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 ... 8, 9, 10 ... 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: Sun Sep 13, 2015 2:58 am    Post subject: Reply with quote

next, i tilted the bus on its side and welded the crossmember securely to the lower struture
Image may have been reduced in size. Click image to view fullscreen.


the lower a-pillars were next. i have taken some good hard looks at these since i got them to find out how to get these into the right position.
first i decided to "notch" them: i cut out parts of the pillar on the side that faces the door (jam), leaving the channel for the seal intact for about 50mm upwards.
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: Sun Sep 13, 2015 3:02 am    Post subject: Reply with quote

then i cut off the corresponding parts so the pillars slid on from the underside
Image may have been reduced in size. Click image to view fullscreen.

taking care to get the lip into the correct position where the nose skin wrapped around, i cut more and more off until it slid all the way up
Image may have been reduced in size. Click image to view fullscreen.


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

sorry for the bad pics, but you get the idea. i will have to shorten the front crossmember some more to get things aligned up front
_________________
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
CamBiscuit
Samba Member


Joined: February 27, 2012
Posts: 82
Location: Adelaide Australia
CamBiscuit is offline 

PostPosted: Sun Sep 13, 2015 4:34 am    Post subject: Reply with quote

Great thread, keep up the good work karl Cool
_________________
1965 ratty single cab
Instagram @cambiscuit
Back to top
View user's profile Send private message Send e-mail Gallery Classifieds Feedback
BarryL Premium Member
Samba Member


Joined: November 01, 2004
Posts: 14218
Location: Casa de Oro, California
BarryL is offline 

PostPosted: Sun Sep 13, 2015 7:56 am    Post subject: Reply with quote

How do you guys that do the lower pillar know when you have the lower hinge mount in its exact position?
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: Sun Sep 13, 2015 8:43 am    Post subject: Reply with quote

thanx for chiming in guys!
well i mount the door, making sure the gaps to the pillars are within tolerance. i also clamp the door shut using a wooden block that aligns the beltline crease. there is some colourful language involved and some serious tweaking using all kinds of tools and my arms and legs to get it to the right position
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 Sun Sep 13, 2015 8:54 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: Sun Sep 13, 2015 8:49 am    Post subject: Reply with quote

since money is tight (as mentioned before), i got the cheap brazilian crossmember that is a royal POS, its hard to get to fit the funky green pillar (i even kicked it)
Image may have been reduced in size. Click image to view fullscreen.

when i was satisfied with the fit i tacked it in a few places, then i took the door off and tacked it some more. i wont weld it completely before the cabfloor and the doglegs are on to be able to modify the fit of all of the parts
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: Sun Sep 13, 2015 8:52 am    Post subject: Reply with quote

the most important things is: TAKE YOUR TIME, or you will regret it later. even walk away and come back at a later time when you cooled down when the words you are using are getting too strong....
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: Thu Sep 17, 2015 12:17 pm    Post subject: Reply with quote

same procedure with the other side
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: Thu Sep 17, 2015 12:24 pm    Post subject: Reply with quote

with the door in place
Image may have been reduced in size. Click image to view fullscreen.

this side is not as straight forward as the right side, the door gap is too tight. the whole a pillar seems to be too far back, maybe because of my windshield repair? some force applied to get the lower pillar further in.
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: Sat Sep 19, 2015 6:59 am    Post subject: Reply with quote

after further investigation i determined that the upper hinge mount of the a-pillar was crusty and didnt support the hinge properly. also the plate that takes the four screws that hold the door wasnt gonna cut it either because i drilled out two of them to get the door off earlier upon disassembly. two screws dont secure the hinge enough so i first cut out the crusty metal over the hinge cage. then i drilled out the spotweld in the middle of the cage to get the little metal tab out that centers the hinge plate, then i was able to slide it out to the side
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 Sat Sep 19, 2015 12:44 pm; 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: Sat Sep 19, 2015 7:03 am    Post subject: Reply with quote

the plate was repaired by drilling oversize holes into it and pressing rounded off 13mm nuts into it, then welding them from the back
wonder how i will replace the metal over the cage, it has a recess...
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 Sep 23, 2015 10:54 pm    Post subject: Reply with quote

after the repair i slid the holding plate back in again and rewelded the tab to keep it located
Image may have been reduced in size. Click image to view fullscreen.

then i started on the replacement metal over it. i crudely formed the recess in a vise and am trying to make it fit. holes for the bolts will be drilled next
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
greasedjesus
Samba Member


Joined: August 23, 2014
Posts: 49
Location: Elizabeth, CO
greasedjesus is offline 

PostPosted: Thu Sep 24, 2015 12:33 am    Post subject: Reply with quote

Going through a lot of this same stuff with hinge mount points and A-pillars on my 62, just not quite as extensively as you form the looks of it. Lookin good, keep it up!
_________________
When life hands you lemons, shut up and eat your damned lemons.
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: Fri Sep 25, 2015 12:01 pm    Post subject: Reply with quote

thanx!
holes drilled
Image may have been reduced in size. Click image to view fullscreen.

And welded in
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 Fri Sep 25, 2015 12:41 pm; 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: Fri Sep 25, 2015 12:05 pm    Post subject: Reply with quote

the edge of the front mask is damadged too, so i will add some metal there
Image may have been reduced in size. Click image to view fullscreen.

made a cut and cleaned it up
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: Sat Sep 26, 2015 7:45 am    Post subject: Reply with quote

and the repaired joint. i use different carbide bits and small flapwheels (same i use for porting heads) in an airgrinder to remove the welding imperfections
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 Sat Sep 26, 2015 7:59 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: Sat Sep 26, 2015 7:48 am    Post subject: Reply with quote

after adding some more welds to the lower pillar i moved the a pillar forward using a VW jack at the upper hinge mount
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: Sat Sep 26, 2015 7:50 am    Post subject: Reply with quote

the doorgap is a lot better now (but the top hinge has to be repaired to have no movement in it and have the gap adjusted a final time), so i welded the lower pillar to the front crossmeber finally and closed the rusthole in the inner valance
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: Sat Sep 26, 2015 7:57 am    Post subject: Reply with quote

the front sheet metal fits pretty good now, but i won´t weld it on now
Image may have been reduced in size. Click image to view fullscreen.

i briefly thought about mounting the doglegs now, but the rear part of them will butt up to air because there is no lower b-pillar. i will repair the outriggers/inner rockers and all the construction under the cargofloor next the be able to replace the lower b-pillars
_________________
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: Sun Sep 27, 2015 8:57 am    Post subject: Reply with quote

i had these made by a local plumber, about two meters long each, so i have to cut and bend the ends myself
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
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 ... 8, 9, 10 ... 17, 18, 19  Next
Jump to:
Page 9 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.