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New Project 1303 Cabrio and first Post
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jhicken
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PostPosted: Fri Dec 06, 2013 6:30 pm    Post subject: Reply with quote

Nice, are you going to keep the original color? I like the lemon yellow. You don't see many in that color.

-jeffrey
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rothaus
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PostPosted: Wed Dec 25, 2013 8:32 am    Post subject: Reply with quote

Yes the Beetle will be painted the same Marino Yellow.

It's also time for an update.

Got a few things done during the last couple weekends.

The chassis is done, also at the top, and ready for assembly.

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Did some power coating. The stove works OK, however, I need to watch the temperature. Some improvement is needed for the temperature control.

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Finally I had it with the small blasting cabinet.

Ordered some bits and pieces and got 2 sheets of plywood.

BUILDING A GOOD SIZE BLASTING CABINET 48 X 24 X 32

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Cutting out for the window

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And the holes for the gloves

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Caulking all the cracks

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Building the bottom part

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Cutting a hole for the light

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Ready for primer and paint

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Still had that blue paint, and it goes nice with the lift

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Assembly of top and bottom part

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Now get some legs

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Here we go, it's standing up.

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I just used some wire shelf pieces inside.

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Building the top light

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I had the 100W 12 DC driver sitting a round, and also 2 HID ballasts and bulbs

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Some flashing left over makes a nice reflector

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The 2 HID bulbs use only 70W

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Here a quick test of the light

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Looks like I have enough light in there

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Here it is ready for a blast

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Here it is the top one to be done, bottom one is clean and ready for powder coating. Hope I can fit it in the stove.

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Cheers
Engelbert
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jhicken
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PostPosted: Wed Dec 25, 2013 10:21 am    Post subject: Reply with quote

Nice job on the cabinet, I wonder how the painted wood will hold up inside.

-jeffrey
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rothaus
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PostPosted: Fri Jan 03, 2014 7:02 pm    Post subject: Reply with quote

OK, it's time for an update....

Bending and installing some brake lines

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Put the rear suspension back together

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New bushings

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Powder coated spring plates and covers

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Now with the control arms

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Moving back the to body, since I waiting for some suspension parts.

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New front piece installed with the left and right bumper support section

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Attacking the rear part of the wheel well, which looked like an easy task.

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Not so... more under the skin

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Reconstructing all the pieces

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Welding it back in

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More stuff to fabricate

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The skin, finally

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All welded in and cleaned up. The next piece is the brace of the strut tower.

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More coming soon.

Cheers
Engelbert
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caffeinebean
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PostPosted: Fri Jan 03, 2014 9:38 pm    Post subject: Reply with quote

Great fabrication work! Looking forward to seeing this project going forward.

Thanks for sharing!
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mountainkowboy
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PostPosted: Sat Jan 04, 2014 8:10 pm    Post subject: Reply with quote

I don't feel so bad about the rust in mine now, great work.
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rothaus
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PostPosted: Sun Jan 05, 2014 6:31 pm    Post subject: Reply with quote

Little update. Completed the right side around the front wheel well, and now move on to the left one.

Strut tower brace is back on, and one more small section to cut out and weld a new piece in.

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Now we are moving to the left side

Doesn't look that bad at first

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A bit crunchy here

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Once the outside skin is gone, it looks not that good any more

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More crunchy stuff.. outch

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Need to make some cuts

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One piece is gone.

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It is getting thin.

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Looks like a few pieces to fabricate... next weekend.

Cheers
Engelbert
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rothaus
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PostPosted: Fri Jan 17, 2014 7:32 pm    Post subject: Reply with quote

I decided to replace the complete reinforcement rail on the left side, since I repaired that piece (I'm shocked) 15 years ago. This way I will have a nice strong base.

OK, enough of this, I will move to something more fun. Re-assembly of the chassis:

Preparing some brake lines


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And installing them, as well the master and rear cylinders

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The rest of the brakes, etc. is for next weekend.
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rothaus
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PostPosted: Tue Jan 21, 2014 7:17 pm    Post subject: Reply with quote

More progress:

Installing the brake shoes

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and drums

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Ok... now we are moving to the right rear corner

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It didn't look that bad, however, as more you dig in....

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And before you know it the hole get's bigger

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Trying to find the good material to weld on to.

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Fabricating some new pieces

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And weld them in. No comments needed

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Finishing up the outside

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To be continued

Cheers
Engelbert
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olmer2
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PostPosted: Tue Jan 21, 2014 9:07 pm    Post subject: Reply with quote

Nice work. Loving the build!
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allsidius
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PostPosted: Wed Jan 22, 2014 2:27 am    Post subject: Reply with quote

Nice build! I used to have a 78 vert. It struck me that 1) it wasn't as watertight as the sedan and 2) it wasn't as well rustproofed as the sedan. All these rubber scrapers could not keep the water out where they wrapped around the nicely chromed brass surrounds, not to mention that in 20 years, the top had been shot for about 10 years, water leaking in and collecting in the floor. The vinyl tops started cracking after just a year or two, I know because I bought a 2 year old Golf vert back in the 80s. Already the vinyl had started cracking. Which was why I chose Stayfast Canvas when I did the top of my beetle 15 years later.

Karmann was a high quality coachbuilder, but these cars were built to be scrapped in 10 or 15 years in any case. I am happy that I did not dig into my vert before I sold it, it was probably just as bad as this, which is probably not worse than the average 35 yr old vert out there.

Keep up the good work, at least the spare wheel well looks fine!
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PostPosted: Wed Jan 22, 2014 6:58 am    Post subject: Reply with quote

Nice work.. Reminds me of when I "de-rusted" my 69 vert. I'm not sure why these cars rusted so much quicker than standards did.

Tell me about your lift? How tall and how much was it?
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allsidius
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PostPosted: Wed Jan 22, 2014 11:18 am    Post subject: Reply with quote

wcfvw69 wrote:
Nice work.. Reminds me of when I "de-rusted" my 69 vert. I'm not sure why these cars rusted so much quicker than standards did.



Karmann did not have the advanced phosphate bath that VW had, so the primer did not stick as good. Karmann was realtively small scale, and could not afford a bath big enought to dip the whole car. The phosphate etches the steel so the primer bites. In addition, the top had to leak almost from day 1, while the sedans are pretty watertight.
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PostPosted: Wed Jan 22, 2014 12:29 pm    Post subject: Reply with quote

As has been said, nice work! If I didn't know better myself, I'd swear I was looking at the pictures I took when I replaced all those areas of my car last Summer, except in green. I also replaced the front firewall while I had it all apart. I noticed the bottom of yours was a little crusty. I see those boxed rails on either side in the front are another common area for rust in the Supers. Keep up the progress!!
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PostPosted: Wed Jan 22, 2014 5:15 pm    Post subject: Reply with quote

I agree, these cars were never build to last that long.

Most of the rust is because of the leaking, and as well to be parked outside, which doesn't happen to my cars.

To the lift, it's a Bendpak. Here is the link with the info

http://www.bestbuyautoequipment.com/2-post-car-lif...kxpr-9.htm

I have a 10 ft ceiling, and it works great for my Porsches and the bug. I cannot put the F150 or the Cayenne on it.

Cheers
Engelbert
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PostPosted: Wed Jan 22, 2014 5:23 pm    Post subject: Reply with quote

rothaus wrote:
I agree, these cars were never build to last that long.

Most of the rust is because of the leaking, and as well to be parked outside, which doesn't happen to my cars.

To the lift, it's a Bendpak. Here is the link with the info

http://www.bestbuyautoequipment.com/2-post-car-lif...kxpr-9.htm

I have a 10 ft ceiling, and it works great for my Porsches and the bug. I cannot put the F150 or the Cayenne on it.

Cheers
Engelbert


Thanks for the lift link. I'm getting too old to want to crawl around on creepers and use jacks and jack stands. Might have to crack the wallet and get one. Very Happy
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rothaus
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PostPosted: Wed Jan 22, 2014 5:45 pm    Post subject: Reply with quote

That's the best investment I ever did, and I'm with you, getting too old to crawl under the cars.

This is maybe a little OT, however, here some pictures how I installed it.

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As you can see, it's not bad for small cars.

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Cheers
Engelbert
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PostPosted: Wed Jan 22, 2014 7:10 pm    Post subject: Reply with quote

Thanks very much for sharing those pictures. My 3 car garage only has 8's ceilings. I see they make one for that size garage as well. I don't need to left the car more than 3-4' off the ground. Enough to pull the engine, oil changes, brake changes, etc. It would be used to replace the floor jack and floor jacks. I had thought about a scissor lift style but I don't like them.

The smaller one can easily be removed and stored out of the way when done with it as well..

Darn it.. I may make a phone call and order one tomorrow.. WE only live once, right?
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PostPosted: Wed Jan 22, 2014 7:12 pm    Post subject: Reply with quote

Another question, why not lift your Cayenne or F-150 with it? It appears to have the capacity or did I read it wrong?
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Decades of VW and VW parts restoration experience.
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**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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jhicken
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PostPosted: Wed Jan 22, 2014 7:49 pm    Post subject: Reply with quote

I recently bought an Atlas 8000lb 2-post lift from Greg Smith Equipment in Delaware. It's a cheaper lift, but for what I need it for, it's perfect. Did a few searches and read mostly positive reviews. If I were buying for a shop, I'd probably go BendPak or Rotary, but for lifting my VW's, this works great.

-jeffrey
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