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1966 Deluxe 21 Window Shamba
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Mr Margaret Scratcher
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PostPosted: Tue Sep 10, 2019 4:51 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Jacks wrote:
Mr Margaret Scratcher wrote:
Jacks wrote:
Mole grips? Confused


Eh?

EDIT: Oh I see - "Vise Grips" over in the US Smile
Huh. Our Vice Grips say “Vice Grips” right on them. Do your Mole Grips say”Mole Grips” on them? I’d love to see a picture of that. Shocked



I've never seen it myself, but apparently:
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Mr Margaret Scratcher
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PostPosted: Sat Jun 27, 2020 7:30 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So the weather is nice in the UK again, so I've started to dig back into this. Quick question about this A-post repair section - is the metal part at the bottom supplied as a repair piece if the a-post bracket has rusted through, ie, if I replace the a-post bracket it is not needed, or does it sandwich in somewhere?


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Mr Margaret Scratcher
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PostPosted: Sat Jun 27, 2020 7:48 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Also, I'm still not 100% sure on the order I need to do all the repairs at the front - I noted down at some point this order:

1 - A Pillars
2 - Inner Valence
3 - Outer Valence
4 - Nose
5 - doglegs
6 - Floor

But i'm kind of lost as to what to chop off/un-spotweld to get to those bits in that order. Currently I have the floor removed, and that's it - is the next step to get the doglegs removed?
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ELMORT
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PostPosted: Sun Jun 28, 2020 1:09 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Mr Margaret Scratcher wrote:
Also, I'm still not 100% sure on the order I need to do all the repairs at the front - I noted down at some point this order:

1 - A Pillars
2 - Inner Valence
3 - Outer Valence
4 - Nose
5 - doglegs
6 - Floor

But i'm kind of lost as to what to chop off/un-spotweld to get to those bits in that order. Currently I have the floor removed, and that's it - is the next step to get the doglegs removed?

Hi, Just look at this episode from MicBergsma (the 17) and next one. They are easily understandable with many tricks. https://youtu.be/-DY9OUcFw-8
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Mr Margaret Scratcher
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PostPosted: Sun Jun 28, 2020 3:28 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

ELMORT wrote:

Hi, Just look at this episode from MicBergsma (the 17) and next one. They are easily understandable with many tricks. https://youtu.be/-DY9OUcFw-8


Ah yeah I've been watching them, some very good shots showing how stuff goes together.

I think for me, it would be a lot easier if my bus was a lot worse up front, as I could just hack all the old bits off, but as it is, the front valance is perfectly intact, the RH side A post is good, the front panel has some issues lower down, but not enough to warrant taking the whole thing off, and the inner front panel/headlight support has some bits that need fixing.

Both doglegs I think could be removed and repaired, rather than sawing them off and chiseling off the ends. Or repaired in situ maybe? (Although the LH A-Post does need repairing so that side dogleg will need to come off.

Or do I just saw through the halfway point, remove the spotwelds at the A-post and have the best of both worlds?


I've just fixed all the images so you can hopefully see what I mean.
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Mr Margaret Scratcher
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PostPosted: Mon Jun 29, 2020 5:57 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Aaaalso, my replacement A posts from Autocraft seem to be different to others, and indeed their own pictures on their site, which have the notch followed by the larger flange which goes up to cover the inner front panel:

Image may have been reduced in size. Click image to view fullscreen.
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BulletBus
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PostPosted: Tue Jun 30, 2020 5:27 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Dag! I hate that. Sad
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Mr Margaret Scratcher
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PostPosted: Wed Jul 01, 2020 2:21 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

BulletBus wrote:
Dag! I hate that. Sad


Although, this pic seems to suggest that that longer flap isn't there, or isn't always there at least:

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Not there in the full KF panel either:

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Also what should I be using as a datum point to measure down to the bottom of the pillar?
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karl h
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PostPosted: Wed Jul 01, 2020 3:28 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

i did the same repair, whaterver you do MOUNT THE DOOR YOU ARE USING!
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Mr Margaret Scratcher
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PostPosted: Wed Jul 01, 2020 3:29 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

karl h wrote:
i did the same repair, whaterver you do MOUNT THE DOOR YOU ARE USING!


No worries, doors are staying on Smile
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Mr Margaret Scratcher
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PostPosted: Wed Jul 01, 2020 1:56 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Then these pics seem to suggest it should be there?

https://www.thesamba.com/vw/forum/viewtopic.php?t=616235
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Mr Margaret Scratcher
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PostPosted: Thu Apr 15, 2021 1:59 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So I decided to dive into this again (you can probably plot the weather in the UK by my activity on this forum and my progress on the bus)

Doglegs: looking at the passenger side, I'm going to try to patch it in situ:

Here's a couple of holes on the outer:
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Cut with a cutting disc on a grinder:
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(I think I need a smaller cutter...)

This little guy decided the dogleg was an appropriate sarcophagus :
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Metal seems thick:
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(I've cut along because I'm planning on recreating the lip on the inner dogleg, and assumed that where the metal was thin and holed would probably be the same all along

Chopped out:

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Should be easy enough to make a section to go in here. (He says, having never made a repair section is his life!)
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Mr Margaret Scratcher
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PostPosted: Thu Apr 15, 2021 2:03 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Crusty A - post: (Bonus points for anyone that can identify the red car with gold wheels...)

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A little concerned that I've accidentally cut into the panel that caps off the cavity inside the A post below the hinge, not sure how I'm going to fix that and close that off. Ideally I want to just patch the A-post that's there rather than replace.
Image may have been reduced in size. Click image to view fullscreen.


Last edited by Mr Margaret Scratcher on Thu Apr 15, 2021 2:09 am; edited 1 time in total
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Mr Margaret Scratcher
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PostPosted: Thu Apr 15, 2021 2:03 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Inner front panel:

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Mr Margaret Scratcher
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PostPosted: Sun Apr 25, 2021 5:28 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So I've made a general welding practise thread for myself over here: https://www.thesamba.com/vw/forum/viewtopic.php?t=752886, so this is a bit of a copy/paste from that


Quote:
Repair panel held in with magnets:
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Started to tack in:
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More tacks:
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So far so good.

Came back the next day and couldn't get a decent weld with the same settings. Tried on the scrap again, great. Was it a matter of the earth clamp being further away? I had it here:
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I filled in some more tacks, but couldn't really then see where I'd missed, so tried to grind back the welds with a flap wheel. At this point I feel like I've made a bit of a boo-boo and made the surrounding metal too thin, and was blowing holes through:
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It seems like there's literally no margin for error when trying to grind back a weld flush on a piece of 1mm steel, and my lower nose repair sections looks like it's even thinner metal... Confused

Quite annoying as I was really happy with how flush I'd got my little repair strip to sit.


I'm going to go back to my practise panels for a bit I think until I'm confident about the grinding back stage, as I really don't want to have to cut this repair panel back any further because of where it tucks under the A post etc.
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Mr Margaret Scratcher
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PostPosted: Wed Jul 21, 2021 11:35 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So I decided to investigate and chop out the lower front panel, as it also lets me get behind the inner front panel if I want to use a bit of copper to weld against.

Top line is where my repair panel goes to, 2nd line is where I cut just to be safe for now:

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Used the trusty 'sardine can' method of spotweld removal:

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Rusty inside:

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Looks like someone has been eating chocolate!

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I was hoping that the front valance was going to be saveable, but I'm a bit worried about the rust that has got in the seam:

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For the sake of £37 (which I think is about $50) it looks like I should probably bin it and weld in a fresh one:
http://www.autocrafteng.co.uk/shop/split-screen-va...-2--67_17/
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Mr Margaret Scratcher
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PostPosted: Fri Sep 17, 2021 4:28 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Jumping around a little bit on this bus, turning my attention to the battery tray:

Spotwelds drilled out and splash pan remove with remnants of the old tray:
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My question here is how the new tray fits in:

I think in one of MikesFnGarage vids on youtube he mentions having to cut a notch/slice in the new tray so that the edge can fit past the wheeltub seam here:
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but there is a similar issue at the rear:


Image may have been reduced in size. Click image to view fullscreen.
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Mr Margaret Scratcher
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PostPosted: Fri Sep 17, 2021 5:27 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Hmmm seems like my tray
https://www.customandcommercial.com/vw-split_scree...olt_12588/

lacks the small indent and slightly angled flange on the section that joins onto the D pillar, which can be seen in the KlassicFab version:
Image may have been reduced in size. Click image to view fullscreen.


EDIT:

It seems mine does actually have the angled flange, but lacks the indent.

As for the fitment, from the underside I can see there is a notch in the D Pillar seam where the flange sits:
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so in order to fit this panel as a whole, I just need to make a horizontal cut across the rear wheel tub seam/flange where the front edge of the tray lays.

Image may have been reduced in size. Click image to view fullscreen.
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Mr Margaret Scratcher
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PostPosted: Sat Sep 18, 2021 6:56 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So further digging, the mesh should have been a red flag, and to be honest with the amount of fibreglass that was in the floors I'm not sure surprised, but yes, there's a bit of bodging gone on in the D Pillar:
Image may have been reduced in size. Click image to view fullscreen.


I couldn't find a late split repair panel for this, but I think it's maybe simple enough for even a noob like me to fab up

Similar to the front panel, there's been a bit of the old "Bash in the rot and fill it straight" on the rear quarter, so I'm going to try to repair this a little more 'correctly'
Image may have been reduced in size. Click image to view fullscreen.


Would it have been fine as it was? Mayyybe, but also maybe not in the damp wet climate of the UK, and is seems like cutting out that area of the rear quarter allows me better access to fix the D post and everything in there, so, why not?


The edge here needs a bit of love
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I'm thinking in how Fitzee's Fabrications (search for him on youtube, he's a metalworking wizard) might do it, and it's making the vertical edge along the engine shut, and then the front(back?) curved face of the rear quarter that butts up against it.

Unless there's a repair section just for that edge? Don't want to buy a whole rear corner, as it all seems pretty solid otherwise.



Used a cutting disc to notch out here, slightly bigger that I wanted, but we can weld that shut once the tray is in:
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Test fit:
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Looks like it's in, but perspective can be deceiving - it's too tight to go in, maybe because of the lack of that indent, which I've marked here:


Image may have been reduced in size. Click image to view fullscreen.


I'm going to zip along that bit with a cutting disc, and see if that allows me to tap it into place.

Other than that, I drilled out the remaining spotwelds joining the remnants of the old tray to the splash panel:

Image may have been reduced in size. Click image to view fullscreen.
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Mr Margaret Scratcher
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PostPosted: Mon Sep 20, 2021 11:55 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So today I put my big boy pants on, took a brave pill and did this:


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Fingers crossed I can reconstruct it... Shocked

I'm a bit puzzled as to how I will weld a repair to the D post along the top where I've cut horizontally, but be able to smooth off the weld so it sits flush where I'll need to put the rear corner patch in. I guess I could leave that, but turn up the welder and hope that when I weld across the patch panel it penetrates through both layers? I worry about head distortion though...
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