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Der faule Kürbis
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67rustavenger Premium Member
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PostPosted: Tue Jan 07, 2020 6:58 pm    Post subject: Re: Der faule Kürbis Reply with quote

^^^^ That's Fn brilliant! Never thought of trying that. Best part is you can get a good bite along the entire piece to pull more than one little section at a time,

Carry on.
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TDCTDI
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PostPosted: Wed Jan 08, 2020 11:13 am    Post subject: Re: Der faule Kürbis Reply with quote

67rustavenger wrote:
^^^^ That's Fn brilliant! Never thought of trying that. Best part is you can get a good bite along the entire piece to pull more than one little section at a time,

Carry on.


Thank you sir. This technique works really well but it does have some pitfalls though. If working on rusty metal, you WILL find the thin spots & I have several that I will need to go back & fill but I'm going to wait until the car is a bit closer to the ground so I can reach the backside of the panel easier before I go back & address those.


Also, if the panel was consistently straight, I'd suggest that you attach the whole length of tabs before you start pulling. In my experimentation, I made a few pulls, to see if the process would actually work, & this caused a few low spots that I needed to go back & reattach a few tabs to pull them out.
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Then I started cutting the tabs off.

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Overall, it worked much better than some of the other options. Here is the panel now with the correct..er...ish bolt flange.
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PostPosted: Thu Jan 09, 2020 12:07 pm    Post subject: Re: Der faule Kürbis Reply with quote

The lower quarter panel on this side was obviously in much worse shape than the other side so I needed to go higher to find decent-ish metal. There again, I went back to my trusty sheet metal source & lopped off another piece.


Due to going further up, I wanted to emulate the original fender arc as much as possible but I needed a sharp edge to recreate the body line. So I found an old timing belt roller & replaced the lower anvil in my English wheel so now it's a tipping wheel.
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Now I'm able to roll the body line into the panel by pushing down while rolling it through.
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After making a few bends, I placed it over the area to be replaced & scribed a line around it.
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And then proceeded to hack away at the rot.
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With the detritus out of the way, I refit the panel to check how it aligned.
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I then carefully pared away at the body seam so I could use what was left of the original body as a reference point.
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And then checked how it fit again.
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I then pressed in a stiffener recess for the captive nut & after drilling a hole through it, I welded a flanged nut into the hole & clamped the panel in place.
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PostPosted: Fri Jan 10, 2020 10:11 am    Post subject: Re: Der faule Kürbis Reply with quote

I can’t believe how fast you are going here Shocked Very Happy thanks a lot for sharing with us your progress !
Keep us updated!
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PostPosted: Fri Jan 10, 2020 11:35 am    Post subject: Re: Der faule Kürbis Reply with quote

Absolutely, thank you sir.


I began stitching the panel in.
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And slowly worked my way around to make it one with the car.
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Unfortunately, I got overzealous when trimming the lower panel & this caused a pretty large gap.
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So I cut it out & made a filler strip & tacked it into place.
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& finally got it welded up.
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PostPosted: Sat Jan 11, 2020 8:27 am    Post subject: Re: Der faule Kürbis Reply with quote

Today I moved to the inside to complete the A-pillar. I slowly worked the panel around to meet the inner structure.
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Then, once I got an idea of where the excess should be terminated, I pulled it back out, lopped off the excess & tucked it back into place.
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Then began stitching it up.
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As I was hammering the crease into the corner, I noticed that the outer panel was starting to move away from the heater channel so I had to get back out of the car, move the welding cart to the other side of the car & finish securing the inner fender to the channel.
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With that completed, I rolled everything back to the other side & climbed back in to finish up the inner pillar
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Then I got it snugged up to the inner fender panel.
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Once it was in place, I then welded it to the channel & drilled a few spot weld points, including where the inner hinge stiffener was originally welded to the pillar.
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After that, I buttoned those up too.
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And finally cleaned up the welds a bit.
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GOFUNDYOURSELF, quit asking everyone to do it for you!


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Do something, anything, to your project every day, and you will eventually complete it.
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PostPosted: Sun Jan 12, 2020 6:00 am    Post subject: Re: Der faule Kürbis Reply with quote

great work . enjoyable and entertaining watching the progress. nice stock pile of oil you got there lol
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PostPosted: Sun Jan 12, 2020 11:03 am    Post subject: Re: Der faule Kürbis Reply with quote

Thank you! I’m glad that this train wreck is entertaining. Laughing


This morning I dug into the the driver side front bulkhead.
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I decided to leave the outer as a reference point & started by cutting out what was left of the inner.
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Here’s the remains.
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After some creative folding, I came up with this...
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I still need to trim off some excess, but here it is sorta in position.
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GOFUNDYOURSELF, quit asking everyone to do it for you!


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Do something, anything, to your project every day, and you will eventually complete it.
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PostPosted: Mon Jan 13, 2020 12:56 pm    Post subject: Re: Der faule Kürbis Reply with quote

With a bit more trimming I got the patch to click into place.
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Then I removed it & welded up the seams.
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And then snapped it back in.
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And then welded it up.

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Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


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Do something, anything, to your project every day, and you will eventually complete it.
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PostPosted: Tue Jan 14, 2020 1:26 pm    Post subject: Re: Der faule Kürbis Reply with quote

Today I hacked out the rotten/mangled part of the outer bulkhead.
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Hey look, there's the new heater channel!
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Then, after lopping off another section of the oil barrel, I copied the remnants & fit it in place.
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GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.
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67rustavenger Premium Member
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PostPosted: Tue Jan 14, 2020 9:48 pm    Post subject: Re: Der faule Kürbis Reply with quote

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Twwwweeeeeet! Foul! "OP not revealing metal forming secrets!"
How'd ja do these creases? Some of the followers might be curious as to how to do it.
I'll just admire them after you have the car delivered to me. Post rust repair and agreed original samba classified asking price. Laughing

Really nice work you're doing. Thank you for sharing.
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TDCTDI
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PostPosted: Wed Jan 15, 2020 8:10 am    Post subject: Re: Der faule Kürbis Reply with quote

67rustavenger wrote:
Really nice work you're doing. Thank you for sharing.


Thank you sir!



67rustavenger wrote:

Twwwweeeeeet! Foul! "OP not revealing metal forming secrets!"
How'd ja do these creases? Some of the followers might be curious as to how to do it.



OK, OK, I did omit that part. Embarassed


Since I wasn't entirely satisfied with the last panel due to the incorrect jaunty angle of the pressing...
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I made it again, & documented the process for y'all this time.



I started by trimming off another section & then positioned in my press.
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Then I worked the edge over with a hammer.
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I then positioned the piece over a void between the two press plates & laid some 1/8" scrap pieces over the panel.
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And then inserted a piece of 5mm bolt that I had cut down to length.
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After that, I set a steel block (This one came from a MkIII Golf/Jetta.) onto everything & pressed the shape into the panel.
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Once the shape was imprinted, I then worked the panel with the press or hammer to flatten it back out.
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Here is the new panel.
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And here it is fitted up in it's soon to be new home.
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67rustavenger wrote:

I'll just admire them after you have the car delivered to me. Post rust repair and agreed original samba classified asking price. Laughing



Now that I've shown you how to do it, you'll just have to get the car & perfect the process for yourself. Laughing
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GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.
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TDCTDI
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PostPosted: Mon Jan 20, 2020 4:12 pm    Post subject: Re: Der faule Kürbis Reply with quote

So, while trying to weld the lower portion of the inner bulkhead in, I found that I hadn't cut far enough up to eliminate all of the rust. So I had to make a patch for the patch. Rolling Eyes

I finally got it "Patched up".
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Then, I realized that I had put my outer patch in a safe place... too safe of a place, it took me 45 minutes to locate where I put it. Evil or Very Mad


Once found, I did one final fitting & clamped it in place.
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And then I made a few tack welds.
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GOFUNDYOURSELF, quit asking everyone to do it for you!


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Do something, anything, to your project every day, and you will eventually complete it.
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PostPosted: Wed Jan 22, 2020 4:18 pm    Post subject: Re: Der faule Kürbis Reply with quote

Nothing too exciting, I finally finished the lower bulkhead patch. This was truly a bitch due to the fact that I really needed to cut out the old metal another 4"-6" higher to get to better metal, what I was trying to weld to was pretty thin & I ended up "chasing the hole" since the metal evaporated 1/8" around where the MIG wire touched it.


Oh well, here it is now.
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PostPosted: Thu Jan 23, 2020 4:45 pm    Post subject: Re: Der faule Kürbis Reply with quote

With only a few minutes to donate today, I grabbed the passenger side pan & perforated the edge to weld onto the pan.
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Then I started slathering some Ospho onto & into the welds & seams.
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Making sure to flood the gaps where the panels meet the channels & then used the runoff on the other side to treat that side too.
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And finally coated the seat tracks.
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Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


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Do something, anything, to your project every day, and you will eventually complete it.
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PostPosted: Thu Jan 23, 2020 6:21 pm    Post subject: Re: Der faule Kürbis Reply with quote

Thanks for the update.
Nice idea using the Ospho run off to coat the other side of the patched area's.
I wouldn't have thought of doing that. Cool Plus I like the idea of flooding the patched panels with ospho to take care of the hidden rust. That beats using weld through primer. Only to have it burn off while welding the panels in place.

Keep up the great work.
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PostPosted: Fri Jan 24, 2020 4:26 pm    Post subject: Re: Der faule Kürbis Reply with quote

Thank you sir.


After letting the Ospho do it's magic overnight, I cleaned everything with a few passes of acetone.
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Then I treated those seams by flooding them with some primer.
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Once done, I wiped off the excess runs (On the outside too.) & shot the heater channels with primer.
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Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.
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PostPosted: Mon Jan 27, 2020 7:14 am    Post subject: Re: Der faule Kürbis Reply with quote

This morning, I picked up a tube of seam sealer & ran a couple of beads into the seams.
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And then forced it into the voids while smoothing it out.
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GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.
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PostPosted: Sun Feb 02, 2020 10:25 am    Post subject: Re: Der faule Kürbis Reply with quote

In anticipation of getting the pans in, I figured that it would be easier to paint the bottoms of the heater channels without the pans in place so I grabbed a couple of cans of paint to seal the heater channels & a bit of seam sealer on the outer seam to prevent water ingress from the wash from the tires.
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It was suggested that Krylon Regal Red was a close match for the original Ruby red.
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Not so much.


But what the hell, not much of it will be seen anyway.
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Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.
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PostPosted: Sun Feb 02, 2020 11:45 am    Post subject: Re: Der faule Kürbis Reply with quote

Looking good! Nice imprinting on that panel repair!
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TDCTDI wrote:
Basically, a whole bunch of fuckery to achieve a look.


67rustavenger wrote:
GFY's Xevin and VW_Jimbo! Smile
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