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Bobnotch
Samba Member
Joined: July 06, 2003
Posts: 22984
Location: Kimball, Mi
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 Posted: Fri Nov 22, 2024 11:19 am Post subject: Re: Square back resurrection |
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It looks like you're making good progress on getting the jig saw puzzle going back together.  Don't forget, somewhere in there you need to add the flap control cable before you close it off. Just a friendly reminder. 
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Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120
| Tram wrote: |
| "Friends are God's way of apologizing for relatives." |
| Tram wrote: |
| People keep confusing "restored" and "restroyed". |
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Fri Nov 22, 2024 2:02 pm Post subject: Re: Square back resurrection |
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| Quote: |
| It looks like you're making good progress on getting the jig saw puzzle going back together. Cool Don't forget, somewhere in there you need to add the flap control cable before you close it off. Just a friendly reminder. Wink |
OY!
Don
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lawn ninja
Samba Member
Joined: January 02, 2006
Posts: 1020
Location: Round Rock, TX
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| Posted: Sat Nov 23, 2024 9:45 am Post subject: Re: Square back resurrection |
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Solid work man. I'm starting to dig into my notch body now and mine looks like the guy before me owned a Deli, because he was a butcher.
If you need the 6v tin for your engine hit me up. I've got a spare set.
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Jason
My 64 1500 S Notchback project here
My 58 sedan project here
My 63 Ghia here |
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Mon Nov 25, 2024 8:55 pm Post subject: Re: Square back resurrection |
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| Quote: |
| If you need the 6v tin for your engine hit me up. I've got a spare set. |
That is a very kind offer. I have no idea what I have or don't have. Two owners ago the car got taken apart by someone who had no idea what he was doing and he just threw everything in a bunch of bins. So I may or may not need those tins.
Anyways a fool and his money are soon parted:
I paid a HUGE amount of money for this.
On to the rust repair. A good evening if I must say so myself.
Begin with this little hole
Now drop down a bit and begin the repairs on the leading edge of the multilayer pinch weld.
I will make a piece that extends right down to the repair section of the heater channel and weld it to this bit once I am satisfied with the fit. But first I have to cut away the front of the A pillar.
This will be an interesting piece to make as it has a slight curve to it.
Don
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Bobnotch
Samba Member
Joined: July 06, 2003
Posts: 22984
Location: Kimball, Mi
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| Posted: Tue Nov 26, 2024 1:32 pm Post subject: Re: Square back resurrection |
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That piece won't be hard to make, as you'll just need to ad a few slices in it to bend it (to shape it).
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Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120
| Tram wrote: |
| "Friends are God's way of apologizing for relatives." |
| Tram wrote: |
| People keep confusing "restored" and "restroyed". |
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Tue Nov 26, 2024 3:10 pm Post subject: Re: Square back resurrection |
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Last winter when I had Tim's '62 in the shop
I borrowed his shrinker/stretcher set. It was so useful and saved so much time that I went and bought myself a set today.
https://www.princessauto.com/en/metal-shrinker-and-stretcher-set/product/PA0008536807
Of course I had to build a mounting bracket but that was a fun easy job.
I can hardly wait to use it.
Don
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Wed Nov 27, 2024 2:52 pm Post subject: Re: Square back resurrection |
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Today I started cutting into the pinch weld that holds the kick panel to the A-pillar and got a nasty surprise!
When I got to the bottom of the cut the A-pillar sprang away from the kick panel. O not good.
But as you can see I bolted the repair panel in very carefully making sure the bolts were in the center of the bolt holes and clamped the top and bottom together.
A couple of clecoes to hold things in place and we are ready to continue.
All the nastiness is cut away
Insider image
This is an interesting little contour, I will have to decide what to do about that.
Excelsior!
Don
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Bobnotch
Samba Member
Joined: July 06, 2003
Posts: 22984
Location: Kimball, Mi
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| Posted: Thu Nov 28, 2024 1:30 pm Post subject: Re: Square back resurrection |
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Keep in mind that the rear part of the front fender bolts to that piece you're now replacing. It also gets a strip of D-19 tape (that starts out about 1/8th inch thick) that gets sandwiched between the parts to keep water from entering the holes. Granted the fender screws (w/washers attached) also have a rubber washer on them for sealing as well.
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Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120
| Tram wrote: |
| "Friends are God's way of apologizing for relatives." |
| Tram wrote: |
| People keep confusing "restored" and "restroyed". |
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Thu Nov 28, 2024 4:40 pm Post subject: Re: Square back resurrection |
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| Quote: |
| Keep in mind that the rear part of the front fender bolts to that piece you're now replacing. It also gets a strip of D-19 tape (that starts out about 1/8th inch thick) that gets sandwiched between the parts to keep water from entering the holes. Granted the fender screws (w/washers attached) also have a rubb |
Ya, I have no idea how any of this goes together. For now I am going to replicate what is there as closely as possible and hope for the best.
Don
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Fri Nov 29, 2024 8:45 am Post subject: Re: Square back resurrection |
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OK, I'm starting to see how this all goes together
Don
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Bobnotch
Samba Member
Joined: July 06, 2003
Posts: 22984
Location: Kimball, Mi
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| Posted: Fri Nov 29, 2024 10:58 am Post subject: Re: Square back resurrection |
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| sunroof wrote: |
OK, I'm starting to see how this all goes together
Don |
Yeah, once you see how things go inside, then they start to make sense. Then things become easier to put back together. Looks like you're making great progress, which means the other side will go quicker.
_________________
Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120
| Tram wrote: |
| "Friends are God's way of apologizing for relatives." |
| Tram wrote: |
| People keep confusing "restored" and "restroyed". |
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| Back to top |
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Tue Dec 03, 2024 6:33 am Post subject: Re: Square back resurrection |
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I stripped out the inner A pillar with the control mechanism for the heater flap
I left a little bit at the bottom to hold things together so no more bad surprises (I hope)
The Back Side
The Front Side and all the associated bits
Unfortunately to get it out I had to do more damage to the lap joint than I wanted to
So it will have to come out too
Now that the inner is completely stripped away I can clearly see what needs to be replaced. I got out Mr. cutoff wheel and did the deed
Now the fabrication process begins
Lots of shaping to do.
I am tempted to get out the spot welder and marry these two and install them together.
Stay tuned!
Don
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Thu Dec 05, 2024 11:13 pm Post subject: Re: Square back resurrection |
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Got all the felt pen cleaned off the part and tacked it in.
Welded it in place then filled all the holes from drilling out the spot welds. Some bubble gum welds there chasing thin metal around making sure there weren't any gaps.
I used a copper backer when filling the holes. It was a bit of a pain to set up but worked nicely. Here you can see it clamped in place to fill the two bottom most holes
These two little things have been invaluable over the years. The flat piece I cut off a piece of copper pipe and flattened it out. It has been many shapes and stuffed into many corners but works a treat every time backing holes and seams.
Up next is this piece. It has a curve to it so it will be interesting to fabricate.
Don
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Bobnotch
Samba Member
Joined: July 06, 2003
Posts: 22984
Location: Kimball, Mi
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| Posted: Fri Dec 06, 2024 1:22 pm Post subject: Re: Square back resurrection |
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Nice work. You're gaining on it. It won't be long until you cap it off, then tie into the rear part and then start the other side, as this area will be done on this side. I think you're finally figuring out how this post assembly all goes together.
_________________
Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120
| Tram wrote: |
| "Friends are God's way of apologizing for relatives." |
| Tram wrote: |
| People keep confusing "restored" and "restroyed". |
|
|
| Back to top |
|
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Sat Dec 07, 2024 6:04 pm Post subject: Re: Square back resurrection |
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Well....It's not pretty but it will do
To reiterate: Must fill gap
Paper template
First approximation
Two minutes with the stretcher
An hour with the grinder tuning and tuning
Some copper primer
Prêt à weldment
Don
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Sun Dec 08, 2024 12:26 pm Post subject: Re: Square back resurrection |
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Oooooo, that went well
Up next the piece that ties the A pillar back into the car
Then I can start piecing the base of the A pillar back together. Another interesting challenge
Don
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Bobnotch
Samba Member
Joined: July 06, 2003
Posts: 22984
Location: Kimball, Mi
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| Posted: Sun Dec 08, 2024 12:29 pm Post subject: Re: Square back resurrection |
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That gap filler piece looks good, and will work quite nicely. You might want to spray something over the weld inside the heater channel to the windshield base while you still have it open, or it'll rust on that visible weld. Just a thought. Your repair work is coming along nicely. I think you've got it figured out how to fix it all.
_________________
Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120
| Tram wrote: |
| "Friends are God's way of apologizing for relatives." |
| Tram wrote: |
| People keep confusing "restored" and "restroyed". |
|
|
| Back to top |
|
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Sun Dec 08, 2024 12:36 pm Post subject: Re: Square back resurrection |
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So speaking of which, this is the outer shell of the base of the A pillar that I am going to try to replicate
Someone has already been in there to make a rust repair. Expanded metal and Bondo crafting a rocker panel. A small surprise.
The important thing is: How am I going to make this part?
Don
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sunroof
Samba Member
Joined: October 06, 2006
Posts: 1885
Location: Winnipeg
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| Posted: Sun Dec 08, 2024 12:41 pm Post subject: Re: Square back resurrection |
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| Quote: |
| You might want to spray something over the weld inside the heater channel to the windshield base while you still have it open, or it'll rust on that visible weld. |
Everything will get primered at least. I used the copper primer extensively during the restoration of the '54, which is misusing it I know, but I really like that stuff. Once things were welded together I sprayed all the primered parts with clear coat to stop it from rusting.
https://www.thesamba.com/vw/forum/viewtopic.php?t=...p;start=80
Don
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Bobnotch
Samba Member
Joined: July 06, 2003
Posts: 22984
Location: Kimball, Mi
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| Posted: Sun Dec 08, 2024 1:16 pm Post subject: Re: Square back resurrection |
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| sunroof wrote: |
So speaking of which, this is the outer shell of the base of the A pillar that I am going to try to replicate
Someone has already been in there to make a rust repair. Expanded metal and Bondo crafting a rocker panel. A small surprise.
The important thing is: How am I going to make this part?
Don |
This might be one of those deals where you buy an outer rocker skin from CIP, as it'll have that area along with the entire length of the skin in one piece. I only say that, as it's really just one big stamping. It basically caps the outer part of the rocker from the upper seam (under the sill plate of the door opening) to the lower seam (just below the floor pan edge). I hope this helps.
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Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120
| Tram wrote: |
| "Friends are God's way of apologizing for relatives." |
| Tram wrote: |
| People keep confusing "restored" and "restroyed". |
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