131227_Resto
Don't know where the time went today.
I've begun work on the Near Side today. I thought I was going to start at the rear wheel arch but instead my attention was drawn to the front wheel arch and B-Pillar. I chopped out the outer skin of the front wheel tub to find that the jacking point section behind it was also in need of repair. So that's where I started. Then I cut out the B-pillar in sections as I don't wanna replace the original metal if it's in good shape. Though when I started picking through I noticed it all was in need of replacing. The B-pillar is an interesting combination of three parts. I managed to clean everything up ready for installation tomorrow.
Take a look at the images while I pop open a cold one.
... And so it begins.
Moderators: warb, Rawdyn, Leroy, byronbus, Tonz Magonz, dmb
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Fathermarc
- DSKer
- Posts: 285
- Joined: Thu Mar 21, 2013 6:25 pm
Re: ... And so it begins.
- Attachments
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- Just look how bad that A-pillar is. The floor above it needs repair to. You may notice the new floor in the image. I removed the fiber glass last night. It was a big piece as large as two hands. Luckily the rot in the floor is smaller. About the size of a match box right above the A-Pillar. So I only need a small patch from the new panel. I'm very pleased 'Cos the new pressing is not identical to the original. Now I can keep the original floor as a whole.
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- The short side was where I thought I was going to start today but after a little think I decided that I needed the Cargo Sill in place before I finish this little bit off.
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- The B-Pillar looked OK when I first had a look. Then When the Sill was removed. I realised just how rotten it was.
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- The new A-pillar section looks better than the rust eaten old section. We are getting somewhere!
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- NS B-Pillar at he weld point for the inner dog leg. Both side where like this. I think moisture builds up at this point. A design flaw. Perhaps a drainage point would be a good idea? Anybody else have any thoughts on prevention?
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- NS front wheel tub - I removed all the Sound deadener and filler to reveal the rot and ascertain where the the good solid steel was.
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- This is the repair I made to the Jacking point sides. Before I closed it off I gave it a soaking of rust converter. I will give the internal a healthy coat of Cold Gal and Enamel later on after the rust converter has done it's work.
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- I like looking at the Off Side. It makes me smile and make me feel positive. It is starting to look like a Kombi once more.
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- I haven't taken a photo of the front for some time. Jacked up while I work on the front wheel arch. The LHS new section is a feast for the eyes.
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- I offer the cargo sill up to guage where to make the cut for the inner B-Pillar section.
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Fathermarc
- DSKer
- Posts: 285
- Joined: Thu Mar 21, 2013 6:25 pm
Re: ... And so it begins.
131228_Resto
I gave myself four days to finish off this side. I think it's going to be a little longer perhaps five or six. There was a lot of chopping and preparation. Lots of rust that needed cutting out and internals that needed treating. Welding the panels into place is the final bit . It's all the preparation that needs to be done first. There's no point rushing any of these jobs. Most of this stuff I never want to see again for a long time so preparation is the key. Rust Eater, fish oil, primers, enamels and then a dry assembly, cut, tap, cramp and check. Then Weld.
So today I installed the Inner box section to the cargo sill and finished off the B-pillar. It really doesn't sound a lot but there's eight hours right there.
Time for a cold one while you peruse the images.
I gave myself four days to finish off this side. I think it's going to be a little longer perhaps five or six. There was a lot of chopping and preparation. Lots of rust that needed cutting out and internals that needed treating. Welding the panels into place is the final bit . It's all the preparation that needs to be done first. There's no point rushing any of these jobs. Most of this stuff I never want to see again for a long time so preparation is the key. Rust Eater, fish oil, primers, enamels and then a dry assembly, cut, tap, cramp and check. Then Weld.
So today I installed the Inner box section to the cargo sill and finished off the B-pillar. It really doesn't sound a lot but there's eight hours right there.
Time for a cold one while you peruse the images.
- Attachments
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- The work shop.
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- Ready to weld this section in position.
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- The inner box section marked out and cramped in position after a arduous couple of hours preparing all the box sections behind.
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- I tried to line the four pieces up together (two shown) but they just didn't want to line up properly. It had me scratching my head.
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- Here you can see that the Cargo sill apears to have been pressed with the top edge leading in. I think a cut, tap and weld should bring it back in line. Everything else so far from Klassic Fab has been a good fit.
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- God it's goo to see the Cargo sill bag in place. although not welded yet.
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- The sill was held in place while I got the B-pillar all lined up. I will have to cut and tap the sill at each end. The seem not have been pressed at 90 degrees. It had me for an hour or so until I worked it out.
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- B-Pillar done!
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Fathermarc
- DSKer
- Posts: 285
- Joined: Thu Mar 21, 2013 6:25 pm
Re: ... And so it begins.
131228_Resto
I'm quickly running out of gas. I hope that BOC are open tomorrow. With that in mind I tried to be a frugal as possible tack welding only. It was time to finish of the front wheel tub and the top of the B-pillar. After that I decided to see just how bad the floor was. I ground away the top coats from top and underneath. The underneath was in better shape than on top. Must have been a leak some where allowing moisture to sit in the foot well. Probably from that dodgy A-pillar. So after much deliberation I cut a nice large new section in, using the pressing as the weld line. That way i can blend it in easier. But before I could weld the floor pan in I need to address the A-Pillar. Replacing the inner section would give me something solid to join the floor pan to. Once that was done the floor pan went in.
I didn't run out of gas so I went back over everything I tacked in today and finished of the welds. In the end I had a smidgen of gas left. I was half tempted to carry on and have a go getting the first part of the wheel arch in. Sadly i ran out of time and energy. But it's coming together.
Enjoy the images... I THINK IT'S BEER O' CLOCK!
I'm quickly running out of gas. I hope that BOC are open tomorrow. With that in mind I tried to be a frugal as possible tack welding only. It was time to finish of the front wheel tub and the top of the B-pillar. After that I decided to see just how bad the floor was. I ground away the top coats from top and underneath. The underneath was in better shape than on top. Must have been a leak some where allowing moisture to sit in the foot well. Probably from that dodgy A-pillar. So after much deliberation I cut a nice large new section in, using the pressing as the weld line. That way i can blend it in easier. But before I could weld the floor pan in I need to address the A-Pillar. Replacing the inner section would give me something solid to join the floor pan to. Once that was done the floor pan went in.
I didn't run out of gas so I went back over everything I tacked in today and finished of the welds. In the end I had a smidgen of gas left. I was half tempted to carry on and have a go getting the first part of the wheel arch in. Sadly i ran out of time and energy. But it's coming together.
Enjoy the images... I THINK IT'S BEER O' CLOCK!
- Attachments
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- NS front wheel tub - new section tacked in place.
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- Top of the A-Pillar new section cramped in place ready to tack weld.
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- As you can see the foot well although solid was pitted. So I cut it back to the good stuff.
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- Cut the old foot well our along the pressing.
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- I couldn't resist getting the dog leg cramped in place.
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- NS foot well tacked in!
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- Coming on nicely
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- NS foot well Done!
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- Inner A-Pillar Done!
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- NS wheel tub done!
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Cam Biscuit
- DSKer
- Posts: 1523
- Joined: Sun Feb 26, 2012 4:56 pm
- Location: Radelaide
Re: ... And so it begins.
You are setting a cracking pace!
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Fathermarc
- DSKer
- Posts: 285
- Joined: Thu Mar 21, 2013 6:25 pm
Re: ... And so it begins.
131230_Resto
Got my first complaint today from Barbara next door. Poor love her nerves must be in tatters by now. I told her it will be completed by the end of the week. So I've set my self a dead line. Complete the rest of the cutting and welding by the end of the week. The gauntlet has been thrown down. GAME ON!
Now I'm just Writting sorry notes and attaching them to a couple of bottles of vino for all the neighbors. If one has said something then they're all thinking the same. Couple of cases of wine is cheap at half the price.
Oh yeh BOC was open...Had to take a visit first thing this morning. On the way back collected a Christmas present from the Post Office (Aus Post). Got myself a nice looking Sharpbuild Porsche fan housing for the Type IV engine conversion. OOOOOH YAH!
Got home at about 10am and managed to get the front wheel arch in.
Enjoy the images while I play father Christmas.
Got my first complaint today from Barbara next door. Poor love her nerves must be in tatters by now. I told her it will be completed by the end of the week. So I've set my self a dead line. Complete the rest of the cutting and welding by the end of the week. The gauntlet has been thrown down. GAME ON!
Now I'm just Writting sorry notes and attaching them to a couple of bottles of vino for all the neighbors. If one has said something then they're all thinking the same. Couple of cases of wine is cheap at half the price.
Oh yeh BOC was open...Had to take a visit first thing this morning. On the way back collected a Christmas present from the Post Office (Aus Post). Got myself a nice looking Sharpbuild Porsche fan housing for the Type IV engine conversion. OOOOOH YAH!
Got home at about 10am and managed to get the front wheel arch in.
Enjoy the images while I play father Christmas.
- Attachments
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- The inner dog leg was tacked in making sure that everything lined up nicely.
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- Cramp up the wheel arch as dry run. Looking sweet.
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- Tack tack tack.
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- Door went in to check the alignment. Not bad. It's all flush but there's a birds mouth between the wheel arch and the bottom of the door.
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- Near Side wheel arch in bur just needs a few tacks on the inside of the wheel tub and the A-Pillar. Notice the birds mouth of the door. I think this is going to need a remedy. The wheel arch couldn't go up any more. I'm guessing the door is the culprit here.
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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dawerks
- DSKer
- Posts: 202
- Joined: Fri Feb 04, 2011 3:11 am
- Location: Kold Kanada!
Re: ... And so it begins.
You're gonna be done in a week!! 
Keep it up! You have the juice now!
Keep it up! You have the juice now!-
Fathermarc
- DSKer
- Posts: 285
- Joined: Thu Mar 21, 2013 6:25 pm
Re: ... And so it begins.
131231_Resto
Here's wishing you all a Happy New Year!
Last night I was thinking about the Near Side Dog Leg. I wasn't that pleased with it. I made a simple mistake and followed the line of the floor pan. The problem was that the pressing was 10mm short on the leading edge. So following it pulled the dog leg in 10mm. So first thing this morning I unpicked the spot welds and forced it out by 10mm this time with the door in place. It meant that the floor pan was short of the dog leg but nothing a bit of weld couldn't fill. So I built it all back up and was much happier with the results. It set me back half a day but I couldn't carry on until it was sorted.
After that I tackled the rust in the floor pan just above the short cill and the chopped out the C-Pillar. This time being extra careful to fit everything in it's place before welding the C-Pillar in place. As I get closer to shutting everything up I realise that i's doubley important to fit all the corresponding panels and supports in it's place before welding.
We're getting closer to finishing off the cutting new metal in. The Kombi is looking whole again.
Enjoy the images while I kick back with a Bevvy!
Here's wishing you all a Happy New Year!
Last night I was thinking about the Near Side Dog Leg. I wasn't that pleased with it. I made a simple mistake and followed the line of the floor pan. The problem was that the pressing was 10mm short on the leading edge. So following it pulled the dog leg in 10mm. So first thing this morning I unpicked the spot welds and forced it out by 10mm this time with the door in place. It meant that the floor pan was short of the dog leg but nothing a bit of weld couldn't fill. So I built it all back up and was much happier with the results. It set me back half a day but I couldn't carry on until it was sorted.
After that I tackled the rust in the floor pan just above the short cill and the chopped out the C-Pillar. This time being extra careful to fit everything in it's place before welding the C-Pillar in place. As I get closer to shutting everything up I realise that i's doubley important to fit all the corresponding panels and supports in it's place before welding.
We're getting closer to finishing off the cutting new metal in. The Kombi is looking whole again.
Enjoy the images while I kick back with a Bevvy!
- Attachments
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- Without thinking I followed the line of the floor pan when pulling the Dog Leg in. This meant that the dog leg stepped in of the door and when viewed from the inside there was a 15mm gap between the floor and the closed door.
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- I had to cut a birds mouth in the Inner A-Pillar so the at dog leg would line up .
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- Unpicked the 10 spot welds to pull the dog leg out to line up with the door. You can see how much I had to move the dog leg out.
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- The Near Side door lines up better on the outside.
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- The door now lines up much better on the inside too.
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- Near side almost complete.
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- Off Side done!
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- Viewed from the inside. The rust was cut out of the floor pan just above the Short sill and new steel welded in place before tapping into shape.
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- C-Pillar cut in and ready for tacking but first get the other pieces in place before any welding.
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- Short side cramped in place whilst I weld in the C-Pillar. Lines up with the cargo door pretty sweet but is a couple if mill too long on the wheel arch. I will have to roll that round when it's all welded in place.!
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Fathermarc
- DSKer
- Posts: 285
- Joined: Thu Mar 21, 2013 6:25 pm
Re: ... And so it begins.
Some more snaps from today...
I know how I like to look at images of others work.
I know how I like to look at images of others work.
- Attachments
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- Looking good with the doors in.. Just need to get that nose section finished off.
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- This rear quarter is coming along. another few hours of tapping should shape this back TO IT'S FORMER SHAPE. i MAY HAVE TO CUT THE CREASE OUT AND WELD IN A NEW SECTION. Sorry Caps locked on.
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- There is still the long side to weld up properly.
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- Will be nice not to have any rust.
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- I can't wait to start preparing the body work.
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- Oh yeah... I can see the finish line. (Of this part)
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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Ian 68
- DSKer
- Posts: 1373
- Joined: Sat May 02, 2009 9:58 pm
- Location: Caloundra, QLD
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Fathermarc
- DSKer
- Posts: 285
- Joined: Thu Mar 21, 2013 6:25 pm
Re: ... And so it begins.
140101_Happy New Year!
I stayed up late last night like everyone else in the World. Had a few beers and watched the fireworks explode over Sydney.
This morning I woke really early and submitted a few more images on this thread then. After breakfast I made a few phone calls the the relatives back in the UK.
The reason I'm telling you all this is because I'm building up to my excuse at not having achieved very much today.
I manged to get the Cargo door Sill (Rocker) in and the short side. I was hoping to get a heck of a lot more done. Still every little counts. I am whacked.
The Klassic Fab panels have been great so far but the Cargo door sill wasn't turned over at the ends at 90 degrees. I had to cut, tap and weld them into shape.
Take a look at today's images while I drink a cold beer.
I stayed up late last night like everyone else in the World. Had a few beers and watched the fireworks explode over Sydney.
This morning I woke really early and submitted a few more images on this thread then. After breakfast I made a few phone calls the the relatives back in the UK.
The reason I'm telling you all this is because I'm building up to my excuse at not having achieved very much today.
I manged to get the Cargo door Sill (Rocker) in and the short side. I was hoping to get a heck of a lot more done. Still every little counts. I am whacked.
The Klassic Fab panels have been great so far but the Cargo door sill wasn't turned over at the ends at 90 degrees. I had to cut, tap and weld them into shape.
Take a look at today's images while I drink a cold beer.
- Attachments
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- Short side
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- The KF Rocker wasn't turned over 90 degrees I had to chop, tap and weld so that it would line up OK.
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
-
Fathermarc
- DSKer
- Posts: 285
- Joined: Thu Mar 21, 2013 6:25 pm
Re: ... And so it begins.
One last photo for today Near side DONE!
Time to celebrate.... But not to much I have the front to do tomorrow.
Time to celebrate.... But not to much I have the front to do tomorrow.
- Attachments
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- Near side done!
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
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scotty*85vw
- DSKer
- Posts: 1278
- Joined: Thu Sep 09, 2010 9:34 pm
Re: ... And so it begins.
he's on a roll
Giddy Up. Best thing about a holiday!!
Giddy Up. Best thing about a holiday!!
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warb
- Mod
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- Location: Penrith, Nsw, Australia
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Re: ... And so it begins.
looks good.. love to have a pop top, where's my nibbler... .. .
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Fathermarc
- DSKer
- Posts: 285
- Joined: Thu Mar 21, 2013 6:25 pm
Re: ... And so it begins.
scotty*85vw wrote:he's on a roll
Giddy Up. Best thing about a holiday!!
I was just reading your Ute thread. Got to the part where your taking time off work (sorry I mean working from home) and thinking that's exactly how I've been going. You got that little monster on four wheel pretty quick. Good work sunshine.
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58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox
-
Fathermarc
- DSKer
- Posts: 285
- Joined: Thu Mar 21, 2013 6:25 pm
Re: ... And so it begins.
warb wrote:looks good.. love to have a pop top, where's my nibbler... .. .
Cheers Fella... We plan on using it as a camper in the near future. The intension was to have used it this summer, think with all the plans I have... We're going to miss summer this year.
Last edited by Fathermarc on Wed Jan 01, 2014 9:11 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
58 Kombi
69 Soft top beetle
65 Izh Jupiter with side car
2006 Ducati 999 Xerox