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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Oct 21, 2014 9:44 pm Post subject: |
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So another bite of the ellefant.
welded the outer panel back in place and smoothed it all out.
I think I might leave the quarter panel off till I've finished with the sandblasting, so much crap gets down the inside of the panel and once it's closed up I'll never get it out, maybe, I'll get bored one night and start welding it up knowing me. _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Oct 21, 2014 9:46 pm Post subject: |
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The next phase in fixing the channel is going to be bloody tricky.
Many parts converge here, the channel, the bottom plate with end cap, the front firewall, the wheel well, the A pillar with door hinge
start chopping _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Oct 21, 2014 9:59 pm Post subject: |
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So i made this thing, which is the end of the channel its self.
goes here
that took a lot of work to get right, pretty happy with it.
After chopping a bit more rust and badly pitted metal out of the very bottom of the firewall, I sandblasted and primed.
made another patch to replace the bottom of the firewall
hot glue gunned it in here.
had to make that tiny patch on the flange thing
welded up the pie cuts I made to shape the metal
and smoothed that out
and finally welded it in.
just tacked in here
the inside view, welded together and to the firewall.
Now. The more perceptive of you will have noticed in that last pic that the channel seems to be missing some metal.
well thats coz i chopped it off!
yes yes, I should have just bought new channels
ah well, in for a penny, in for a pound, or some such rubbish!
this me checking the bottom plate still fits.
these bottom plates are actually pretty good, the pressing are not exactly the same as the old stuff, but the main thing it that the bolt holes are in the right place and line up with the pan perfectly, I will fill in the big drain holes that are in them, and they will need a wee bit of trimming but thats okay.
Next up will be the A pillar and the rusted channel that it joins to, so with that in mind, I made this.
_________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Oct 21, 2014 10:02 pm Post subject: |
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While I am getting better at welding, I'm still no pro.
I am however, getting bloody good with the grinder!
absolutely stoked with how it looks, some of the weld/join is right where that angle is so I'm very please I managed to keep it looking factoryish. _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Dec 02, 2014 5:30 pm Post subject: |
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Got some more work done.
was in a bit of a rush when i chopped this out, used a thicker cutting disc than the usual 1mm one, so now I have a whacking great gap to fill, as I'm going to try and repair this mess. I had a look at the cheap repair panels that you can get for the A pillar, they were terrible. And as I'm to tight to spring for the good ones I'll give it a go at fixing the old one.
Then I did this to the channel.
I thought long and hard about the best way to go about this, as this bit was ok, but this bit was fucked, anyway seemed to make sense at the time.
This is the inner rust trap, part #12679666
what was left of the sill
like i said "fucked'
replacementness
primed
I also sandblasted the inside and outside, managed to get the thread plate thing that the door bolt to, out without breaking the strap the holds it in, . But then I forgot to sandblast said bolt plate thing _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Dec 02, 2014 5:31 pm Post subject: |
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new inner rust trap
_________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Wed Dec 17, 2014 1:10 pm Post subject: |
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Got the channel patch finished up, had to cut down a tube for the air pipe as the one I had was to large.
this is it nearly finished
did some grinding after this, notice the dents to fake the factory look.
in place
start tacking
camera is on the way out, flash has stopped working.
getting there
and done.
not all that happy with this join, but will be covered by the inner wheel well.
this is better
might be able to get some more done over the holidays, maybe.
merry christmas everyone! see you in 2015.
_________________ If you can't join them, beat them! |
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HUGO bOSS Samba Member
Joined: April 27, 2008 Posts: 2602 Location: Madeira Island - Portugal
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Feb 17, 2015 4:35 pm Post subject: |
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Didn't really get much done over the holidays, so hot in the shed, swimming is better.
I did wire wheeled/blasted these parts up.
don't think I will be able to save the hinge cover though, just to tricky with my limited skills and tools.
Also wirewheeled my arm
was so stupid with the grinder, I was holding the metal in my left hand and the grinder in my right. the wire wheel grabbed the edge and BANG! super quick it tour though my glove and across my wrist
Welded the scoop to the new inner panel thing(there is a hole on the other side!)
and welded it in here.
I hoping to get the heat working when she back on the road.
I have been spending a lot of time messing around with bottom plate, I think the best thing is to finish all the other repairs to the channels on both sides, then test fit the shell to the pan before welding the bottom plates on for good.
I don't know, I've never don this before!
The plates seem to fit the pan perfect, but when I stick them on the shell they seem 5-10mm short?
So a test fit seems prudent.
I had to dig the pan out to get to all the camping stuff for the hoilday so I took a couple snaps.
A little pitting, but so solid
I've been working on the patches for the front and rear quarters this week, but can't actually weld anything yet until the A pillar in back in place and I can fit the door, so till then i'll keep hammering. _________________ If you can't join them, beat them! |
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HUGO bOSS Samba Member
Joined: April 27, 2008 Posts: 2602 Location: Madeira Island - Portugal
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Posted: Tue Feb 17, 2015 4:51 pm Post subject: |
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The chassis looks good... But will be better to make a "final fit" before welding all or even paint...
About the drill... is a real pain... once mine get my t-shirt and punch me on the noose...
Keep us posted... _________________ http://www.thesamba.com/vw/forum/viewtopic.php?t=538182 |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Wed Mar 04, 2015 9:04 pm Post subject: |
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So whats in the box?
oh, this is!
I'm just using the outside part of these panels as my my inner was mostly complete.
here it's all ready to start fitting into place, I say "start" as it's a bloody tricky bastard to get right!
so many points to line up. _________________ If you can't join them, beat them! |
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HUGO bOSS Samba Member
Joined: April 27, 2008 Posts: 2602 Location: Madeira Island - Portugal
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Wed Mar 11, 2015 6:52 pm Post subject: |
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another update guys
This thing is all stuck together, I welded it in place last night.
This thing still sucks.
Hugo, this is the black one.
not quite finished the welding/grinding in the very corner.
I also need to finish the wheelwell panel before I can fold the edge over, which I'm working on now.
The door seems to fit well, might need a 2mm spacer, but I can live with that.
The problem I'm having, is that the lower hinge screws are really hard to tighten, REALLY hard!
I'll do them up as tight as I can, and the door/hinge will still move.
But much easier with the spacer in between the hinge and the A pillar, and tight as a nuns. ???
The thing that confuses and pisses me off is I tried real hard to use as much factory metal as possible, only the outer "cover" of the A pillar is repop steel, and it all seems to line up pretty well.
I guess something somewhere has moved or whatever. Maybe I need to tap the threads out in the bottom of the A pillar?
Ah fuck it! I'm looking forward to finishing up this side and starting the other. _________________ If you can't join them, beat them! |
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HUGO bOSS Samba Member
Joined: April 27, 2008 Posts: 2602 Location: Madeira Island - Portugal
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Mar 24, 2015 5:57 pm Post subject: |
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Yeah, I'm using the one that come out, I'll double check that they are all the same thanks.
Welded the front cap/bolt plate thing in and ground it all down.
made a patch for the corner of the firewall
I saw this on someone else's thread, this little step lets the edge sit flat against the bottom of the inner wheelwell panel and the double layer of metal of the channel end cap thing.
here
this is a close up of the stepped detail and how it attaches to the side of the channel, this makes a nice flat flange for the wheelwell panel to be welded to.
like this.
Which is the other thing I've been working on,
my patchwork inner wheelwell panel
I started making this before the A pillar panels arrived and I forgot that the pillar actually came down another cm from where I'd cut the quarter panel off.
Luckly it's only metal so you just stick it back together and add a little bit more.
The curved magnet is a rare earth magnet I pulled out of a dead hard drive I found at work, Hole lee shit it's good!
Very powerful, pretty hard to get off actually, wish I'd got some ages ago!
ground it down on the weekend, looks okay.
I also ground the welds down on the firewall patch last night, before the kids went to bed, and turned the shell around 180 degrees. Will be starting the drivers side channel/A pillar/under rear seat rust next.
I hate leaving parts unfinished but there is still sand falling out from when I blasted the first side, so once all the blasting is done, I'll weld it all up.
only another 572 spot welds to drill now! _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Mon May 04, 2015 9:43 pm Post subject: |
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On to the other sill!
chop chop!
it's actually better than the other side, still has rust in the same places, just not quite as rotten. _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Jun 16, 2015 5:57 pm Post subject: |
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Update time!
some more holes patched up.
still need to grind the welds down on the inside, just need some new discs for the dremmel, as a normal grinders to big to fit.
As well as the channel end, I had to replace the flange where the wheelwell meets the panel under the rear seat.
Feels good to have another corner solid.
Small batch on the rear of the sill, was all pin holed.
Larger patch up front.
I think I've good at making those little dents down now.
smoothed out welds
no one will ever know! ahahahahahahahaha!!! _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Jun 16, 2015 6:03 pm Post subject: |
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Then I patched this thing up.
and made it pretty.
just need to weld the stud for the bottom fender hole and that can be welded back on. _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Jun 16, 2015 6:21 pm Post subject: |
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And next on the list.
This fucking mess!!
_________________ If you can't join them, beat them! |
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bobnorman Samba Newfoundlander
Joined: August 09, 2010 Posts: 1389 Location: Newfoundland
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Posted: Tue Jun 16, 2015 6:51 pm Post subject: |
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Great work! Been enjoying your thread for a while. I'll refer to this when I get around to doing the same with my '60. I may however opt to remove my channels altogether and rebuild them on the bench.
By the way, how do you make those little dents?? _________________ Air does not freeze. Air does not boil.
http://www.thesamba.com/vw/forum/viewtopic.php?t=289807 |
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