TheSamba.com :: View topic - 1975 Beetle Convertible Resto/Mod Build-Chop,Dash,Suicide,Shave.

Mon Jan 27, 2025 7:56 pm

Hi All,
I was able to get a free afternoon and my A/C Vents came in from China. I got some inexpensive(CHEAP) ones. It looks like they will do the job though. I was looking for awhile, trying to find vents that would fit in the center of the dash and still have enough of an opening to give me a decent volume of air coming out. The best I could do were these, however, that would mean mounting them in a stacked configuration. I'm not too sure how I feel about that but, Oh well...
I made a carboard template with the vent holes and transferred that to the Dash.

I had hopes for the look I had imagined. I would be able to save the Wiper and Hazard mounting holes, and I could have the Chrome strip from the Glove box continue through the middle of the Vents. Neither of those hopes came true! The two tick marks on either side of the Radio are the continuation line for the Chrome strip. The vent is too large and pushes that line up about 3/4". And, although the cut lines for the vent clears the Wiper mounting hole, the Vent's finished face is about 1/4" larger. So, it will cover the indent quite a bit. Again...Oh well.

So, I will just cut them out and hopefully I can use them later. Here is the new, Larger cut lines.

Cut that out and made a patch piece. There is a very subtle curve to the Dash. So, that was a thing :( But, I got pretty close and welded it in. That took awhile(still trying to be patient).

Transferred the cut holes back on and cut them out. And gave it a shot.

I don't trust my cutting skills, so I try to give myself a little wiggle room by cutting small. Then, I can shave away a little at a time to try and get a decent fit. Looks like I got a little shaving to do. But if you can see in the background, It's Dark Out!!
The wifey insisted that I come in for Dinner. Actually, what she said was,
"Get in Here and make Dinner!"

Mon Jan 27, 2025 11:52 pm

You got it done! Another step closer!

Tue Jan 28, 2025 9:24 am

Slow & Steady, MacJelly, looking good! I missed it, what AC system are you installing?

Tue Jan 28, 2025 10:45 am

Great to see you back at it!
Nice fab work. Those should work well.

J.

Tue Jan 28, 2025 7:32 pm

Thanks JIMBO, inspirational as always. Watching you get out to the garage and looking like you are having so much fun. I mean who knew that fabricating Engine Tin and Heater Box parts could be so entertaining. Much appreciated!

And Yup, DUNGBTL, It's sure is nice to be doing something. I'm a little rusty though. My back is stiff and my knees are grumbling. I gotta try and get out there more regularly and loosen everything up!

Hey VAMRAM,
I've been researching that for years now :roll:
Everyone seems to have great results using the "GILMORE" kits. Looks like quality and made specific to our Beetles.

That being said, what I have is a twisted, Frankenstein Freak! The "GILMORE" kits would have to be severely modified to work for me. Also, I didn't like the early model(1302), under dash Evaporator's location in the passenger side area.

Then, the later model(1303) Evaporator's location in the Trunk(Boot) is rather large and appears to have some of the output to the stock Dash vents. While the intake is through the rear of the Glove Box. Both of those things would not work for me.

So, I think I'm going with a kit from, "COLD MASTER". It's a piecemeal kit that allows me to configure the components as I like. As to how I'm going to make it all come together, HAH! That's going to be an adventure!

Tue Jan 28, 2025 8:36 pm

What alternator are you using with that AC?

Wed Jan 29, 2025 6:27 pm

MACJELLY58 wrote: So, I think I'm going with ...a piecemeal kit that allows me to configure the components as I like.

This was always the only viable answer.

"When you come to know yourselves, then you will become known." [Gospel of Thomas, @(3)].

:popcorn:

Wed Jan 29, 2025 6:46 pm

I'm just going with the 90amp Alternator, VAMRAM. I'm also researching running two batteries in tandem. Just because of all the Door, trunk actuators and the A/C components, Stereo and assorted extras. It's all up in the air. May or may not be necessary. I don't know, we'll see. :D

I think (know) you're right, BUGGEEE. It was a thing, because of the half early Bug and half late Super Bug, Dash and under Dash. I wish it wasn't so, but that's the world I made for myself.

And...just because I like Pics, here's a couple of sweet rides from a local island show.

Thu Jan 30, 2025 8:58 am

MACJELLY58 wrote: ...a piecemeal kit that allows me to configure the components as I like...

I think it has more to do with the builder than the build. :D

I may have mentioned this, but this build reminds me so much of the wildly custom led-sleds I would read about in the magazines as a kid. I'm really digging the thread, posting of real-time insights and processes that go into this art form.

Sun Feb 02, 2025 8:02 pm

Thanks BUGGEE! Yup, that's surely me. A Lead Sled builder to me is, a dude in his garage winging it. Making things with just a whim and imagination. Make shift tools and techniques, just trying to make it happen. Thanks for rooting for me. I guess I got it from my Father. He was a Backyard Fiddler. His tool box consisted of a hammer, screwdriver and a vice grip. It was not pretty to watch and the end result wasn't pretty either, but he'd get it to work.

At least I moved on from Lead filler. Although, it's an art and I'd probably never be any good at it. :lol:
I forced in some time to finish up the Vents. I was tired of having to clean everything again, after leaving it to rust for a week or more. I trimmed the openings just a hair and got a good fit. Put some filler and primer.

I popped them in and enjoyed. I guess, I think I like it. Too late now anyway.
Now I gotta figure out the two side under Dash vents. More FUN!

Mon Feb 03, 2025 12:21 am

SWEET! Nice progress! And it looks clean! You are getting way better at this.

Fri Feb 21, 2025 9:29 pm

Thanks JIMBO,

Experience is helpful, but my real accomplishment is getting better at being patient. I've resigned myself to the fact that I'm not gonna get 'er done on my timeline. I just gotta enjoy the journey.

Speaking of which, I was able to squeeze in an hour here and there the last couple of weeks. I didn't really have a plan for the side A/C vents. The main thing was to get the holes made for the hoses. I want to get as much done as possible before paint. I can always use some Touch Up paint for the unforeseen.

I started on the passenger side with a template. Then, drill them holes!

Transferred that template to the Hardboard and kept adding pieces. The wife requested a drop space for her Sunglasses and stuff- :roll: WOMEN! Just a little tray that I'll put some Cargo netting on the front.

It took a few iterations to get it right. I made the Driver's side there at the bottom.

I bit the bullet and went treasure hunting for the Steering Column. Of course it was at the bottom of the parts pile. This is the first time that I've had it fitted since the new(old) dash. I was pleased that it look okay. I was worried that it might stick out too much from the Dash. Next was to start making a cover for the column to clean it up a bit. Then, a little piece on the other side of the Column. Tying it all together.

I found some Brackets in my junk box and started to figure out the mounting. I made the Brackets into Hangers that are bolted to the Dash in the Trunk. I didn't quite finish the mounting. But, at least I have more to look forward to. :wink:

Fri Feb 21, 2025 10:42 pm

Very nice Jellyman! It is cool to see, watch the progression in your technique through the years! I know that I have the same things going on! It is the creator, learner in us! So cool! I have never seen anyone else with a skillet like my own, well, except for my father, and grandfather. It was in the blood line for sure! Really cool!

Keep going! I am liking the boxey look around the steering wheel. It will be neat to see it in steel!

Go Man Go! (Like the Dr. Suess book!) :P

Mon Mar 03, 2025 1:10 am

VW_Jimbo wrote: I am liking the boxey look around the steering wheel. It will be neat to see it in steel!

Sorry to disappoint, Bradduh JIMBO.

The "Boxey" terminates at the Steering Column and there's no steel. :D
Like the Center Console, the Hardboard remains and will be covered in leather. I'm not that ambitious!

Next up is the mounting. I always have trouble drilling the blind holes in this type of situation. I usually try my best to measure the screw holes to line up with the intended "blind" target. But, I find myself guessing and missing. Finding that I have a few holes to choose from at the end. So, my new plan is to drill the top hole first, position the bracket on the Hardboard, then weld a capture nut to the bracket.

Then, I spread some Gorilla glue on the Hardboard in the area of where the bracket will sit. Then I taped the Hardboard in place under the Dash. Wait for the glue to dry and then remove the Hardboard with the bracket now glued perfectly in place, and then screw the glued bracket to the Hardboard. PERFECT!!

Probably not the most efficient or scientific solution, but it worked.
I hope it makes sense. I was too busy trying to figure it out to take a lot pics.

With the mounting done, I put some braces in the angles to stiffen them up a bit. Mounted them up and they are really solid and tight.

You can see here that I got the box to narrow down to the Steering Column. I think when I get it upholstered it will look pretty good.

The last piece is the top of the column. The plan is to have it just snap in, like press fitted. I need a piece to slide under that Column mount lip, then snug up against the plastic Column cover.

I found a piece of ABS black plastic and cut it to size and shaved it here and there to juuuust fit in there. It actually "SNAPS" in place!!

I was feeling pretty good. Then, I remembered the reason I was doing this now. I was supposed to have the A/C hose holes sized and finalized. Hahaha!! So I got those trimmed out and primed, the hose fitted nicely. I ran outta time, so I gotta wait to put it all together for a final fit and looksy.

Mon Mar 03, 2025 12:31 pm

I think you are having way too much fun.

:popcorn:

p.s. I might have missed it but do you cover the hardboard in fiberglass resin or something to make strong and moisture proof, or does it just work good as it is covered with a decorative leather?

Fri Mar 07, 2025 12:24 pm

Really love what you're doing with the dash! Those vents are so cool!

Fri Mar 07, 2025 7:31 pm

Thanks guys!

I'm just stumbling along, piece by piece. No real plan, except get them in some how. I continued with coating the pieces in Oil Based Polyurethane. Much like the Center Console. However this time, I put a deep scratch of 80 grit. In hopes that it would soak in there and help with any condensation and maybe a little extra strength. I guess it worked, the color is way darker than the Center Console.

It was kinda funny, BUGGEEE, I was waiting for the first of three coats to dry and of course, I decided to kill the time by looking at theSamba site. There was your post about the treatment. HaH! But to answer your question, the Hardboard seems to be plenty strong for their purpose. No load or moving parts. Just to be sure, I put in those angle braces at the joints. Anywas, here's where I'm at.

Sat Mar 08, 2025 5:13 am

They do look like they took it in well. Maybe if Volkswagen had done this I would still have the original glove box. :)

Sun Mar 16, 2025 1:26 am

So right, BUGGEE. But then again, It's kinda amazing that the Cardboard Glove Boxes lasted so many years before they literally disintegrated. I guess they even made Cardboard better back then! We'll have to see just how long these Vent boards last. Hopefully, longer than I do. :wink:

I got them finished off and installed. Well, almost finished off. I forgot to mention those center "wings". Those angled pieces that just kinda float towards the Tunnel. I still need to fit them to integrate into the Center Console I had made earlier. Thus, I made them longer than I think they needed to be until then.

It came together quickly, so I moved on to some body work. The Trunk Channel that I welded for the rusted out portions still needed to be addressed and the patch for the removal of the Fresh Air Vents. Then, that turned in to tweaking the top of the Dash and so on...

I got a lot further towards completion but, I bit off more than I could chew...again. I ran outta time and patience. So, I still have a few problem areas to fix later in the finishing phase.

A little disappointing, but I was very pleased with the progress on the patched rust hole on the side cowl. The new body line came together pretty well.

Overtime is back, so hopefully I can get out there again soon.
SHAKA, Braddahs!

Sun Mar 16, 2025 8:56 am

This is looking fantastic. Lots of progress.