Fubar64 The rebuild of an ex show car

[vwhelmot]

I plan on having it ready for paint by the end of this year, I`m about two months away , maybe less in finishing the panel work then its onto rubbing it down.. Hopefully back from paint in the spring and then the rest of the year for assembly, finishing in time for VoWo 2017 .That's the plan. :)

PS The motor in your bug is a thing of wonder and delight! :D

[vwhelmot]

So while the scuttle was off I tackled this area. I converted it to standard style.

Smoother and neater

Other side. These areas were really tricky to clean the weld, really awkward job and getting my pinky stuck in the sander didn't help. Nice 45 degree chamfer though. Bit of insulation tape and carry on :D

[vwhelmot]

Back onto the scuttle, before tacking it in I fitted the hinge mount panel just to make sure that it was in the right place.

Deck lid fitted ok.

Gap still needs adjusting

As the deck lid mount panel is still going to be a bolt on affair, I wanted it to look clean from the inside so instead of welding m6 nuts on the inside like last time I got some Henk nuts and pressed them on with my hydraulic press.

Neater

Tack time

Getting to the inside to smooth the weld was a bitch.

[vwhelmot]

Edge needed building up.

While I was there I tidied this bit

Other side

Welded and tidied up the seam too

Hinge mount tidied up.

[vwhelmot]

Done

[wcfvw69]

You're doing great work here. Very inspirational. Having done some of these repairs myself (no where near your quality), I know how you are burning up tons of hours to fix this to this level.

It's amazing what our hearts and nostalgia do to us. I should of scrapped my 69 vert when I saw how rusted it was. I didn't and spent hundreds of hours welding in new/used panels. There's still SO MANY rust free bugs in the SW USA that don't require this kind of welding yet I did it as well.

Great job to you!
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[vwhelmot]

Thank you. You are right when you say lots of hours, some of it is mind numbing but I have a vision in mind and I'm doing this to the best of my abilities and doing it it for myself. You are also right in that I could have just bought a lhd rust free shell or complete car to start and most of this work would have not been needed but that wasn't the point for me. I know this sounds strange but I feel I owe it to the car as it looked after me for so long. :D.
As you will see later on I've made a few small personal changes from stock just to give it my stamp. Now that I'm a member of DBK UK, there are standards that have to be kept too so that's driving me on.

[vwhelmot]

Remember the crusty egay rear valence? Well I thought about using it instead of my NOS one as I still want to convert it into a quick release panel and the thought of cutting up a genuine new one fills me with dread. I`m going down a different route with this and I`m going to try and make it release in two sections.

I blasted it first to see how bad it was . It was bent and twisted but not too badly pitted.

Edge had disappeared

Made a new one

old new and new old ;D

The inner panel was removed and modified with a few choice dimple holes. I had to rebuild the corners too.

I`ve still got to finish and figure out how I`m going to do this but I will make some quick release mounts so that the inner panel can be removed separately as not to scratch paint or have the fixings showing from the outside.

[vwhelmot]

[vwhelmot]

One of the previous owners had fitted aluminium panels so I had to get rid of the nutserts and weld up the holes.

[vwhelmot]

Going back to the N/S rear wheel arch , where I had replaced the rear quarter panel previously , the original square nutserts had gone so I had to replicate them. Again this took hours and hours as I didn't want to warp the quarter panel with heat.
Before

Made a new section.

Patented super tool

Another one

And another

No filler required

[aka pip]

[DBK UK]

looking good Lyndon!
_________________
DBKUK

[63Ragtop NZ]

Yeah, very cool.

How are you going to attach it to the vent side?
_________________
If you can't join them, beat them!

[vwhelmot]

Thanks
I
I welded countersunk m5 screws to the vent side and made slots in the vent panel. I made some dished washers to suit. Those have been there for 14 years and work fine. :)

[Blinker]

Happy to see you updated your avatar..!!

DBK_UK :2gunfire:
_________________
D.B.K.

WWW.DBKVW.COM

[vwhelmot]

Flying the flag 8)

[vwhelmot]

Next I had to tackle the channels. As I had replaced them all those years ago I knew they were rot free but the wrong shape so I had to convert them to the early smooth style. Some of you may question why I did this and not just put in a pair of gerson ones but I had fitted these old ones correctly, the doors fitted nice so to me it was easier to modify these plus I'm getting rid of the heater vents at the front too so I would have had to modify the gerson ones too. I also had to get rid of the harness mounts I had welded to them too.

I had to cut a section out and replace it as I had indented this area for the harness mount.

Big section to cut out

[vwhelmot]

Cut out

I first had to make an infill panel to make up for the indent left from the pressing used for the later heater outlet.

Onto the roller with some fresh steel. I used the old section to get the correct curve.

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[vwhelmot]