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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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Posted: Mon Dec 30, 2013 12:49 am Post subject: |
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thank you for the interest, guys!
welding of the roof is finished, i will grind down the welds next.
now for the IRS conversion: i like using the early bay parts as these are obviously made for a bus and not a bug and come with the right brake size and are 5x205. and on top of that they are much easier to install than a bug IRS with stock parts. i could only think of very few drawbacks, as thers is minor cutting involved and availability might be not as good as a Type 1 setup.
first a trip to a friends shop nicely separated the torsion and springplate parts, not always an easy task. the torch was required only once (on a fifteen ton press)
next the 61 torsions are stuck into the bay springplates and inserted into the torsiontube with the rubber donuts. to get an idea where to cut i bolt the IRS arm to the springplate with only two bolts (upper Arm Location to lower springplate location)
i will make a cardboard template to remove as little material as possible from the motormount
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 |
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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Posted: Wed Jan 08, 2014 12:33 am Post subject: |
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using the template i made the cuts. i should have taken templates from the first time i did this on my deluxe.....
the motormount parts are bent out of the way so they dont touch the flanges and allow the IRS to be welded on in the right place:
one side finished:
repeated on the other side and - voilá - an IRS setup. after welding the flanges to the torsontube (with the bus laying on its side and the arms removed) the motormount will be welded to the flange so nothing hits
_________________ 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 |
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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Posted: Mon Jan 13, 2014 3:32 am Post subject: |
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one more small modification is necessary: to not have the IRS arm hit the motormount when in its uppermost position, there has a small recess to be bent into it
the motormount has been welded to the IRS mounts on 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
Last edited by karl h on Mon Jan 13, 2014 4:09 am; edited 1 time in total |
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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wcfvw69 Samba Purist
Joined: June 10, 2004 Posts: 13382 Location: Arizona
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Posted: Wed Jan 15, 2014 6:29 pm Post subject: |
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Wow. You're dedication and tenacity to save this bus is amazing. Looking at your thread makes me feel like a lazy ass. I loved your videos of saving that other bus by craning it over the fence.
Keep up the great work. I've really enjoyed your efforts so far.
Good job! _________________ Contact me at [email protected]
Follow me on instagram @sparxwerksllc
Decades of VW and VW parts restoration experience.
The Samba member since 2004.
**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours** |
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twentyshitty Samba Member
Joined: September 25, 2011 Posts: 1 Location: Norway
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Posted: Thu Jan 16, 2014 5:50 am Post subject: |
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finally I found a fresh thread with an example about as bad as mine
Beeing a newbie I need all the inspiration I can get!
I cant see that you strenghten the chassis/bus before all the cutting... At what point of cutting do you have to do that? (or maybe Im blind...)
Keep up / Exellent thread! |
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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Posted: Thu Jan 16, 2014 7:40 am Post subject: |
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thanx guys for your interest, its always nice to see someone appreciating your work
As for the strenthening question, going through my second nut and bolt of a bus i think that:
if you dont have to touch the frame of the bus there is no danger of the wheels getting out of alignement no matter how much of the upper structure you cut.
if you have to touch vital parts of the frame it depends. for the repair of the torsion tube i left as much sheetmetal in place (especially the cargofloor and engine mount) as posssible to give it some rigidity. if you have to mess with the complete torsion tube, i think there is no way around a chassis jig. the same holds true for the bolts of the front beam to frame joint.
on the upper structure of the bus its more important to get the parts to align and have even door gaps. when i repaired the roof, the corners got pretty wobbly and i took care to get the gap of the rear hatch right. in hindsight i am glad i didnt opt for replacing the whole roof (i had a donor allready). geting this straight would be very hard for a one-man-show such as me.
the front of the bus has to be taken care of too, that is why i replaced the windowframe before cutting off the lower part, i just wasnt comfortable with it just hanging from the heater pipe . it now is pretty wobbly, but a brace in the door is not needed IMHO, because you have to mount the doors anyway before repairing any of the dogleg/front apron/cabfloor parts. i have seen the doors welded shut temporarily, brutal, but it works.
good luck with your build, lets see some pics! _________________ 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 |
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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rubbachicken Samba Member
Joined: October 05, 2004 Posts: 3058 Location: socal
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Posted: Thu Jan 23, 2014 6:21 pm Post subject: |
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nice job
with spot welding the roof, and other panels, i found that it's best to grind the welds flush as you go, it takes a little longer, if you go at it too mcuh with the grinder afterwards, you can get as much heat and panel distortion, i also found it's easier to find the bits that were missed by overlapping the welds. _________________ lucy our westy
lucy's BIG adventure
meet 'burni'
markswagen {mobile mechanic} san diego area all early VW's cared for.
619 201 0310 or 617 935 4182 |
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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Posted: Tue Mar 04, 2014 12:18 am Post subject: |
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i had some minor things i wanted to do before sandblasting:
a little hole in the frame underneath the crossmember:
some carefull cutting:
welded:
i have some more little patches around the welded in IRS pivots and inner frame, but thats just about it before blasting. now i just have to find the money for the blaster _________________ 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 |
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Huetti_1989 Samba Member
Joined: February 13, 2011 Posts: 1118 Location: Austria
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Posted: Tue Aug 26, 2014 1:40 pm Post subject: |
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Are there any news?? |
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brettsvw Samba Member
Joined: November 22, 2007 Posts: 2145 Location: Florida
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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EverettB Administrator
Joined: April 11, 2000 Posts: 69733 Location: Phoenix Metro
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karl h Samba Member
Joined: October 10, 2005 Posts: 573 Location: austria
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Breckskier Samba Member
Joined: December 16, 2002 Posts: 239 Location: Grand Rapids, MI
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Posted: Tue Oct 21, 2014 7:36 pm Post subject: |
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This is an awesome thread! You really are going after it! _________________ BreckSkier
67 13w Deluxe-"St. Pete" the Airport Jet Bus
65 13w Deluxe-"St. Nikolas"
67 912(911.5 Outlaw build spring 2015), 90 C4Cab. Formerly: 59 DD, 78 SuperB, 81 911Cab, 82Vanagon, 81Vana & other German / US stuff.. |
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