TheSamba.com :: View topic

Sat Oct 25, 2025 6:01 am

Think I have the transmission hump panel figured out.

I will press in the ribs and use a 3 D printed die to help with the bend.

Now to start pressing.

Sat Oct 25, 2025 2:46 pm

I love that pressing tools!
They are a game changer :)

-Christian

Sun Oct 26, 2025 12:22 pm

Ruff pressing done. Lots of tidying to do but will wait until it is almost finished too fix a lot of the details.

The ribs positions came out matching the original. I am getting better at estimating the shrinkage.

Next I will form in the hump. Hopefully it will take up most of the extra metal but may need to heat shrink.

Mon Oct 27, 2025 3:11 am

sgellis, that is stunning! You are a master.
=D> =D> =D>

sgellis wrote: Ruff pressing done. Lots of tidying to do but will wait until it is almost finished too fix a lot of the details.

The ribs positions came out matching the original. I am getting better at estimating the shrinkage.

Next I will form in the hump. Hopefully it will take up most of the extra metal but may need to heat shrink.

Wed Oct 29, 2025 5:10 pm

Bit more done. Not an easy part to get flat. I may need to put in a couple relief cuts.

It is good enough to put in the long bends so will see how the back reacts to the bend. Maybe I can get away with some more shrinking.

Sat Nov 01, 2025 2:52 pm

Bends in. The 3D printed die worked great at getting the ribs around the 50 mm radius.

The bulge over the transmission is not working out so will cut it out and create that part separate. Too much extra steel there to take up.

Thu Nov 06, 2025 7:55 pm

Getting bits fitted. I will need to do some repairs to the original parts before welding them together.

Always super satiating to lay an old rusty part on the new piece and having the ribs lay together perfectly. :)

I have to do a repair to the vin. A few of the stamping were very deep and the rust from the rear made a few pin hols in the bottom of the digits. Plan is to spread a thin layer of JB weld on the back and sand smooth. I will spay a few layers of zinc on the front to prevent the JB weld from coming through. The zinc is easy to remove after.

Fri Nov 07, 2025 8:29 am

sgellis wrote:

I have to do a repair to the vin. A few of the stamping were very deep and the rust from the rear made a few pin hols in the bottom of the digits. Plan is to spread a thin layer of JB weld on the back and sand smooth. I will spay a few layers of zinc on the front to prevent the JB weld from coming through. The zinc is easy to remove after.

Can you please expand on this and show us when you do it?

Fri Nov 07, 2025 3:34 pm

Bloody amazing!!

Sat Nov 15, 2025 3:34 pm

Finally done... Mostly. Still a few details to add.

If doing it again I would make two parts and seam along where the fire wall panel meets.

Sun Nov 16, 2025 1:34 pm

Looks like a bought one! That’s impressive!

Mon Nov 17, 2025 10:31 am

Well done sir

Thu Nov 20, 2025 7:27 pm

On to the rear wheel wells.

Inner panels needed to be removed as they are very rusty along the seams. One seat bolt cover was rusted and needed removing. It had an excessive amount of spot welds. Decided I should remove the other one also.

Started patching the left side. Would be much faster to just make new ones.

Sat Nov 29, 2025 4:03 pm

Left wheel well finished, mostly

I need to trim 10mm off the lower front of the inner panel. I wasn't 100% sure of the size until everything was fitted. Always easier to trim than to add some on.

Sun Nov 30, 2025 8:59 pm

Looks great!!

Tue Dec 02, 2025 2:15 pm

you're a madman, I expect no less from the barndoor forum though!!

Sat Dec 06, 2025 1:19 pm

I needed a quick part to build so finished off the front valance.

I clamped the panel in place to insure the bumper bracket holes were lined up.

The angle is 18g. Curved it with the stretcher. I clamped the panel on high and spot welded the angle on to ensure it had the correct curve.

Mon Dec 08, 2025 2:02 pm

Ready for the bumper now! :D

-Christian

Fri Dec 12, 2025 10:22 am

Decided to finish up the front structure. Last bit is the dash pod. The pod bracket is in good condition but the cross braces are rusted along the bottom and beyond repair.

I knew the braces were going to be a pain to bend as my brake can only do 1/2" offset bends. I was able to do a short section by bending the first to 45° followed buy second bend and then finishing the first bend. On full length sections i could not get a good bend as it would slip in the brake.

Ended up using my largest step die in the bead roller with a guide. I offset the dies to give the correct distance between bends. After a few passes it gave me all the bends at around 45°. Then just finished them off in the brake. Work better than i expected.

Now i need to add the bends to the top brace. Haven't decided if I will print some dies or work it by hand.