1958 A T2 coupe restoration

jan_t4 · Posted: Tue Sep 23, 2014 1:54 pm Post subject:

Some minor progress.

Some final Expoxy on new panels.

Image may have been reduced in size. Click image to view fullscreen.

Need to build the side door window frame lower brackets. Just have one rusty sample and started building 4 of those for A-model window frame without front vent window.

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My 356A T2 Resto.Blog: http://www.thesamba.com/vw/forum/viewtopic.php?t=579964

jan_t4 · Posted: Tue Sep 23, 2014 2:14 pm Post subject:

Replaced the rear lower engine surrounding panel for A-Model 4-cam engine.

Testfitted "normal" engine surrounding panel and removed some broken bolts. Some litte welding and planishing necessary.

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blink · Posted: Fri Sep 26, 2014 1:06 am Post subject:

Looking amazing mate

Keep up the great work. Love watching it come together!!

harveyjoe · Posted: Mon Oct 06, 2014 3:55 pm Post subject:

This is some of the best work I have ever seen! Absolutely amazing. I am using these on my 66 beetle restoration and I smile every time I see an update. Cool

jan_t4 · Posted: Thu Oct 23, 2014 12:55 am Post subject:

Hi again, a long time I was busy, but now there is a little progress again.

A friend of mine helped me straightening the rear panel with his Eckold.

We closed the exhaust outlets, because they where too big and rusty. Final adjustments have to be done on the car.

All other holes where closes, except the ones for Porsche-Script and shine up light.

Started Spotwelding with no gap to fix it in position.

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My 356A T2 Resto.Blog: http://www.thesamba.com/vw/forum/viewtopic.php?t=579964

roy mawbey · Posted: Thu Oct 23, 2014 9:17 am Post subject:

WOW Jan,

That rear end fitment and line up is amazing so far. You must be very pleased with that. Looking forward to the finishing process of that welding. Will be nice to see how you approach that.

Roy
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Roy
RHD356A super75 106954

jan_t4 · Posted: Mon Oct 27, 2014 2:03 am Post subject:

When the driver door was closed, it always stuck a little bit and the rear door area was rubbing at the striker plate. After inspecting the replaced Lockpost, I realized, that the lower area for the striker plate was not low enough. On the original Lockpost the striker plate was in vertical level with the Lockpost. On the replacement panel, it stands some Millimeters outwards and it was too narrow for the door when closing.

So I cut the area, bent it a little backwards and rewelded it again. Needs to be finally grinded.

Original Codriver side - striker plate is equal level.

Replacement Driver side - striker plate is not equal level, more outwards.

Cutting ...

... benting rearwards (needs to be more than in the picture) ...

... rewelding.

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My 356A T2 Resto.Blog: http://www.thesamba.com/vw/forum/viewtopic.php?t=579964

jan_t4 · Posted: Wed Oct 29, 2014 2:18 am Post subject:

Front fenders are next area to repair. I used the repair panels with a preformed rear edge - which fits okay. Just little adjustments at the outer ends are necessary.

This was the old panel, which somebody already repaired in a bad way.

Cut out a smaller area to test fit.

After final adjustment and reforming, I marked the line to finally cut the original fender and fit the replacement panel seamlessly (in theory Very Happy

)

Final spotwelding with a gap. Later this will be WIG-welded without extra material.

This was one area, I had most respect for - because of the 3D-structure and smooth round curvature. Fits really nice - I realy like it Very Happy

Other side will be more complicated, because the area is much bigger and the replacement panel needs to be wider up to middle of wheel arch.
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My 356A T2 Resto.Blog: http://www.thesamba.com/vw/forum/viewtopic.php?t=579964

roy mawbey · Posted: Wed Oct 29, 2014 6:12 am Post subject:

Jan,

I have looked a number of times at the fender repair. I have few questions:

1). The cowling or ( skuttle ) seems to look perfect now. Did your friend repair it and is it in final place. It looks almost like a new panel?

2). The fender where it meets the front door shut line seems to be short? The material for it to be turned over, is not there? ( Hard to explain sorry)

3).Likewise the fender wheel arch looks new? I know you can buy now wheel arch repair sections that are 'wired' Did you do that or is it original? I think there is some small rust damage where the fender meets the hood opening? Is that correct.?

Looks a very difficult repair. I really like your clamping tools though.

Well done!!

Roy
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Roy
RHD356A super75 106954

jan_t4 · Posted: Wed Oct 29, 2014 11:58 am Post subject:

Hi Roy,

dont' know, if I got you right - but I will try:

1) you mean the part below the windscreen, which you measured the profile for me? If yes - it is the old original panel, which was straightened and equalized. Didn't I show pictures? I will check and bring pictures here otherwise. It is really nice and straight now. It's not finished yet. Could be, that I will have to "shorten" it in the center area - but will tell in detail later.

2) The material is already turned over around 15mm. You can't see it in the pictures. I will make a detailed picture next time. You get an impression on the following picture:

So the fender-meets-door area is ready. The "turned-over strip" sits on the inside of the rear front wheel house panel - like originally from Porsche. Ready for spotwelding together.

3) Yes, there is a small rust area where the fender meets the hood. The whole fender and front mask were just fixed temporarily with a few spotwelds and metal screws to align everything. Now the fender repair panel is fixed in place and the whole front is dismantled again. The fenders will be WIG-welded "outside" of the car and straightened and planished (Eckold). Afterwards testfitting again and welding body-fender-frontmask-fender-body together.

Unfortunately my camera battery was over, so I could not make any pictures of dismantled front.

The wheel arch is original yet, but on the driver side I need a repair panel. Where did you see wheel arch repair panels already wired? I will think about buying one?

Hope that answers your questions? Jan
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My 356A T2 Resto.Blog: http://www.thesamba.com/vw/forum/viewtopic.php?t=579964

jan_t4 · Posted: Fri Oct 31, 2014 11:11 am Post subject:

Here you can see the turned over material and the final WIG-welding of front fender repair panel.

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My 356A T2 Resto.Blog: http://www.thesamba.com/vw/forum/viewtopic.php?t=579964

roy mawbey · Posted: Sat Nov 01, 2014 5:18 am Post subject:

Jan,

Thanks for the answers its clear now to me. I did not see the ' cowling' repair photos of the panel under the windscreen. Maybe I missed the page they are on?

The wheelarch repair panels are being sold by www.karmannkonnection.com
These ' wired' repair panels are new products by karmannkonnection for all 356 models. They were listed several months ago in ' Classic Porsche ' magazine and are £90-00 each plus VAT.

I tried to find them on the website above but not yet listed. For your info you have wired arch then approx 60mm of flat steel fender ( wing ) material so you can weld to the existing fender.

The website has a ' contact page' on there you enter your details and request and they will forward info to you.

They already stock Simonsen 356 panels possibly these wheel arch repair items are made by them?

Roy
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Roy
RHD356A super75 106954

jan_t4 · Posted: Sat Nov 01, 2014 12:39 pm Post subject:

Hi Roy, thanks for the answers. I did not find them on Karman-Page - like you. Will give them a call or email on Monday. Checked the Simonsen-Page but there are no wheel arch repair panels listed. Restoration Design and Trevor Hammerworks have not listed repair panels like that.

Does anybody know where to get "Front Wheel Arch repair panels"?

Thanks, Jan
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My 356A T2 Resto.Blog: http://www.thesamba.com/vw/forum/viewtopic.php?t=579964

jan_t4 · Posted: Sun Nov 02, 2014 1:35 pm Post subject:

Same procedure on driver side - repair front fender. Problem on driver side was a much bigger bad older repair. Had to make the repair panel about 30cm wider.

Area before repair ...

... cut out old repair ...

... big hole in front fender.

I used some tubes of different diameter to bend around the repair panel to fit the curvature of orignal front fender. The repair panel has to sit flat without tension on the old original fender. Otherwise the new stronger repair panel could distort the smooth surface.

Finally spot welded in place to fix for WIG-welding outside after removing from the car again.

Nearly without a gap between original and repair panel - good for WIG-Welding without extra material.

Does anybody know where to get "Front Wheel Arch repair panels"?
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My 356A T2 Resto.Blog: http://www.thesamba.com/vw/forum/viewtopic.php?t=579964

James Davies · Posted: Mon Nov 03, 2014 6:57 am Post subject:

Trevor makes full fenders

http://www.356panels.com/fenders.html

but I'm sure he'd be happy to make you just the lower part with the beaded edge if that's all you need. He's always happy to do custom work, and this would be pretty easy for him as he already produces the complete fender.

I would contact him and see what he can do for you. His work is very good.

jan_t4 · Posted: Mon Nov 03, 2014 7:17 am Post subject:

Hi James,

I already asked him a few days ago. His answer was:

Jacks · Posted: Mon Nov 03, 2014 9:18 am Post subject:

http://www.lazzemetalshaping.com/index.cfm/page/pt...prd274.htm
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Jack Staggs
Actual name

roy mawbey · Posted: Mon Nov 03, 2014 12:51 pm Post subject:

Jan,

Did KarmannKonnection not let you know about the wired repair panels??

Would you like me to phone them for the info and if they can ship these items to Germany. I expect they have a specialist make them. I have looked before on the machine that Jack showed on his last post. I wondered for years how they did it.

Maybe they could mail some info so I can forward it to you?

Let me know if I can help

Roy
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Roy
RHD356A super75 106954

jan_t4 · Posted: Tue Nov 04, 2014 1:12 am Post subject:

Hi Roy, I wrote an email to KarmannKonnection yesterday morning, but did not get an answer yet. I also asked Joma-Parts and did not get an answer yet.

It might could help, if a "local" calls at KarmannKonnection. If you want to try to phone them, it might help to get some basic informations, if they generally have these parts.

Roy, thanks for your help, Jan
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My 356A T2 Resto.Blog: http://www.thesamba.com/vw/forum/viewtopic.php?t=579964

roy mawbey · Posted: Tue Nov 04, 2014 11:13 am Post subject:

Jan,
I have spoken to Karmann Konnection about the 356 wheel arch 'wired' repair panels and indeed they can supply them. They are producing these panels (probably through a sub contractor ) and Simonson are not involved. So, they are only available through KK. By the way they also produce now a set of steel door cappings with bushes to accept side screens ( curtains ) for Speedsters!

So I am sending them a request for a quote for wheel arch repairs for a 1958 356A T2. They told me parts can be shipped to Germany without problem.
As I told you a 'guide price' is £90- plus VAT. I guess you would not pay the UK VAT tax but pay your tax on arrival. I have asked him to include a photo of the parts on the offer. ( I wonder if I can then forward this to you by using your e-mail?)

I guess you will get a quote as well as you have asked. When I receive it I will advise.

Roy
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Roy
RHD356A super75 106954


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1958 A T2 coupe restoration
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