Hello! Log in or Register   |  Help  |  Donate  |  Buy Shirts  See all banner ads | Advertise on TheSamba.com  
TheSamba.com
 
Shortening a Pan
Page: 1, 2, 3  Next
Forum Index -> Kit Car/Fiberglass Buggy/356 Replica Share: Facebook Twitter
Reply to topic
Print View
Quick sort: Show newest posts on top | Show oldest posts on top View previous topic :: View next topic  
Author Message
turboghia
Samba Member


Joined: February 15, 2004
Posts: 210
Location: Long Beach, Ca.
turboghia is offline 

PostPosted: Thu Sep 22, 2005 7:21 am    Post subject: Shortening a Pan Reply with quote

Has anyone shortned a pan themselves? or is this a job best left to a pro?
Thanks,
Steve
Back to top
View user's profile Send private message Visit poster's website Gallery Classifieds Feedback
vicsvw
Samba Member


Joined: February 27, 2003
Posts: 1001

vicsvw is offline 

PostPosted: Thu Sep 22, 2005 8:49 am    Post subject: No Problem Reply with quote

No Problem if you have a welder. Just be sure to make your cut at an angle not straight across. We often install support rails at the same time as the VW Bug relied on the body for some of the strength. Vic www.vwhelp.com
Back to top
View user's profile Send private message Visit poster's website Classifieds Feedback
Mr. Unpopular
Samba Member


Joined: September 20, 2005
Posts: 3709
Location: Tampa Florida
Mr. Unpopular is offline 

PostPosted: Thu Sep 22, 2005 9:36 am    Post subject: Reply with quote

Why cut at an angle? Just curious.
Back to top
View user's profile Send private message Send e-mail Gallery Classifieds Feedback
DSC
Samba Member


Joined: March 08, 2005
Posts: 127
Location: Southern Maryland
DSC is offline 

PostPosted: Thu Sep 22, 2005 11:43 am    Post subject: Reply with quote

If you cut it at an angle you spread the stress across a wider area than just at one straight seam. The body will get less flex if you cut the angle as opposed to straight across.

Read for yourself in this book. I read it front to back. It filled in a lot of blanks.

http://www.amazon.com/exec/obidos/tg/detail/-/1901...mp;s=books
_________________
1993 RX7 pT-67 .81 a/r
1308cc Two Rotor motor
[email protected]
Street Buggy currently under construction.
Back to top
View user's profile Send private message Visit poster's website Gallery Classifieds Feedback
subybaja
Samba Member


Joined: July 06, 2005
Posts: 1026
Location: Anchorage
subybaja is offline 

PostPosted: Mon Sep 26, 2005 3:55 pm    Post subject: Reply with quote

Here's a link to a "How-To" on the official Myers Manx site:

http://www.meyersmanx.com/garage/garage_shorten_p1.htm

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


...where it says to cut straight, but I also disagree. Rather than a bar straight across, your section to be removed should be shaped like a chevron, slanting back toward the torsion housing at the outside ends.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Tim10
Samba Member


Joined: April 06, 2004
Posts: 1433
Location: Minneapolis
Tim10 is offline 

PostPosted: Mon Sep 26, 2005 7:53 pm    Post subject: Reply with quote

Yep...

Angle cut... straights are not forgiving.

T.
_________________
Dub Infested- PART WI$H LI$T-CLICK
Back to top
View user's profile Send private message Visit poster's website Gallery Classifieds Feedback
turboghia
Samba Member


Joined: February 15, 2004
Posts: 210
Location: Long Beach, Ca.
turboghia is offline 

PostPosted: Tue Sep 27, 2005 12:17 pm    Post subject: Reply with quote

subybaja wrote:
Here's a link to a "How-To" on the official Myers Manx site:

http://www.meyersmanx.com/garage/garage_shorten_p1.htm

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


...where it says to cut straight, but I also disagree. Rather than a bar straight across, your section to be removed should be shaped like a chevron, slanting back toward the torsion housing at the outside ends.


How much of an angle?
Steve
Back to top
View user's profile Send private message Visit poster's website Gallery Classifieds Feedback
subybaja
Samba Member


Joined: July 06, 2005
Posts: 1026
Location: Anchorage
subybaja is offline 

PostPosted: Tue Sep 27, 2005 12:47 pm    Post subject: Reply with quote

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


My $.02- "The right way to shorten a VW pan for a buggy. Stronger than just a straight slice, since there is no "Fold Here" line. The section removed is the same width all the way out. Be careful of the tubes inside the tunnel. You'll lose your jack-points, and have to relocate the seat-belt mounts."
Back to top
View user's profile Send private message Gallery Classifieds Feedback
turboghia
Samba Member


Joined: February 15, 2004
Posts: 210
Location: Long Beach, Ca.
turboghia is offline 

PostPosted: Tue Sep 27, 2005 2:04 pm    Post subject: Reply with quote

Great info. Thanks for all the help. I'm glad I asked before cutting the pan.
Thanks Again,
Steve
Back to top
View user's profile Send private message Visit poster's website Gallery Classifieds Feedback
DSC
Samba Member


Joined: March 08, 2005
Posts: 127
Location: Southern Maryland
DSC is offline 

PostPosted: Thu Dec 08, 2005 7:05 pm    Post subject: Reply with quote

I'd only add that make sure to be careful when cutting through the main tunnel that you do not cut through all the guide tubes inside. You need to let them push through the back as you pull the cut setcions together and shorten them from the rear after the pan has been tacked back together.
_________________
1993 RX7 pT-67 .81 a/r
1308cc Two Rotor motor
[email protected]
Street Buggy currently under construction.
Back to top
View user's profile Send private message Visit poster's website Gallery Classifieds Feedback
iceluke
Samba Member


Joined: November 09, 2002
Posts: 117

iceluke is offline 

PostPosted: Thu Dec 08, 2005 11:44 pm    Post subject: Reply with quote

I did my own. Now working on my neighbor's (sux2bu).
If I ever do it again it will cost the poor soul a cool grand. Brick wall

just in my labor....
_________________
dual purpose....more fun that way
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Genom
Samba Member


Joined: January 03, 2003
Posts: 657
Location: Weyers Cave, VA
Genom is offline 

PostPosted: Wed Feb 15, 2006 8:07 pm    Post subject: Reply with quote

I'm gonna dig up this old thread and say the "angle cut" shown only allows the floor pans to come together cleaner, and has little if anything to do with the structural integrity of the finished product.

When I had my Sandwinder, I shortened the chassis using the "Z cut" method shown on this website: http://membres.lycos.fr/dbn/ (Look under Project Diary and then Frame) Yes it was a whole lot of extra measuring and fitting, but the finished product was well worth it.

I didn't need any further reinforcement on the tunnel, and the two halves came together real neat and clean...especially where the end of the tunnel flares out.
_________________
They call me James...
Back to top
View user's profile Send private message Send e-mail AIM Address Gallery Classifieds Feedback
dirtydeedss
Samba Member


Joined: November 19, 2005
Posts: 613
Location: Aldergrove BC Canada
dirtydeedss is offline 

PostPosted: Wed Feb 15, 2006 8:46 pm    Post subject: Reply with quote

just cut mine on an angle and u just have to do a bit os smashinn with a hammer to get the edges to meet on the curvey sections of the pan.
Back to top
View user's profile Send private message MSN Messenger Classifieds Feedback
Jimmler
Samba Member


Joined: November 18, 2004
Posts: 262

Jimmler is offline 

PostPosted: Thu Feb 16, 2006 9:08 am    Post subject: Reply with quote

Here's some real life photos of how I did mine:

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

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

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


Here's how I made sure all the lines were nice and straight and properly aligned. I used a Craftsman Laser Trac and a white paint pen:

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

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


The rest is easy!
_________________
-Jim
Nipomo, CA
Back to top
View user's profile Send private message Classifieds Feedback
UncleBob
Grease Midget


Joined: August 21, 2002
Posts: 2862
Location: Northeast Florida
UncleBob is offline 

PostPosted: Thu Feb 16, 2006 9:41 am    Post subject: Reply with quote

Great Pictures, Jimmler. Nothing like seeing the real thing. Did you use some of the 'liberated' tunnel section over the tunnel joint for reinforcement? What did you use for cutting?

Feel free to post the rest of the pics and the finished product.
_________________
OG JHC

don't worry, the ciggaret is fake.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Jimmler
Samba Member


Joined: November 18, 2004
Posts: 262

Jimmler is offline 

PostPosted: Thu Feb 16, 2006 10:26 am    Post subject: Reply with quote

The pan is not officially welded back together yet, so there's not much more to tell at this point. I have a broken clutch tube I'm repairing.

I probably will not brace over the weld with a section of removed tunnel. In this last picture you can see I left some "tabs" from the rear section. I think by bending those in and welding them to the sides of the tunnel, it will reinforce more than a strip across the top. The tunnel is stamped in that area that almost makes it look like those tabs are supposed to go there.

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


Most of the cutting was either by a sawzall or an air powered body saw from Harbor Freight. The tunnel is some pretty tough stuff. Buy plenty of blades. Also be careful not to slice the various tubes. That's the wrong place to shorten them! Wink
_________________
-Jim
Nipomo, CA
Back to top
View user's profile Send private message Classifieds Feedback
MURZI
Samba Member


Joined: August 25, 2005
Posts: 5014
Location: Madisonville, La
MURZI is offline 

PostPosted: Thu Feb 16, 2006 4:53 pm    Post subject: Reply with quote

I left a tongue on the bottom of the rear half of the pan that was about 8 inches long. I feel that it really strengthed the whole job. I like the idea of the flaps on the sides too. If I had to do it over I would do the flaps and the tongue. I wasn't concerned about the pans because I used sheet metal and 1x2 box tubing. EDIT--If I had to do it over I would buy a BERRIEN chassis. That job was a b*^%ch!!!
Image may have been reduced in size. Click image to view fullscreen.

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

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

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

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

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


MURZ
_________________
62 vert
2276
Timís welded heads
45 Dells
A1 sidewinder
Fk44 cam
Back to top
View user's profile Send private message Gallery Classifieds Feedback
bim55
Samba Member


Joined: February 11, 2005
Posts: 431
Location: Dennis Port, MA
bim55 is offline 

PostPosted: Thu Feb 16, 2006 6:57 pm    Post subject: Angle Cut or Delta Cut is the best Reply with quote

If you've ever worked with the metal floor pans, it's hard to believe that either a straight cut or a delta cut adds any integrity to the structure at all. They are just too flimsy even without any cuts.

The strength comes from the boxed tunnel section and the section or height of the sidewalls in the fiberglass body itself. Think of or visualize an I beam, the top and bottom plates control compression and tension.

But without a doubt, the two halves will match up better and require less work if you use the angle or delta cut.

You can cut the whole VW chassis with any metal cutting blade in a recip sawl, jig saw, circular saw, just about anyhting will work. As stated, be carefull in the tunnel section, and a small mig works perfectly on this gauge metal.

Also, great photos in this thread, nice to see projects like this.

Boston Bob E.
Back to top
View user's profile Send private message Visit poster's website Facebook Gallery Classifieds Feedback
DSC
Samba Member


Joined: March 08, 2005
Posts: 127
Location: Southern Maryland
DSC is offline 

PostPosted: Thu Feb 23, 2006 6:37 pm    Post subject: Reply with quote

Here were some photos from when I did mine a couple of months ago.

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

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

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

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

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

_________________
1993 RX7 pT-67 .81 a/r
1308cc Two Rotor motor
[email protected]
Street Buggy currently under construction.
Back to top
View user's profile Send private message Visit poster's website Gallery Classifieds Feedback
phatbstrd
Samba Member


Joined: June 26, 2006
Posts: 2
Location: Oilton, OK
phatbstrd is offline 

PostPosted: Fri Feb 23, 2007 7:10 am    Post subject: Putting the halves back together Reply with quote

I cut the pan and am now in the process of welding it back together. Everything went well with the cutting, but the shape of the tunnel halves obviously doesn't match up. Is it correct that I need to do some reshaping on the back half to match the front, or am I missing something? I don't want to mess anything up at this point, the body fits well, and the cuts are straight.

Thanks for your help.

Matt "The Newbie" Purvis
Oilton, OK
Back to top
View user's profile Send private message Classifieds Feedback
Display posts from previous:   
Reply to topic    Forum Index -> Kit Car/Fiberglass Buggy/356 Replica All times are Mountain Standard Time/Pacific Daylight Savings Time
Page: 1, 2, 3  Next
Page 1 of 3

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum

About | Help! | Advertise | Donate | Premium Membership | Privacy/Terms of Use | Contact Us | Site Map
Copyright © 1996-2018, Everett Barnes. All Rights Reserved.
Not affiliated with or sponsored by Volkswagen of America | Forum powered by phpBB