some Kombi time. The wife has gone away to visit her folks for Christmas and i have a list of jobs to do as long as my arm,
Saturday morning I rocked out of bed and armed witha bacon butty ans a few cups of coffee I set to work.

First up was to finish of the sand blasting of the engine bay which came up great. Even right up inside the air ducts. I then gave it a coat of rust beater in case I missed some little specks and to seal it all off. I'll prime it when I've finished panel beating the rear quarter.

Sunday I rolled the kombi out back as not to disturb the neighbours with angle grinding. It seems to piss people of less when I work around the back. I had to weld up the rear of the engine lid hinge carrier as in the past someone had cut holes in her to slip in new hinges. Then chop of the seriously corroded weather strip (top section) I cut a new one out of a late bay tail gate which has been a good donor part so far. Tacked it all in and tidied up with the grinder. I welded up the holes in both rear quarters where aftermarket lights had been fitted. Then re welded the section I tacked in a few months back. The weld was OK for a first attempt but I could see pin pricks of daylight in my welds. Finally I cut out the small corrosion in the Off Side rear quarter and patched it up with a patch I made from a long side section which I didn't like.

Gave it all a coat of primer and pushed her back under cover.

Note: I think my confidence is improving with welding and personally I think its starting to show. :)

Phots:
Attachments
Off side rear quarter patch - in place
Off side rear quarter patch - in place
DSC06341.JPG (37.76 KiB) Viewed 2971 times
Off side rear quarter patch
Off side rear quarter patch
DSC06342.JPG (24.56 KiB) Viewed 2971 times
Taking shape
Taking shape
DSC06343.JPG (49.46 KiB) Viewed 2971 times
Holes welded
Holes welded
DSC06346.JPG (26.79 KiB) Viewed 2971 times
DSC06347.JPG
DSC06347.JPG (23.7 KiB) Viewed 2971 times
Cross member and weather strip - Done!
Cross member and weather strip - Done!
DSC06348.JPG (26.66 KiB) Viewed 2971 times
Welded up the read quarter - view below the battery tray.
Welded up the read quarter - view below the battery tray.
DSC06351.JPG (39.81 KiB) Viewed 2971 times
Both sides are rust free
Both sides are rust free
DSC06360.JPG (39.14 KiB) Viewed 2971 times
Following a sand blast the engine compartment looks nice and clean.
Following a sand blast the engine compartment looks nice and clean.
DSC06362.JPG (42.16 KiB) Viewed 2971 times
Her she is bearing whats left of her.
Her she is bearing whats left of her.
DSC06330.JPG (49.36 KiB) Viewed 2971 times
Last edited by Fathermarc on Mon Dec 09, 2013 8:05 pm, edited 1 time in total.
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Re: ... And so it begins.

Post by Fathermarc »

Photos cont.
Attachments
Hole are now gone
Hole are now gone
DSC06340.JPG (48.98 KiB) Viewed 2967 times
Just need to tap those ripples out.
Just need to tap those ripples out.
DSC06343.JPG (49.46 KiB) Viewed 2967 times
Welded quarter
Welded quarter
DSC06344.JPG (37.08 KiB) Viewed 2967 times
Shes looking anorexic
Shes looking anorexic
DSC06331.JPG (48.71 KiB) Viewed 2971 times
Everything ready to ROCK!
Everything ready to ROCK!
DSC06332.JPG (46.91 KiB) Viewed 2971 times
before
before
DSC06333.JPG (33.27 KiB) Viewed 2971 times
cross rain befrore
cross rain befrore
DSC06333.JPG (33.27 KiB) Viewed 2971 times
Inside shiny and new
Inside shiny and new
DSC06337.JPG (40.92 KiB) Viewed 2971 times
---------
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69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Cam Biscuit
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Re: ... And so it begins.

Post by Cam Biscuit »

Great progress mate
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Re: ... And so it begins.

Post by 63 left hooker »

Great work!!

It's terrible what one must do when the wife goes away :shock:
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Re: ... And so it begins.

Post by Fathermarc »

Cheers fellas: It's satisfying to see little triumphs along the way.

I've been contemplating this for some time and having the engine out was really the icing on the cake. I did a lot of research and although it's a deviation from the original plan I decided to take the option to upgrade the engine and it arrived today from (N)WA. I saw this advert on Gumtree for a bay window. The guy was offing his project and although the advert said he wouldn't be willing to sell off the parts individually I thought I'd give him a call. There was a mention of a 2Lt engine with a new top end rebuild and Dellorto 40 Carbies that caught my attention and the price for the Kombi was set at the low end of reasonable. we had a good chat and i managed to get the engine and all the tin ware Dellorto's etc.... All a very reasonable price.

Anyway it turned up and you know when someone had really started with good intentions but never quite finished it off well here it was. The guy was building a nice motor here and just got side tracked. The story goes that he was restoring his bay for a works vehicle (plummer I think) and wife got preggers last year and he never got to finishing it. Then she goes and gets preggers again and he just will not ever get to finishing it. So he went out and bought a T5. Enough said! Loss...Gain.

Well here's a few snaps an the new born.

Now we are gonna start seeing changes around here... STAY TUNED!
Attachments
Oh now we're gonna have some fun!
Oh now we're gonna have some fun!
Engine stand and Hoist Clutchin T'baby!
Engine stand and Hoist Clutchin T'baby!
Engine Lift on lone...
Engine Lift on lone...
---------
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Re: ... And so it begins.

Post by 63 left hooker »

Have recently experienced the whole 'Loss - Gain" concept.

Beginning of this year someone in Vic had a problem with a twin turbo Subaru half cut (bent conrod) = his loss

Having to selling his 67 notch to fund the repair = my gain!!!

Feel bad (but not too bad) :D
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Re: ... And so it begins.

Post by Fathermarc »

131223 - Resto

I'm so glad it's the holiday season. Eleven days of uninterrupted Kombi time. I can finally get a good run at the welding which is starting to become a mountainous mole hill. It just has to be completed otherwise I'm in fear of being stuck in this purgatory for eternity.

So here's a few snaps of the long side that I am tackling first.

Tomorrow we'll look at the A-pillars and then the dog leg.
Attachments
The back of the A-pillar needs to be cut out just below the floor.
The back of the A-pillar needs to be cut out just below the floor.
Here's the A-pillar. Needs to be cut out!
Here's the A-pillar. Needs to be cut out!
Tap everything in line and clean everything up. Pilot holes for the plug welds.
Tap everything in line and clean everything up. Pilot holes for the plug welds.
Inner Long rail tacked in.
Inner Long rail tacked in.
End support in place.
End support in place.
Middle support in and primed.
Middle support in and primed.
Bottom of the B-pillar was removed and replaced.
Bottom of the B-pillar was removed and replaced.
All supports in.
All supports in.
End closed off.
End closed off.
All in ready for stage two tomorrow.
All in ready for stage two tomorrow.
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69 Soft top beetle
65 Izh Jupiter with side car
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Re: ... And so it begins.

Post by Fathermarc »

131224_Resto

Today the weather was a lot kinder. Cloudy sky and just a little breeze which is a good thing when welding with an Argon shield. I started work on the A-Pillar cutting away the rot and fitting the inner section below the hinge. I welded just one face and cut it too long. this is so I can make adjustments after the dog leg has been installed. Once in I had had a dry fit of the Off Side Dog Leg. It wasn't a perfect fit and will need a few minor adjustments. But before I get carried away i need to check all my welds and grind off all the welds in the wheel arches. Once these areas have been blocked off with the long side and dog leg it's going to be difficult to get to those spaces again. Once happy with everything I made a the final cut for the Long side and dry fit this too. Checked everything fitted correctly before removing it once more to give everything a coat of Cold Gal and then a coat of cheap black Enamel for added protection. Looks ready for shutting off tomorrow with the skin panels.

Tomorrow is Christmas Day.... Merry Christmas to all at DSK

I got a text from a friend today of a Beige and white Splitty which he'd spotted in Byron Bay. I'll try and attach it. Holla if you know who's it is.
Attachments
No saving the A-Pillar
No saving the A-Pillar
This is gone!
This is gone!
A-Pillar chopped out.
A-Pillar chopped out.
Starting to take shape
Starting to take shape
Long Side Dry fit and ready to go.
Long Side Dry fit and ready to go.
A-Pillar welded on one side.
A-Pillar welded on one side.
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Re: ... And so it begins.

Post by Fathermarc »

:P 131225_Resto

Merry Christmas everybody on DSK.

I've just popped a bottle of Hoegaarden and put my dinner on. I've been playing with my Christmas present today. Due to the rain I was working in the car port. All the neighbours are away and the ones that are around are far too happy to worry about a little noise now and then.

It was a good day. I managed to get all the pre finished off and got the long side on and the inner Dawg leg... Dawg.

Photos attached...
Enjoy while I have a drink and some dinner.

Much love to yah all!
Attachments
I remember when I first opened this section up and there were rust holes where the weld points used to be. I decided to give the welds a final coat of Sikaflex for good measure. Yuel notice I gave it a lovely coat of baby blue> I'm just using up all the rattle cans on the garage shelf.
I remember when I first opened this section up and there were rust holes where the weld points used to be. I decided to give the welds a final coat of Sikaflex for good measure. Yuel notice I gave it a lovely coat of baby blue> I'm just using up all the rattle cans on the garage shelf.
Long side IN! I'm so please to close that side off finally. The butt weld is nice and neat. Everything level and tight.
Long side IN! I'm so please to close that side off finally. The butt weld is nice and neat. Everything level and tight.
Plug welds going good.
Plug welds going good.
Dry fit and cramp up. I just plugged the original spot welds. Using a drill bit which I ground down to one degrees so it would drill all the way through the new dog leg.
Dry fit and cramp up. I just plugged the original spot welds. Using a drill bit which I ground down to one degrees so it would drill all the way through the new dog leg.
This is a great feeling getting this little bugger in.
This is a great feeling getting this little bugger in.
Dog leg lined up pretty good. I'm pleased.
Dog leg lined up pretty good. I'm pleased.
Inner Dog leg tacked in.
Inner Dog leg tacked in.
Long side all tacked on nicely. I wanna finish it but I don't wanna run out of filler sticks over the holidays. So I'll just leave it tacked and prime with Cold Gal.
Long side all tacked on nicely. I wanna finish it but I don't wanna run out of filler sticks over the holidays. So I'll just leave it tacked and prime with Cold Gal.
Starting to look like a Kombi again...
Starting to look like a Kombi again...
Put the door on to check all the gaps. Looking good.
Put the door on to check all the gaps. Looking good.
---------
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
paul willans
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Re: ... And so it begins.

Post by paul willans »

Looking good mate
clk500 AMG
64 s Notch
57 Boronia Brown bus
59 Pmg ute
62 Beryl Green bus
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Fathermarc
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Re: ... And so it begins.

Post by Fathermarc »

Cheers Paul. :wink:

131226_Resto

This morning was a little rain again and the skies didn't look to promising so I decided to stay under cover of the car port. which means I can't grind (thinking of the neighbors) That doesn't bother me as I needed to shut off the dog leg and with the whole day ahead of me I had the luxury of taking my time. I talk you through the snaps.
Attachments
Right after all that plugging this needs a damn good grinding. Heads up.. You don't need to add so many plugs near the bumper braket as there are drainage points here and the bumper bracket gets welded to the outer skin anyway.
Right after all that plugging this needs a damn good grinding. Heads up.. You don't need to add so many plugs near the bumper braket as there are drainage points here and the bumper bracket gets welded to the outer skin anyway.
I checked the gap between the cab floor and the dog leg outer skin with an old piece of door rubber. I   plugged welded the outer skin at both points of contact.
I checked the gap between the cab floor and the dog leg outer skin with an old piece of door rubber. I plugged welded the outer skin at both points of contact.
Before closing off the A-Pillar I gave the insides a good spraying with the cold Gal and a good coating of Enamel
Before closing off the A-Pillar I gave the insides a good spraying with the cold Gal and a good coating of Enamel
All finished a coat of Cold Gal on the spot welds ready for a grinding tomorrow.
All finished a coat of Cold Gal on the spot welds ready for a grinding tomorrow.
...And inside the dog leg is tacked in place. A little clean up and a smidgen of Sikaflex and she'll be good to go.
...And inside the dog leg is tacked in place. A little clean up and a smidgen of Sikaflex and she'll be good to go.
Check for line up...
Check for line up...
The Bumper bracket is welded to the outer skin of the dog leg as per the original.
The Bumper bracket is welded to the outer skin of the dog leg as per the original.
Finally the door goes on for a final check. All lines up perfectly. Tres Bon!
Finally the door goes on for a final check. All lines up perfectly. Tres Bon!
---------
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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