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sunroof
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Joined: October 06, 2006
Posts: 1778
Location: Winnipeg
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 Posted: Mon Feb 19, 2024 12:52 pm Post subject: Re: 1962 Deluxe restoration |
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A professional welder/instructor friend of mine once told me that if you can jump across it you can weld across it
This also went well.
You can see a spot on the center left where I did not wait long enough between spots and put a little too much heat into the panel. This drew the panel in a little in that spot but I can get in behind it with a dolly so I can straighten things out easily.
This I will leave for a separate session so I can focus on what it all needs
Don
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1778
Location: Winnipeg
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| Posted: Wed Feb 21, 2024 12:24 pm Post subject: Re: 1962 Deluxe restoration |
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Last night I finished welding the outside of the rear quarter apart from the attachment to the heater channel This will have to wait for a bit.
A couple of things we are waiting for are the clamp strips for the bottom of the B pillar covers and welder repair.
I made a bit of a mistake with the welder I bought and now it is coming home to roost in a way. I bought a Lincoln MIGPAC 140 from a local dealer because they were close and now I am regretting it. The welder does not have a solenoid valve for the gas just a valve in the handle which leaks significantly. I am on my 3rd bottle of gas since November so something has to be done. I brought it back to them but it turns out they closed their service department and now contract out repairs to a 3rd party. The upshot is that I now have to wait 2 weeks for a very simple repair. Very Annoyed!
With that in mind I will spend some time cutting apart the passenger side.
Don
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Kafer_Mike
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Joined: June 23, 2004
Posts: 348
Location: Noblesville, IN
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| Posted: Thu Feb 22, 2024 6:36 am Post subject: Re: 1962 Deluxe restoration |
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Great progress with a minor setback. Sure you'll be back at it soon enough.
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Kafer_Mike
Build 'em fast...or let 'em sit. |
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1778
Location: Winnipeg
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| Posted: Sat Feb 24, 2024 8:07 pm Post subject: Re: 1962 Deluxe restoration |
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With the welder in the shop I will start cutting into the other side
Don
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VW_Jimbo 
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Joined: May 22, 2016
Posts: 9974
Location: Huntington Beach, CA
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| Posted: Sat Feb 24, 2024 11:43 pm Post subject: Re: 1962 Deluxe restoration |
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Why is the quarter panel so far from lining up with the door bottom?
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Jimbo
There is never enough time to do it right the first time, but all the time necessary the second time!
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1778
Location: Winnipeg
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| Posted: Sun Feb 25, 2024 3:34 pm Post subject: Re: 1962 Deluxe restoration |
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Why is the quarter panel so far from lining up with the door bottom?
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You weren't supposed to notice that. It is a problem with the repair piece. I thought I had made another mistake and was really kicking myself so I looked at the other side and realized that the panel is supposed to drop below the heater channel and it doesn't. Before I welded it in place I had already trimmed the bottom of the B pillar to get things lined up more or less. Also there is a cut along the bottom where I stretched it a little to try to get it to fit better. If you look closely what you will see is that the rear of the panel lines up exactly but the front is about a half inch too high. If I just trimmed it to fit, it would be significantly crooked, I would have to make extensive modifications to it to get it to line up. Next time the owner is in the shop I will show it to him and if he wants it fixed then I will fix it. Otherwise it will stay and lesson learned.
Don
Don
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sunroof
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Joined: October 06, 2006
Posts: 1778
Location: Winnipeg
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1778
Location: Winnipeg
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| Posted: Thu Mar 07, 2024 9:28 pm Post subject: Re: 1962 Deluxe restoration |
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OK lets get started on the A pillar
And now the front corner
Don
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Apostle_
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Joined: July 02, 2023
Posts: 39
Location: Texas
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| Posted: Fri Mar 08, 2024 9:38 am Post subject: Re: 1962 Deluxe restoration |
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| Wow! That looks familiar. I'm doing that on my 63 right now! |
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1778
Location: Winnipeg
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| Posted: Thu Mar 14, 2024 2:23 pm Post subject: Re: 1962 Deluxe restoration |
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Got this buttoned up in the last couple of days. A little more grinding and a couple more holes to fill and I'll call it done.
Don
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Busstom
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Joined: November 23, 2014
Posts: 3855
Location: San Jose, CA
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| Posted: Thu Mar 14, 2024 9:50 pm Post subject: Re: 1962 Deluxe restoration |
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How is something like this typically handled, do you treat that rust, or just weld new metal over it and call it good?
Does it stop rusting as long as no more water hits that rust?
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Kafer_Mike
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Joined: June 23, 2004
Posts: 348
Location: Noblesville, IN
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| Posted: Fri Mar 15, 2024 5:26 am Post subject: Re: 1962 Deluxe restoration |
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If just surface rust, I would remove via wire wheel or sandblasting, then treat with a rust convertor/encapsulator.
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Kafer_Mike
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1778
Location: Winnipeg
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| Posted: Sat Mar 16, 2024 3:07 am Post subject: Re: 1962 Deluxe restoration |
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How is something like this typically handled, do you treat that rust, or just weld new metal over it and call it good?
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I've done both on this job. Some rust I treat with rust convertor, some I grind off and prime and some I replace the metal. In the case of the A pillar bottom I will do like the other side:
It has to happen with the heater channel in place to make sure everything is in its proper place, which can't happen until the front is taken care of
Getting the sequence right is where experience comes in. I've had to cut things back apart in the past because I got the sequence wrong.The price of learning.
Once the front is done I can get rid of this brace because it has to go before I can fix the inner A pillar
but before I can get rid of this brace I have to build its replacement which means making mounts
And cutting this apart and rebuilding it to work with this scheme
BTW I added it up on my time sheet and as of February 29 I am 186 hours into this job. With occasional setbacks...
However:
https://www.youtube.com/watch?v=KIdfFwKceDk
I am really enjoying myself. Working on my TR6 is always work but a beetle is a joy.
Don
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Last edited by sunroof on Sat Mar 16, 2024 4:11 am; edited 2 times in total |
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1778
Location: Winnipeg
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| Posted: Sat Mar 16, 2024 4:00 am Post subject: Re: 1962 Deluxe restoration |
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Of course the lower hinge is frozen on the passenger side, jeez, didn't anyone read the manual?
So I got out the Mighty Merta pin press
Got the pin halfway out
And broke the shit out of the tool. I exceeded the 30 Ft-lbs ever so slightly.
Now I will have to cut the hinge in half to get the pin the rest of the way out. A job I have done before:
Meanwhile Tim brought over the wheels for the car and I noticed one of them looked pretty old, don't ask how I could tell, I just could. So we looked for the date code and whaddya know!
I know someone with a '53 who is looking for wheels, we may have to arrange a swap.
Don
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Busstom
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Joined: November 23, 2014
Posts: 3855
Location: San Jose, CA
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| Posted: Sat Mar 16, 2024 11:24 am Post subject: Re: 1962 Deluxe restoration |
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| BTW I added it up on my time sheet and as of February 29 I am 186 hours into this job. With occasional setbacks... |
Wow. At a scant $50/hr, that would already be >$9k (example only). Rust ain't cheap.
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sunroof
Samba Member
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Posts: 1778
Location: Winnipeg
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| Posted: Sat Mar 16, 2024 2:36 pm Post subject: Re: 1962 Deluxe restoration |
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Wow. At a scant $50/hr, that would already be >$9k (example only). Rust ain't cheap.
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Luckily I am both cheap and easy.
I have a friend who charges $1000 a day for bodywork. He, however, is a maestro unlike me who is more of a butcher hacking and chopping my way along.
Don
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sunroof
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Location: Winnipeg
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| Posted: Mon Mar 18, 2024 2:30 pm Post subject: Re: 1962 Deluxe restoration |
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Moving right along...
Don
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sunroof
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Posts: 1778
Location: Winnipeg
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| Posted: Sun Mar 24, 2024 7:09 pm Post subject: Re: 1962 Deluxe restoration |
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Bolted the body to the chassis to check door fit, not going to make that mistake again.
OK that will do
Like the other side I cut the inner quarter out
Lots to do here
This one was in much better shape and will need far less rebuilding
Built a much better door brace and lifted the body off the pan again
Got well into this:
Looks real good to me
Don
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sunroof
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| Posted: Mon Mar 25, 2024 4:42 pm Post subject: Re: 1962 Deluxe restoration |
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While I've got the body on the pan I will dig into the A pillar
Rusty bits gone and new bit ready to step in
The NOS piece is disappointing me a little
Anyways, trimming to fit
Don
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sunroof
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Posts: 1778
Location: Winnipeg
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| Posted: Thu Mar 28, 2024 12:43 pm Post subject: Re: 1962 Deluxe restoration |
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Well, that will have to do.
Now to fill in this little gap
Welding this was a challenge, makes me wish, once again, that I had a rotisserie.
Anyways done.
Just the lip and some grinding and the bow is done. Oh wait, front corner. I've been watching Leo lately and thinking in boatspeak.
https://www.youtube.com/watch?v=YgWkYtoFi7M
Don
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