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'75 UK 1303 Build Thread
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beetlenut
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PostPosted: Thu Oct 30, 2014 5:58 pm    Post subject: Reply with quote

Nice work Dodgy! I think I had sympathetic Kidney pains looking at those photos! Nice to have photos to look back on. Once it's all painted you forget all the work under there!

Keep on rollin!
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Wetstuff wrote:
... I spend more time shaking it than directing it?! I get a pretty decent blast for 8sec. then have to shake it again.
- Words to live by right there!

My 74 Super rebuild thread: http://www.thesamba.com/vw/forum/viewtopic.php?p=6507104#6507104
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Dodgy
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PostPosted: Tue Nov 18, 2014 12:26 pm    Post subject: Reply with quote

So, no suprises, I took the 'more work' option.

Split the pattern panel

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


Dodgy wrote:
Knowing Klokkercrap, the gap between these panels is already rusty from new

Yep Evil or Very Mad

Pattern panel had no return lip around the inner panel recess, much less stiff, even before taking into account thinner material etc

Overlaid the two panels - both are aligned by the lower edge of the panel and the recess where the frame horn / damper mount fits against the panel.
Check out the different position of the body mount - red shows the position on the pattern part, blue on the original part.

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


People fit these pattern panels every day - how do they do it? They are so awful to be almost unusable really

Welded together - waiting for body mount to be fitted once in place on the body

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


Final fit - tacked the panel onto the body before dropping the body back onto the floorpan for final alignment of the body mount.

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

_________________
'75 1303 (current project) owned since 1989!
'72 Squareback - full resto completed 2008 - now sold
356 Speedster kit, completed 2005 - now sold


Last edited by Dodgy on Sat Jan 10, 2015 10:47 am; edited 1 time in total
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Dodgy
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PostPosted: Tue Nov 25, 2014 12:25 pm    Post subject: Reply with quote

Small update on progress...

Body dropped back on the floorpan, patched panel tacked on to fix position, body mount bolted in place (with rubber spacers) to set the alignment

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


All welded up, plug welds around panel and through body mount bracket
Coat of primer on (for now) - 100% solid again and looking factory fresh Very Happy

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


Next job - rusty wing mounting area I think.
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'75 1303 (current project) owned since 1989!
'72 Squareback - full resto completed 2008 - now sold
356 Speedster kit, completed 2005 - now sold
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JasonBaker
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PostPosted: Fri Nov 28, 2014 6:40 am    Post subject: Reply with quote

Your body work looks great. VW Logo
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Volks Wagen
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PostPosted: Fri Nov 28, 2014 10:49 am    Post subject: Reply with quote

Dodgy wrote:


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


Next job - rusty wing mounting area I think.


Hope this goes ok for you... mine looked like that and I went digging and had to do the fastening section with a replacement panel, as well as the lower wheel arch and up along about 30cm and in about 5-10, and lower rear quarter and the rear section of the heater channel... and the inner wheel arch at the bottom behind the body mounting bracket, and about a 10x20x20 triangle between the crescent vent and the wheel arch, and then back to the end of the roof drip rail to the engine compartment... The worst bits for me were trying to get the patch panel with the fasteners to fit with the rest of the car, and trying to re-create the 'waistline' on the rear quarter where I'd had to cut the shite out. Beware Shocked

Basically, the outlined areas were in various states of fooooked on mine:
Image may have been reduced in size. Click image to view fullscreen.


EDIT: just went back over your thread... you've been through the mill! I see you've encountered similar areas as I outlined and have fixed a lot of them. I hope this doesn't mean I'll find the same as you as I move forward towards the front of mine... Anxious
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1973 1303 with AB-motor - sporadic
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I'm definitely, probably, the worlds greatest lover.

Aithníonn ciaróg ciaróg eile.
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Dodgy
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PostPosted: Fri Nov 28, 2014 12:37 pm    Post subject: Reply with quote

JasonBaker wrote:
Your body work looks great. VW Logo


Thanks, I've just picked up tools & skills over the years by just getting on and doing it - practice makes perfect. Mostly it's being brave enough to try! I've got a few car builds under my belt now, and try to do a better job on each one. Plus having the luxury of time with this build, and less pressure to make do with short-cuts.

Volks Wagen wrote:


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




Yikes! Shocked Well I'm pretty sure that mine's not that bad. There's no sign of rot under the vent (so-called 'death foam') and the rust on the wing mounting face gets more superficial toward the top. I think it was mostly caused by me cleaning back previous rust in this area maybe 20 years ago, and not knowing back then how to prep the panel properly to stop it coming back. Hopefully this time round I'll be able to do a more thorough job!
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'72 Squareback - full resto completed 2008 - now sold
356 Speedster kit, completed 2005 - now sold
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houseofboyd
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PostPosted: Tue Dec 09, 2014 3:12 pm    Post subject: Reply with quote

Looking good! You do great work!
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vwkirb
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PostPosted: Tue Dec 09, 2014 4:02 pm    Post subject: Reply with quote

The interesting thing about "death foam" is that it does not hold/absorb water. Though it may keep some moisture close to the body.

I honestly think the majority of rust happens because of the wiring harness traveling through the body. It seems more often than not like that side is the damaged one.
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Volks Wagen
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PostPosted: Wed Dec 10, 2014 6:21 pm    Post subject: Reply with quote

vwkirb wrote:
The interesting thing about "death foam" is that it does not hold/absorb water. Though it may keep some moisture close to the body.

I honestly think the majority of rust happens because of the wiring harness traveling through the body. It seems more often than not like that side is the damaged one.


Like 'wet' electrons or something? Smile
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1973 1303 with AB-motor - sporadic
reconstruction as time permits, 1986 ex-Bundeswehr Doka - on the road again.

I'm definitely, probably, the worlds greatest lover.

Aithníonn ciaróg ciaróg eile.
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vwkirb
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PostPosted: Wed Dec 10, 2014 7:58 pm    Post subject: Reply with quote

Something like that, haha. I think if there is a leak water sticks around the harness. The rust on my car runs perfectly along that line. The foam itself is hydrophobic.
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Dodgy
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PostPosted: Thu Dec 11, 2014 12:45 am    Post subject: Reply with quote

Volks Wagen wrote:
Like 'wet' electrons or something? Smile


Is this the VW equipment of the Lucas wiring harness smoke that was fitted as standard into 60s and 70s British cars? Laughing Laughing

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

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'75 1303 (current project) owned since 1989!
'72 Squareback - full resto completed 2008 - now sold
356 Speedster kit, completed 2005 - now sold
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beetlenut
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PostPosted: Thu Dec 11, 2014 8:04 pm    Post subject: Reply with quote

vwkirb wrote:
Something like that, haha. I think if there is a leak water sticks around the harness. The rust on my car runs perfectly along that line. The foam itself is hydrophobic.


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


Mine was a little higher up on the rain gutter. The problem was that they used open-cell foam which did retain water.
_________________
scrapyards are for quitters
---------------------------------------
Wetstuff wrote:
... I spend more time shaking it than directing it?! I get a pretty decent blast for 8sec. then have to shake it again.
- Words to live by right there!

My 74 Super rebuild thread: http://www.thesamba.com/vw/forum/viewtopic.php?p=6507104#6507104
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Dodgy
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PostPosted: Wed Dec 17, 2014 10:38 am    Post subject: Reply with quote

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


Lower wing mounting area is now patched. I pressed recesses around each captive nut location in the replacement panel so it looks more factory and better matches the other holes that don't need repair. Another area that no-one but me will see!

Cut out the other thin / holed area, what's hiding behind the 'death foam'?

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


Wiring harness buried under the foam, I managed to miss it when cutting out the panel - phew!

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


And... NO RUST!

This is as bad as it gets on the inner panel, very superficial and localised

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


And about the same on the outer panel. Mostly the factory paint is still in place (photo is looking up into the access hole)

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


Once this access hole is patched up, that's the entire LH rear quarter complete! I'll call that a significant milestone! Very Happy
_________________
'75 1303 (current project) owned since 1989!
'72 Squareback - full resto completed 2008 - now sold
356 Speedster kit, completed 2005 - now sold


Last edited by Dodgy on Wed Dec 24, 2014 12:49 pm; edited 1 time in total
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beetlenut
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PostPosted: Wed Dec 17, 2014 1:38 pm    Post subject: Reply with quote

Another bullet dodged by not having much rust in that rust-prone area. Nice to have a whole section finally finished. When you find other areas of the car that are rusted through, it's always good to have a section of the car that's finished to look back on, to spur you on!
_________________
scrapyards are for quitters
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Wetstuff wrote:
... I spend more time shaking it than directing it?! I get a pretty decent blast for 8sec. then have to shake it again.
- Words to live by right there!

My 74 Super rebuild thread: http://www.thesamba.com/vw/forum/viewtopic.php?p=6507104#6507104
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Dodgy
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PostPosted: Wed Dec 24, 2014 8:25 am    Post subject: Reply with quote

Hurrah! Some significant progress!

Final patch on the LH rear quarter welded in, cleaned up and covered with temporary primer (garage can be a bit damp at times, and it'll be a while before I'm properly preparing the body for paint, this is just to keep rust at bay until then)

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


Body off the pan again... How many times does a body normally go on & off the pan during a rebuild??? Never mind, I've got a couple of pulley systems rigged up now, and not all bolts to remove. Probably takes less than half an hour, working on my own.

Back to the LH front quarter. Now the bulkhead is complete and heater channel fully welded in, I could refit the corner reinforcement bracket. Plug welded in place as originally done by VW

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


And after that was fitted, once the box section in the inner wing had an internal coat of paint over the welds, I could finally fit the patch for the inner wing I made 15 months ago Shocked

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


Welds ground smooth & blended, coat of primer - looking good!

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


Feels like suddenly that's a LOT of progress all at once.

Just have to make up a small repair to rebuild the rear edge of the suspension tower reinforcement, then all the welding on the LH side of the body is complete Very Happy
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'75 1303 (current project) owned since 1989!
'72 Squareback - full resto completed 2008 - now sold
356 Speedster kit, completed 2005 - now sold
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Volks Wagen
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PostPosted: Wed Dec 24, 2014 10:08 am    Post subject: Reply with quote

Dodgy wrote:

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


Once this access hole is patched up, that's the entire LH rear quarter complete! I'll cann that a significant milestone! Very Happy


Good stuff. Did you treat that little bit of rust up there on the outer panel somehow? I cut most mine out because it was worse, but treated little areas like that with rust converter and paint.. just wondering have you found a magic spray or something that would help in the tight areas?
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1973 1303 with AB-motor - sporadic
reconstruction as time permits, 1986 ex-Bundeswehr Doka - on the road again.

I'm definitely, probably, the worlds greatest lover.

Aithníonn ciaróg ciaróg eile.
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Dodgy
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PostPosted: Wed Dec 24, 2014 12:49 pm    Post subject: Reply with quote

Volks Wagen wrote:
Did you treat that little bit of rust up there on the outer panel somehow? I cut most mine out because it was worse, but treated little areas like that with rust converter and paint.. just wondering have you found a magic spray or something that would help in the tight areas?


No I didn't, but when all the work on the body & pan is complete I'll get one - or a few - of the internal chassis coating sprays, the kind with a long flexible wand that spray 360° (sort of) and go over all the closed sections. I'm building a list of areas... Places like the heater channels and box section at the front of the body will need coating too, where welding will have burnt off the paint inside.

The rust on the outer panel shown in the photo was so superficial - I figure if it's taken 40 years to get [not very] bad, when the car spent most of that time used daily and kept outdoors, it'll take another 40 years to get any worse, with the car molly-coddled rather a lot more Smile

How I've got away without any rust in this area, even living in a country with fairly high humidity / unkind environment for old cars, when others have had very serious rust issues, I don't know. But I'm not complaining...!
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Dodgy
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PostPosted: Thu Jan 01, 2015 9:17 am    Post subject: Reply with quote

Suspension tower repair complete...

New patch for the bottom section - this had been poorly repaired in the past
Centre piece reinstated - this had been removed to properly repair rust on the inner wing panel

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


Welds smoothed and coat of primer

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


So that's the LH side done. Just have to do IT ALL OVER AGAIN on the RH side Evil or Very Mad

RH rear crossmember is in worse condition than LH, so that will be interesting...
But at least the front bulkhead repairs are done, nothing can be harder than that!
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'72 Squareback - full resto completed 2008 - now sold
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beetlenut
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PostPosted: Thu Jan 01, 2015 12:01 pm    Post subject: Reply with quote

I swear we bought the same car, lol! Nice to know I have company in the "Why didn't you send that to the scrap yard" club! At least you'll know you have solid steel under you for the next 40 years.

My RH rear crossmember:
Image may have been reduced in size. Click image to view fullscreen.


Keep up the great work, you've passed the half way mark, and it's all down hill from here!

Bill
_________________
scrapyards are for quitters
---------------------------------------
Wetstuff wrote:
... I spend more time shaking it than directing it?! I get a pretty decent blast for 8sec. then have to shake it again.
- Words to live by right there!

My 74 Super rebuild thread: http://www.thesamba.com/vw/forum/viewtopic.php?p=6507104#6507104
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Dubmatix
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PostPosted: Tue Jan 06, 2015 3:18 pm    Post subject: Reply with quote

Great work! It's good to see another big 1303 rebuild and one with such good quality work too, i need to up my game! Smile I too am annoyed by the poor pattern panels and as such decided to do extensive repairs to my n/s floorpan as i wasn't happy with the complete o/s one i fitted 14 years ago.

Part way through my 75 shell reworks, I ended up picking up a 73 shell despite being very attched to my original 75 1303, but have resolved to revert it to 75 spec.

The boot floor additional channel you noted and removed (i thought about removing mine but grudgingly left it in in the whole floor panel i had) was for the wiring loom on mex cars. They ran it out through a 2" grommet in the rear bulkhead i think as i had to make a disk to weld up the hole.

My wiki i have been keeping for my own sanity and motivation is here :
http://www.thebughaus.co.uk/wiki/doku.php?id=bonita

Keep up the build thread, it is good to see others resolving similar problems and helps to keep up motivated. Smile

John
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