My 61 panel (and a 66 panel digout)

karl h · Posted: Tue Nov 26, 2013 6:59 am Post subject:

thanx guys
its isnt fully welded at the joint between window frame and front, the stock seam is all on the donor piece. i did this because it is very hard to get a stock looking joint. this is welded at the factory with a spot welder, with my spot welder i cant reach around the dashboard. at the factory the dashboard was mounted after welding the two front pieces i assume. sorry for the bad pics

did some more work on the torsoin tube:
from the top:

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

new inner frame made from 2.5mm sheet metal:

first positioned with the mig welder, i used the arc welder for getting enough penetration on the tube. the new piece is thicker than the stock tube

thanx for looking
_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

durfeec · Posted: Tue Nov 26, 2013 8:06 pm Post subject:

I posted that and then went and tinkered on my bus. I remembered the pic kinda and realized that you had welded lower than the og seam. Sorry about that. Embarassed

_________________
1960 Bus Panel/Camper

karl h · Posted: Thu Nov 28, 2013 1:42 am Post subject:

if i motivate somebody to get going on their own bus, thats cool!

strangly i have been pretty motivated too:
fabrication of the outer part of the frame:

outer part testfitted:

broke out hammer and dolly to shape the upper ond lower part:

i have only spotwelded them to make a good fit. the part now kinda snaps in place. i will weld it on the inside before instalation:

stay tuned
_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

karl h · Posted: Thu Nov 28, 2013 11:57 pm Post subject:

some more work done:
welded the repairsection and primed it inside. sandblasting will not get to the inside after welding it up

_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

karl h · Posted: Fri Nov 29, 2013 12:00 am Post subject:

the rails to tilt the panel to the left side are working as advertised. the big radius lets me easily manipulate the car into every angle i want:

_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

karl h · Posted: Fri Nov 29, 2013 12:03 am Post subject:

pretty crusty, eh? (nothing i was suprised of, just no good pics until now)

_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

karl h · Posted: Tue Dec 03, 2013 12:03 am Post subject:

the inner frame part is now welded.
then i decided to cut my hand with the anglegrinder, so i am out for a week. nothing serious....
oh well i like to think that all complete restos draw a little blood, all of my others have Smile

_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

karl h · Posted: Thu Dec 12, 2013 2:47 am Post subject:

the torsion tube is now fully welded, some more cleanup to do after sandblasting

i have also repaired the framepart where the handbrake goes with the help of the donor part. a torch and some colourful words were necessary to take out the handbrakeleverpin

at last i started to cut off the rear part of the roof to graft in the rear donorsection and repair the inner gutter

comments and critique welcome
_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

karl h · Posted: Fri Dec 13, 2013 12:51 am Post subject:

last night i made some progress on the roof. parts of the upper sidewall will have to be patched. the inside gutter was very bad.

here the cut will be on the donor section

_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

karl h · Posted: Mon Dec 16, 2013 6:18 am Post subject:

fitting of the donor part
first very careful cutting to have enough material left:

some parts of the sidewall had to be patched on the upper end/flange:

rear part slid underneath:

_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

karl h · Posted: Mon Dec 16, 2013 6:24 am Post subject:

when the rear part was cut i found out the roof had come off about a foot from the raingutter, so i cut a donorpiece. this was taken from the passenger side of it, the donor was rusted on the driversside too:

cutting:

flange exposed. i had a little trouble getting it off clean at the strengthener inside, but finally managed

trial fit:

this thread doesnt seem to generate a lot of interest, but posting progress keeps me going Very Happy

_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

DONGKG · Posted: Mon Dec 16, 2013 6:25 am Post subject:

Long way to go buddy! But with the dedication you got there, that Split will soon see the light and glory of the day! Keep up the awesome work, buddy
_________________
'67 KG Cabrio (Mickey) ;
'66 Type 3 (Sharky 2)
'72 Type 2 Homey
'67 Splitty Bus
'65 beetle;'69 Country Buggy; '44 Kubelwagen (replica) TOOB MEMBER #20

zozo · Posted: Mon Dec 16, 2013 6:28 am Post subject:

It is VERY interesting, and I for one enjoy watching your efforts. Please keep posting, and please keep including the pics. You're providing a lot of valuable insight for others that may be looking forward to the same repairs.

karl h · Posted: Tue Dec 17, 2013 12:40 am Post subject:

thanx guys, i really appreciate it!

next i removed the rotted part of the inside gutter. pretty tricky to get just the upper part out, but i managed to cut it with the airdisc and airsaw, then wiggle off the rest:

fabrication of the new upper part was next, it reaches to the roof bow and attaches to it with a little flange. the bow is loose on the sides (probably from the body flexing during decades of driving)

a littel crude, but it works for a part you can hardly see. i will spot weld it in place after sandblasting the gutter. hope there will be no more holes to patch then....

the donorpiece was fitted next, welded from the inside

i will fit the large rear part before finishwelding the roofskin. and yes i used a flange tool. i know this can be seen from the inside, but i feel i can do better adjustments that way - and hey, this is no pebble beach resto Confused

_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

karl h · Posted: Thu Dec 19, 2013 12:19 am Post subject:

next i drilled out the chanell for the rear hatch seal from the old roofpart

and checked the fit:

i pulled the sidewalls together a bit:

and checked the gaps with the help of the (donor) hatch and some wooden wedges

after tapping all of the screwholes i attached the hatch to the roofsection

some more tweaking necessary, but you get the idea. its not so easy getting this part on alone

stay tuned
_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

karl h · Posted: Thu Dec 26, 2013 10:40 am Post subject:

i used some clamps to align the hatch and corners

first i welded the raingutter because its the most visible part and no bondo can be used there

one spot at a time to get no heat warping:

from the inside:

_________________
61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
arctic alice (63 on irs): http://cal-look.no/lounge/index.php/topic,27456.0.html
86 Caravelle
04 new beetle vert

eastcoast63 · Posted: Thu Dec 26, 2013 2:17 pm Post subject:

Keep up the good work....subscribed! Cool

Ant
_________________
Fort Lauderdale, Florida
1967 Standard Microbus
Wide 5 Vintage Volkswagen Club

rustytortoise · Posted: Thu Dec 26, 2013 2:39 pm Post subject:

fixing roofs is so fun! cool thread, i like the extraction of the 66.

Cool

_________________
-Jonathan


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My 61 panel (and a 66 panel digout)
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