Hello! Log in or Register   |  Help  |  Donate  |  Buy Shirts See all banner ads | Advertise on TheSamba.com  
TheSamba.com
 
My 61 panel (and a 66 panel digout)
Page: Previous  1, 2, 3 ... 6, 7, 8 ... 17, 18, 19  Next
Jump to:
Forum Index -> Split Bus Share: Facebook Twitter
Reply to topic
Print View
Quick sort: Show newest posts on top | Show oldest posts on top View previous topic :: View next topic  
Author Message
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Mon Dec 30, 2013 12:49 am    Post subject: Reply with quote

thank you for the interest, guys!

welding of the roof is finished, i will grind down the welds next.
Image may have been reduced in size. Click image to view fullscreen.


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

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


i will make a cardboard template to remove as little material as possible from the motormount
Image may have been reduced in size. Click image to view fullscreen.


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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Wed Jan 08, 2014 12:33 am    Post subject: Reply with quote

using the template i made the cuts. i should have taken templates from the first time i did this on my deluxe.....

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


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:

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


one side finished:

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


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

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

_________________
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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Mon Jan 13, 2014 3:32 am    Post subject: Reply with quote

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

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

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


the motormount has been welded to the IRS mounts on the inside

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

_________________
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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Mon Jan 13, 2014 3:35 am    Post subject: Reply with quote

next i started to remove the cargofloor. pretty ehausting work Confused

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

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

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

_________________
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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Wed Jan 15, 2014 2:34 am    Post subject: Reply with quote

some more work on the floor:
i used a brakerbar to loosen it from the crossmembers. beats drilling out or chiseling off a zillion rivets
Image may have been reduced in size. Click image to view fullscreen.

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

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


at last:

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

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

_________________
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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
wcfvw69 Premium Member
Samba Purist


Joined: June 10, 2004
Posts: 13382
Location: Arizona
wcfvw69 is offline 

PostPosted: Wed Jan 15, 2014 6:29 pm    Post subject: Reply with quote

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**
Back to top
View user's profile Send private message Send e-mail Gallery Classifieds Feedback
twentyshitty
Samba Member


Joined: September 25, 2011
Posts: 1
Location: Norway
twentyshitty is offline 

PostPosted: Thu Jan 16, 2014 5:50 am    Post subject: Reply with quote

finally I found a fresh thread with an example about as bad as mine Smile
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!
Back to top
View user's profile Send private message Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Thu Jan 16, 2014 7:40 am    Post subject: Reply with quote

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 Surprised . 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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Wed Jan 22, 2014 4:20 am    Post subject: Reply with quote

next, i started to remove the lower sidepanel on the drivers side up to the inside stiffener:

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


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


lots of dryfitting to have no suprises later

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

_________________
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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Wed Jan 22, 2014 4:23 am    Post subject: Reply with quote

i decided to remove the lower hingepoint on the a-pillar. it was rusted pretty bad, so it wouldnt be repairable anyway. some funky green is in order here

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


i also cut the lower rear corners, the pillars beside the enginelid will also come out (got these allready)

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

_________________
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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
rubbachicken
Samba Member


Joined: October 05, 2004
Posts: 3058
Location: socal
rubbachicken is offline 

PostPosted: Thu Jan 23, 2014 6:21 pm    Post subject: Reply with quote

nice job Cool

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
Back to top
View user's profile Send private message Send e-mail Facebook Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Thu Jan 30, 2014 7:26 am    Post subject: Reply with quote

thanx for the tip rubbachicken, i try to go slow and not heat the panel too much.

i had to cut out a piece of the rear frame on the drivers side and fit a donour piece. tried to clamp on all of the surrounding sheetmetal to get a decent fit:

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

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

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

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

_________________
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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Tue Mar 04, 2014 12:18 am    Post subject: Reply with quote

i had some minor things i wanted to do before sandblasting:
a little hole in the frame underneath the crossmember:

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


some carefull cutting:

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


welded:

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


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 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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Huetti_1989
Samba Member


Joined: February 13, 2011
Posts: 1118
Location: Austria
Huetti_1989 is offline 

PostPosted: Tue Aug 26, 2014 1:40 pm    Post subject: Reply with quote

Are there any news??
Back to top
View user's profile Send private message Gallery Classifieds Feedback
brettsvw
Samba Member


Joined: November 22, 2007
Posts: 2145
Location: Florida
brettsvw is offline 

PostPosted: Tue Aug 26, 2014 3:20 pm    Post subject: Reply with quote

I have been following from the beginning. You have no fear of rust my friend.
_________________
.







My 59 kombi build.
http://www.thesamba.com/vw/forum/viewtopic.php?t=635003&highlight=

My buggy build.
http://www.thesamba.com/vw/forum/viewtopic.php?t=558601&highlight=

http://www.thesamba.com/vw/forum/viewtopic.php?t=289807
Back to top
View user's profile Send private message Send e-mail Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Tue Aug 26, 2014 10:49 pm    Post subject: Reply with quote

Not really any news unfortunately.
i am trying to raise the funds for sandblasting and the rest of the sheet metal, but building a house at the same time doesnt help at all....
as soon as i start work again i will post progress, but i have to do a few fixer upper bugs first
_________________
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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Tue Oct 21, 2014 1:53 am    Post subject: Reply with quote

SCORE! fond a backrest LOCALLY (!) for a very reasonable price
Image may have been reduced in size. Click image to view fullscreen.

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

i always thought the grey benches came without pipping?
it is an earlier backrest, but i can use it if i grind down the tabs slightly to fit the 61 brackets
_________________
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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
EverettB Premium Member
Administrator


Joined: April 11, 2000
Posts: 69733
Location: Phoenix Metro
EverettB is offline 

PostPosted: Tue Oct 21, 2014 7:53 am    Post subject: Reply with quote

The piping was used on 1963 Commercials.
Since that is a full bench seat, it must be a 1963 Double Cab rear seat backrest.
The frame and everything is the same shape as a 58-60 Bus front bench seat, except for the piping.
_________________
How to Post Photos
Everett Barnes - [email protected] | My wanted ads
"Water is the only drink for a wise man" | "Communication prevents complaints"
Stop dead photo links! Post your photos to The Samba Gallery!
Back to top
View user's profile Send private message Send e-mail Visit poster's website Facebook Instagram Gallery Classifieds Feedback
karl h
Samba Member


Joined: October 10, 2005
Posts: 573
Location: austria
karl h is offline 

PostPosted: Tue Oct 21, 2014 9:50 am    Post subject: Reply with quote

thanx, Everett
a seatback like this is pretty uncommon in austria, not many DCs araound here. most of them were used by the military and are long gone.
but i got lucky after all, i can use it!
_________________
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
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Breckskier
Samba Member


Joined: December 16, 2002
Posts: 239
Location: Grand Rapids, MI
Breckskier is offline 

PostPosted: Tue Oct 21, 2014 7:36 pm    Post subject: Reply with quote

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..
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Display posts from previous:   
Reply to topic    Forum Index -> Split Bus All times are Mountain Standard Time/Pacific Daylight Savings Time
Page: Previous  1, 2, 3 ... 6, 7, 8 ... 17, 18, 19  Next
Jump to:
Page 7 of 19

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum

About | Help! | Advertise | Donate | Premium Membership | Privacy/Terms of Use | Contact Us | Site Map
Copyright © 1996-2023, Everett Barnes. All Rights Reserved.
Not affiliated with or sponsored by Volkswagen of America | Forum powered by phpBB
Links to eBay or other vendor sites may be affiliate links where the site receives compensation.