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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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 Posted: Sun Nov 29, 2020 10:33 am Post subject: Re: Der faule Kürbis |
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| toxicavenger70 wrote: |
| I love the fab work you are doing. Sorry to hear about the Ghia, that totally blows. |
Thank you sir. Yeah, since the Ghiapet has been down, I find myself once again bound to the modern, paved right of ways. 
| Chickensoup wrote: |
| sooo. are u gonna paint this one or just clear coat it? just curious. |
Ima gonna rock this bitch in all of her natural splendor, there’s a certain beauty in the homeliest of cases, they’re the most willing to get down & dirty & work to please you. 
Additionally, if your car is the ugliest in the parking lot, those SUV & minivan driving assholes think twice before parking on top of your precious ride.
This morning I plugged away (literally) at the patch again.
After drilling a few holes, I found that the way I manipulated the patch to get it to fit at the upper edge caused a gap between the patch & the previously made end cap.
With no way to clamp the two together, I sank a self-tapping sheet metal screw into one of the other holes & drew the panel in.
After welding up the first hole, I moved the screw to the next & welded up that hole.
This in turn caused the, we’ll call it a box channel, to not snug up, so I made a relief cut & beat it into place & secure it with the same screw.
I then welded up the relief cut & continued to weld the panel in place & grind off the excess.
_________________
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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EVfun
Samba Member
Joined: April 01, 2012
Posts: 5481
Location: Seattle
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| Posted: Sun Nov 29, 2020 12:03 pm Post subject: Re: Der faule Kürbis |
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| TDCTDI wrote: |
One of the problems that i ran into was the fact that the brake shoe groves on the replacement wheel cylinders was fairly narrow.
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Just curious, where did you find those wheel cylinders? Those are 1958-1964 front cylinders as near as I can tell. I haven't been able to find the right ones for some time. Even the new wheel cylinders sold by Wolfsburg West have the wider slow. Those older brake backing plates didn't have the shoe resting stops up by the wheel cylinder or down by the adjusters and relied on narrow slot shoes and narrow slot adjusters to provide the locating function for the shoe ends. A number of us would like to run the correct wheel cylinders.
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| Wildthings wrote: |
| As a general rule, cheap parts are the most expensive parts you can buy. |
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Chickensoup
Samba Member
Joined: January 06, 2018
Posts: 5368
Location: Good Hope, GA
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| Posted: Sun Nov 29, 2020 12:20 pm Post subject: Re: Der faule Kürbis |
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Looks good!
_________________
-'85 c10 5.3 LS, 222 cam, long tubes, x pipe, 3 inch spin tech's
-'05 B5.5 TDI Wagon 17in sport rims ;EGR + BSM + ASV Delete, Stage-2 Tune, straight pipe
'65 Tourist Delivery Build
'66 RIP
'69 RIP
Hosea 4:6 "My people are destroyed for lack of knowledge" |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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| Posted: Sun Nov 29, 2020 12:23 pm Post subject: Re: Der faule Kürbis |
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It’s a wholesale place that has an incorrect listing, these were ordered for the later car, I ordered a few sets & then ordered a few more to replace the incorrect ones but ultimately just carved out the groove to make them work in my car  Good news is, I can get plenty more.
_________________
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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Chickensoup
Samba Member
Joined: January 06, 2018
Posts: 5368
Location: Good Hope, GA
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| Posted: Sun Nov 29, 2020 2:36 pm Post subject: Re: Der faule Kürbis |
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Haha. Now I know why you clean so many of the threads! I'm referring to a few pages back. I was just having trouble threading in some drum bolts and I recalled when you were tapping this and that to clean up the threads. Now mine thread flawlessly! Thanks 
_________________
-'85 c10 5.3 LS, 222 cam, long tubes, x pipe, 3 inch spin tech's
-'05 B5.5 TDI Wagon 17in sport rims ;EGR + BSM + ASV Delete, Stage-2 Tune, straight pipe
'65 Tourist Delivery Build
'66 RIP
'69 RIP
Hosea 4:6 "My people are destroyed for lack of knowledge" |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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| Posted: Sun Dec 06, 2020 9:19 am Post subject: Re: Der faule Kürbis |
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| Chickensoup wrote: |
| Haha. Now I know why you clean so many of the threads! I'm referring to a few pages back. I was just having trouble threading in some drum bolts and I recalled when you were tapping this and that to clean up the threads. Now mine thread flawlessly! Thanks |
Nice! I’m glad someone gets some use of this thread, if it’s not only what not to do. 
Speaking of what not to do, (perhaps we should start with not finding the rustiest POS.), remember when I said that the flux core would weld to rust? Well, it does! Unfortunately after carving out the driver side rear corner, my OCD wouldn’t just let me cover it up with new(ish) metal.
So I carved out the rot until I found better metal.
Now then, one of the pitfalls of using an old oil drum as patch panels is that, like a Beetle, there really aren’t many perfectly flat areas. Even the straight sections between the ribs have a pretty drastic compound curve to them.
Who woulda thought that I’d be using an English Wheel to flatten out metal? 
Oh well, that’s the end of today’s misadventures.
_________________
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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bad91teg
Samba Member
Joined: February 13, 2007
Posts: 473
Location: florida
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| Posted: Sun Dec 06, 2020 10:13 am Post subject: Re: Der faule Kürbis |
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| great work your doing on the bug . im watching along keep up the good work . |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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| Posted: Sun Dec 06, 2020 1:58 pm Post subject: Re: Der faule Kürbis |
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Thank you sir! I just keep forgetting that this car is just the warm up for doing the same thing in my Oval.
_________________
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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VW_Jimbo 
Samba Member
Joined: May 22, 2016
Posts: 9966
Location: Huntington Beach, CA
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| Posted: Sun Dec 06, 2020 2:30 pm Post subject: Re: Der faule Kürbis |
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| TDCTDI wrote: |
| Speaking of what not to do, (perhaps we should start with not finding the rustiest POS.) |
It’s all good! It is about the journey, not the final resting spot!
Carry on. I like seeing someone else dealing with RUST.
_________________
Jimbo
There is never enough time to do it right the first time, but all the time necessary the second time!
| TDCTDI wrote: |
| Basically, a whole bunch of fuckery to achieve a look. |
| 67rustavenger wrote: |
GFY's Xevin and VW_Jimbo!  |
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bad91teg
Samba Member
Joined: February 13, 2007
Posts: 473
Location: florida
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| Posted: Sun Dec 06, 2020 3:00 pm Post subject: Re: Der faule Kürbis |
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| would love to see the oval |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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| Posted: Sun Dec 06, 2020 3:12 pm Post subject: Re: Der faule Kürbis |
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| bad91teg wrote: |
| would love to see the oval |
Yes sir. Here’s the thread where I began the same process on it.
https://www.thesamba.com/vw/forum/viewtopic.php?t=717191&highlight=
Now it seems that all of the Ghiapet goodness will find its way under it.
_________________
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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didget69
Samba Member
Joined: July 22, 2004
Posts: 4927
Location: Raleigh, North Carolina
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| Posted: Sun Dec 06, 2020 6:01 pm Post subject: Re: Der faule Kürbis |
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Bam-ba-Lam...
Bryan
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I never found the need to impress people with any mechanic certifications, trophies or track wins... unless it was for Mom to post on the refrigerator door. |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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| Posted: Mon Dec 07, 2020 11:12 am Post subject: Re: Der faule Kürbis |
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Hey Bryan! I thought that song & name totally fit that project.
I’m fighting the urge to toss that narrow eye kit you gave me (thanks again!) onto this beast. 
Today I began whittling & shaping the new patch panel.
Once it lined up on the inside, I marked off where to make the final folds to cap off the heater channel.
I then perforated it where it would be welded to the end of the heater channel.
And then fit it up one last time...
And proceeded to attach it permanently.
_________________
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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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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| Posted: Tue Dec 08, 2020 3:32 pm Post subject: Re: Der faule Kürbis |
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Today’s task, even with limited time, was to recreate the outer end cap patch.
I started by clamping a straight edge to the donor metal so I could zip right through it with the pneumatic shears.
I’ve gotten pretty good at making warpy metal flat again with the English wheel.
With the appropriate sized patch in hand, I warmed up the old paint & seam sealer .
And scraped it off.
After paring the patch down a bit & transferring some locating points, I positioned a few bits of 1/8” steel scrap onto the press.
And then I placed the patch over it & strategically tossed a few more bits on & began pressing the shape into the panel.
Once done, I fit the piece into place to locate where my next bends would be...
And after a few adjustments & trimming I fit the panel back in place.
_________________
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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lhd65bug
Samba Member
Joined: September 04, 2020
Posts: 49
Location: United Kingdom
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| Posted: Tue Dec 08, 2020 3:53 pm Post subject: Re: Der faule Kürbis |
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Correction; you're very good at making warpy metal flat again!
Good job! |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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| Posted: Wed Dec 09, 2020 1:00 pm Post subject: Re: Der faule Kürbis |
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| lhd65bug wrote: |
Correction; you're very good at making warpy metal flat again!
Good job! |
Thank you sir!
Today I continued plugging away at the driver side outer heater channel end patch panel.
After I made the last fold where it passes behind & where the quarter panel attaches to it, I cut it at the folds & bent the lower end in .
I then stitched it up.
While the flux core welds are ugly, I have it turned up so as to ensure penetration. The quarter of a second bursts definitely fuse it all together & here is what the weld looks like from the back side.
This way, when I grind the excess off of the outer side, I haven’t removed all of the weld.
Anyway, I continued cleaning up the weld on both sides.
And then, after final trimming, I tacked the panel into place...
And then set about permanently fusing it in place.
Here again, I employed the self tapping sheet metal screw to draw the panels together.
And glued it together.
Here it is after a quick cleanup.
Tune in next time when our intrepid hero asks “What does this button do?”.
_________________
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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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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| Posted: Wed Dec 16, 2020 8:01 pm Post subject: Re: Der faule Kürbis |
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Well, if you thought the heater channels were the only issue with this beast, you would be wrong.
Not only is the front completely rotted, the nose was hit & is still pretty twisted.
The rear of the tire well is quite bent.
And you can see that the front apron has a significant tilt to it when lined up with the rear of the spare tire well.
Sooo, with no desire to patch & repair this crap, there was only one thing to do...
I’m going full Mad Max on this bitch.
_________________
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.
Last edited by TDCTDI on Thu Dec 17, 2020 9:25 am; edited 1 time in total |
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Chickensoup
Samba Member
Joined: January 06, 2018
Posts: 5368
Location: Good Hope, GA
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| Posted: Wed Dec 16, 2020 8:13 pm Post subject: Re: Der faule Kürbis |
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EFF YEAH!!!!!  me like very much!
_________________
-'85 c10 5.3 LS, 222 cam, long tubes, x pipe, 3 inch spin tech's
-'05 B5.5 TDI Wagon 17in sport rims ;EGR + BSM + ASV Delete, Stage-2 Tune, straight pipe
'65 Tourist Delivery Build
'66 RIP
'69 RIP
Hosea 4:6 "My people are destroyed for lack of knowledge" |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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| Posted: Fri Dec 18, 2020 1:57 pm Post subject: Re: Der faule Kürbis |
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One of the problems with installing a Baja kit is getting it to fit. The issue is magnified when that kit has been previously installed on another car, or has been stored off of a car for who knows how many years. Fiberglass, like plastic, will deform & warp & really like to hold that shape forever after.
That was definitely the case with the nose panel. So I began to make a support “beam” out of some angle iron that I had laying around & made some relief cuts in it to shape it to the profile of the hood & welded it up as I went along.
I continued this until it matched the hood.
Here is how it compares to the nose panel...
I then removed the hood pin studs & refit it.
And then clamped it it place.
I’ll leave it clamped for a few days until I get time to mount the support to the car. I will then (probably) bond the nose panel to the support.
_________________
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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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12858
Location: North Carolina
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| Posted: Sat Dec 19, 2020 10:23 am Post subject: Re: Der faule Kürbis |
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In anticipation of reattaching the body to the pan, I sourced a few needed parts that will be much easier to install before that happens.
Like the master cylinder... (Hey, whaddaya know, the bolts & spacers actually stayed in place through all of this!  )
I then removed the remains of the brake line from the rear junction so I could fab up a new line.
The union was quite seized, so I warmed it up a bit to coax it free(and apparently the phone decided no on that pic). I then grabbed the coil of brake line, stepped on one end & rolled it out. (I showed this step because someone in another thread actually bought a tool to do this.  )
And after a few minutes of manipulation to copy what was left of the old line, & flaring the end, I slipped it in place.
_________________
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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