1962 Deluxe restoration

[67rustavenger]

Don,
Just so you know. We are, well, at least I am, following along on your customer build.
I almost daily check on your progress, and am amazed at what you are getting completed.
If I tried this, it would be a years long project. With dismal results.

Keep the great work!
_________________
I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!

[sunroof]

Pieced together a final patch

Shot some sparks

Done like dinner

Don
_________________
Better and better mistakes!

[sunroof]

[sunroof]

So that pretty much buttons up the front end

I just have to fold the pinch weld over and finish that. It will have to wait till the next time the body is on the pan since the door brace is in the way right now.

This is as done as it is going to get

All this turned out beautifully

And super happy with this

Up next is all this business

Don
_________________
Better and better mistakes!

[sportin-wood]

Your skills are very impressive! Looking forward to more progress. Keep it up!
_________________
.
Paused 66 project bug
.
"Relax, all right? My old man is a television repairman. He's got this ultimate set of tools. I can fix it." --- Jeff Spicoli

[sunroof]

So it begins

Oh boy this is not good

I am likely going to have to replace this whole section

Meanwhile

This is pretty straight forward

Also this

A trick I picked up from blondiehacks, a large felt pen and a scriber to mark out the cut lines

Well on my way

Don
_________________
Better and better mistakes!

[sunroof]

Bottom all folded over and trimmed to fit

Another piece taken care of today as well

I remember this one being a challenge from the other side. I think I will try to take it slow.

A good start

BTW, this is what my bench looked like before I called it quits for this afternoon

Once the patch is fitting the way I want of course everything will get cleaned up and put away.

Don
_________________
Better and better mistakes!

[sunroof]

Excelsior

Or: onward and upward

Begin making corrections to the Klokkerholm piece beginning with the mount doubler which spent the night in Evaporust

Once again the spot welder makes things easy

Have to carve out this little pentagonal doubler bit

Now it looks more or less correct with all the extra stuff carved away

Gaping hole: (also a good name for a grunge band if that's still a thing)

Relegated to the scrap heap of life, minus the pipe of course

This should be easy

Don
_________________
Better and better mistakes!

[sunroof]

That went well

Don
_________________
Better and better mistakes!

[sunroof]

Having learned my lesson from the drivers side I measured 8 inches up from the bottom of the panel and laid a line to get the funky green panel in the right place

I have made some trims to get the quarter panel in the right place.

I am really wishing I had done the passenger side first as the experience I got from that is making a big difference to how this is all going together

I am going to have some figuring to do tomorrow to get the back part to match up bit I don't expect it will be too difficult

I'll keep you posted how it goes

Don
_________________
Better and better mistakes!

[Dan22]

Hi Don.

Yes I am watching your thread as well. Your skills and capabilities have notably improved over the years. Clean metal and good tools does wonders.

Bummer about the door alignment. I hope it straightens out OK. The body without a heater channel is very flimsy for sure. Bracing (I like adjustable) is essential. And Check, Check, and Recheck!


_________________
1-0900722 die langsame grüne Schildkröte
https://www.thesamba.com/vw/forum/viewtopic.php?t=765074

[VW_Jimbo]

Nice work Don! Remember, you are a student. Makes things easier when they sag. Which then leads to learning a whole bunch more stuff!

Your process is spot on. Really enjoy seeing you work through the repairs!

Oh, by the way, no matter how many cars you piece back together, not one of them is straight forward. However, when you hit a hard spot, your bag of trick can typically get you through the most difficult of situations!

Rooting for you! BTW I keep checking on you!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[sunroof]

Same as the other side, this bit needs fixed

That went well. I missed a little on my cut so had to weld in a little bridge piece at the back top to fill the gap.

I will make sparks today or tomorrow.

Don
_________________
Better and better mistakes!

[sunroof]

[sunroof]

So this is the 4th quarter panel I have replaced in the past couple of years. I am finally starting to appreciate why I have had so much trouble with these. As soon as I start welding it gets pulled all out of shape even with clamps in place. There must be a sequence of welds where the shrinkage pulls it into the shape I want instead of away from it. I usually clamp the ends real tight and make a few spots in the middle then have to reclamp the ends and spend time reshaping things to get them back to where they were before I started. Perhaps if I started on the ends and moved towards the center.

Don
_________________
Better and better mistakes!

[sunroof]

Evaporust is such amazing stuff

Anyways, a good afternoon of welding. Least amount of warpage yet. Just as I am finishing I am finally learning to weld.

Before we can do any more welding we must address this

Don
_________________
Better and better mistakes!

[67rustavenger]

Impressive weld quality.
I wish mine looked that good.

The underside of the luggage tray looks like a fun area to clean up.
I need to replace one in my driver soon. Luckily I have a spare parts car that I can cut the tray out of.

Keep up the fantastic work.
_________________
I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!

[sunroof]

Cleaning the field to prep for surgery

Cancer excised

Hmmmm, what to do, what to do...

Wire brush it a little to knock off the loose stuff then into the Evaporust.

Don
_________________
Better and better mistakes!

[sunroof]

Two days in the evaporust and we have this:

I now feel that I know what needs to be done

Don
_________________
Better and better mistakes!

[sunroof]

I decided to piece the repair sections together. This has worked well for me in the past. I started by carving away the worst of the rust and fabricating the most complex bit first.

Two hours later...

All that to make this little piece

Surprisingly complex but a perfect fit

The rest should be easy.

Don
_________________
Better and better mistakes!