TheSamba.com :: View topic - Front nose job. PM me if you don't want to post

Mon Mar 15, 2010 7:00 pm

So, I'm trying to get my balls big enough to tackle the hardest part of the bus. I'd like to be be chirping gears and pulling brodies at a stop light with one of my split bus friends on the samba this summer with my stock 1600 dp and stock transmission :D , so I'd appreciate any responses or PM's on how to proceed. Here is what I have to do going forward.

1. Drivers side a-pillar graft between lower/upper hinges - complete
2. Lower windshield section - Gerson
3. Donor nose
4. Lower 8 inches of Gerson nose
5. Lower outer valance - gerson

So I'm in the process of fitting sections 2-5. I'd love some advice on how to proceed. I'm hesitant to plug weld the lower windshield section at the bottom of the front window frame. Should I get a spot welder? The lower valance fits pretty good. I plan on the following

1. Weld in the lower windshield section. I have removed the paint from the backside of this section.
2. Weld in the lower valance.
3. Fit the donor nose, and cleko it to the lower windshield section
4. Hack off the bottom of my donor nose and fit the 8 inches of the gerson section.

I'd appreciate any tips.

Mon Mar 15, 2010 8:25 pm

Sounds like you got it all figured out. Perhaps you could do a little test fit and adjust as needed before you weld. Do whatever it takes to grow your balls big enough because I feel confidence is key.

I don't know what type of spot welder they used at the factory though a "pinch style" spot welder will not fit for the windshield frame to the nose. When I did my nose the toughest part was making a tight fit between the windshield frame and nose. After the fact a buddy suggested to drill out every other plug weld all the way through the windshield frame and nose. Then pop rivet these every other holes to tighten the frame and nose. Plug weld between the pop rivets. Drill out the pop rivets and then weld those holes completely. I think this is what I'll do on my next nose job.

Be careful as well while plug welding so that you don't burn the metal away between the plug weld hole and lower windshield frame. I did this on a few of my welds. Hope this makes sense and helps.

Mon Mar 15, 2010 8:35 pm

looks like you have a pretty good handle on that project. One thing I do when I'm doing plug welds is depress the trigger to make sure I have sheilding gas at the tip of the nozzle quickly cut the excess wire and drop a quick weld down.
If you leave the "ball" on the end of the wire it gives you a not so nice start on these little welds. And after taking a break or making adjustments the shielding gas is not right up at the nozzle.
Of course make sure the two pieces are clamped tight and clean.

Mon Mar 15, 2010 9:21 pm

You seem like the type of guy that should be answering these questions not asking them. I would think the hard part is over. happy welding!

Mon Mar 15, 2010 10:45 pm

I like to use self tapping screws that are used for metal stud frameing when clamps can't be used.

Tue Mar 16, 2010 7:21 am

Wouldn't it be easier to do the A-pillar graft before welding in the front clip?

Tue Mar 16, 2010 10:41 am

X2 on the metal stud frame screws.
Only predrill the top overlapping metal and let the screw self tap the bottom of the two overlapping matal. It will pull together tight.

Tue Mar 16, 2010 10:46 am

TimGud wrote: Wouldn't it be easier to do the A-pillar graft before welding in the front clip?

Yes it would. The A-pillar graft is already complete. You can barely tell the pillar was replaced.

Tue Mar 16, 2010 10:48 am

brettsvw wrote: X2 on the metal stud frame screws.
Only predrill the top overlapping metal and let the screw self tap the bottom of the two overlapping matal. It will pull together tight.

I'll probably use these or cleko the nose to the lower windshield by drilling through the bottom part of the window frame.

Tue Mar 16, 2010 1:35 pm

I just want to compliment you on the use of the word "brodies" which I have not heard for years.

Tue Mar 16, 2010 1:48 pm

busmike wrote: I like to use self tapping screws that are used for metal stud frameing when clamps can't be used.
Never thought of using self tapping screws. Sounds like a great idea.

Tue Mar 16, 2010 5:16 pm

Major Woody wrote: I just want to compliment you on the use of the word "brodies" which I have not heard for years.

That is a direct quote from the movie Joe Dirt. I love that movie.

Courtesy of urbandictionary.com

A brody is essentially a half doughnut, essentially a U-turn but in a much tighter radius because the rear wheels have broken loose, thus steering the car. A 180 burnout, if you will. A brody may be executed either from a stop or while in motion, as long as you travel in the opposite direction when the manuever is completed (i.e. not driving backwards on the freeway because you're a "fast & furious" idiot).

While a full 360(+) doughnut is pretty much useless except for showing off, pulling a brody can be used in any situation in which the driver needs to get the hell out of dodge quick. Whether it be fleeing from police, an army of zombies, or your mother after curfew, a brody will get the job done, and guarantee that you'll look good doing it.

Warning: not for pussy front wheel drive cars, you'll look like a dumbass trying to U-turn too enthusiastically. With any luck, you'll leave a mark on the curb. Dumbass.

Tue Mar 16, 2010 9:21 pm

bherder wrote: I'd like to be be chirping gears and pulling brodies at a stop light with one of my split bus friends on the samba this summer]

Maybe a trek to the Helvetia Tavern, since it's in your neck of the woods?

Tue Mar 16, 2010 10:15 pm

bherder wrote: Major Woody wrote: I just want to compliment you on the use of the word "brodies" which I have not heard for years.

That is a direct quote from the movie Joe Dirt. I love that movie.

Courtesy of urbandictionary.com

A brody is essentially a half doughnut, essentially a U-turn but in a much tighter radius because the rear wheels have broken loose, thus steering the car. A 180 burnout, if you will. A brody may be executed either from a stop or while in motion, as long as you travel in the opposite direction when the manuever is completed (i.e. not driving backwards on the freeway because you're a "fast & furious" idiot).

While a full 360(+) doughnut is pretty much useless except for showing off, pulling a brody can be used in any situation in which the driver needs to get the hell out of dodge quick. Whether it be fleeing from police, an army of zombies, or your mother after curfew, a brody will get the job done, and guarantee that you'll look good doing it.

Warning: not for pussy front wheel drive cars, you'll look like a dumbass trying to U-turn too enthusiastically. With any luck, you'll leave a mark on the curb. Dumbass.

So thats kinda what I was doing when I pulled the e-brake at high speed in my 84 Toyota Celica? Good times, esp on gravel roads with about 20 beers in me...

Wed Mar 17, 2010 6:35 am

sfspanky wrote: bherder wrote: I'd like to be be chirping gears and pulling brodies at a stop light with one of my split bus friends on the samba this summer]

Maybe a trek to the Helvetia Tavern, since it's in your neck of the woods?

Ooooooo, I love the Helvetia Tavern. Double cheeseburger with onion rings and beer. I live super close to that place.

Wed Mar 17, 2010 7:32 am

Major Woody wrote: I just want to compliment you on the use of the word "brodies" which I have not heard for years.

...and catching scratch.

I think the specialty spot welder would be cost prohibitive for just that windshield section.

Wed Mar 17, 2010 9:44 am

BarryL wrote: Major Woody wrote: I just want to compliment you on the use of the word "brodies" which I have not heard for years.

...and catching scratch.

I think the specialty spot welder would be cost prohibitive for just that windshield section.

From what others have said, I think I'll plug weld with 3/8th inch holes on the inner channel of the windshield section to the dash lip.

Wed Mar 17, 2010 10:49 am

Major Woody wrote: I just want to compliment you on the use of the word "brodies" which I have not heard for years. +1 Although I would not have expected to hear it used with a bus, lol!