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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Sep 13, 2011 9:46 pm Post subject: |
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The first welding I actually did on a part of the car is this repair on the sparewheel tray bottom thing?
40 odd years of wear and tear and rust.
very tricky!!
and all finished up in weldable primer ready to be attached back to the valance, one day.
_________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Wed Sep 14, 2011 3:00 pm Post subject: |
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Still having trouble getting the fenders fit nicely with the valance and the edge of the bonnet.
asked for some help on the body/paint page, cheers spook! slowly getting there!
Strangely it's the right side I'm having the hardest time with
even though the left had more damage.
The other issue is the bonnet, or hood whatever. It has never fitted very well, plus rust, bog.
Started chipping away like a carpenter, check out the shape!
little bit of mud!
got this nice solid OG replacement
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Wed Sep 14, 2011 3:58 pm Post subject: |
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Started work on the valance, finding out 80% of the time is getting it to fit, 2% is welding and the rest grinding the welding away!
tacked in place
test fit, not bad. the bumper mount is still a bit bent in this shot.
stitched up
close up
back side
I forgot to take any pics before I sprayed primer but i'm pretty friggin happy with how it's turned out.
back
close up of the bottom
just like a new one!
I did the other side the other day, I joined it at the bumper mount hole, as it wasn't as damaged as the left side, saved a bit of welding too!
really like seeing it come back together, can't wait to do more. _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Mon Nov 14, 2011 9:47 pm Post subject: |
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Finished taking the old baja apart
Started work on the edge of the front quarter.
I carefully cut the cancer out and blasted aanything that was left.
something is missing here?
all covered with weldable primer
inside and out
hole drilled for the bumper mount to be plug welded
tacked in
and after some shit welding, all smoothed out
fits just like a new one
Started on the right side
this is why I wanted to sandblast the insides of the mounts
got to here and ran out of wire
here are the captive nuts
the bottom two just fell out with all the banging and hammering
the other two where cut out with the rust, you will notice one ahd been welded over at some point, well I guess I've been reading to many of the detailed restos on here and just had it make it pretty
I think I may have a problem
had bit of a mock up to see how it's looking
[/img] _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Fri May 31, 2013 6:05 pm Post subject: |
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So I'm way behind in this thread, like a year!
I've not giving up though, here are some pics of the rest of the front repairs
Took the paint of several trouble spot's which i knew would need welding and also found a few I didn't know about
the bottom has been repaired at some point, swiss cheese is all natural.
this one I didn't see coming but should be fairly easy to fix
it was three tiny cracks in the paint under the trim strip, oh well.
The other side is a little worse, should be fun!
So once I had most of the old paint off I set up the sand blaster
after
much better!
All the welds on the front are all smoothed out and primed
Started on the patchwork here.
getting pretty handy with the cut off wheel
still crap at welding!
removed the aerial, which was easier than i thought. The small bolt/nut under the where the actual aerial attached had rusted away to nothing.
you can see the bit that was still on the aerial base on the left
sorry sideways pic, the bottom hole should only be about 5mm
I think I will weld up the other hole too, I've always liked those aerials with the two chrome mounts, they look a bit more oldschool.
cut
patch
weld
smoothed out
primed
also, in a effort to stay motovated I stuck the fenders on and loaded eight concreate blocks under the hood to grt the front down to the old ride height
it's the little things.[/list] _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Mon Jun 03, 2013 8:44 pm Post subject: |
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So I'll save yous the repeat pics on the right side of the car, but i think it's looking pretty good, still a bit wavey but better than full of holes!
and on to the ass end.
then i got bored and started chipping some bog
nice!
home sweat home _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Mon Jun 03, 2013 8:51 pm Post subject: |
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getting ready to drop the engine
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Mon Jun 03, 2013 9:04 pm Post subject: |
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Here's my pimped out 90's style engine
and out, forgot what a pain in the ass that is, removable valance for sure!
built this wee table last week to keep the engine out the way, cost me a box of piss for the steel from the workshop across the road for work, the dude even cut it all up for me.
the reason for this is that I don't actually have that much room in the shed( wife insists on keeping the honda in there
as well as all the bikes, lawnmowers and kids junk, It's going to be very interesting when the shell comes off the pan _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Jun 04, 2013 9:09 pm Post subject: |
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Sorry if this is boring you all to death, I know you've all seen a engine being removed before!
This is the reason the engine had to be moved
This is the inside of the rear bumper mount, both inner panels are like this, the left being the worst for some reason
here is the outside
and the right hand side
After having a small fight with the brazed area's, I got the rear valance off. Would have been easier if i had some kind of torch to melt the braze but I got there in the end.
although there is not as much rust damage as the front this things still had a rough life
this is from the where the header flange bolts onto the mufflers pipe, when the flange would drag on the road
pulling out of a driveway, this area would get punched in. I've see people cut in a third exhaust hole in the center of the apron and usually weld up the other two, but I kinda like the shape of the stock metal for some reason.
so I removed the inner panel spot welds and trimmed the return edge of the valance about 30mm and started rolling the metal under. I think I'm going to have to reinstall the inner panel in some way as the valance seem very flimsy without it, any ideas? prolly just mod the old panel to fit.
check out this mess!
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Wed Jun 05, 2013 8:46 pm Post subject: |
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Patching up of rear valance started here, also removed the rubber seal holder thing, lots of rust under there.
all sanded down
the valance also need heaps of small repairs like this
i was very happy with this fab work, i managed to make it without cutting,
but did have to make it out of four parts
i could not have made this any harded for myself, this patch was a bitch!
tacked up
smoothed out
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HUGO bOSS Samba Member
Joined: April 27, 2008 Posts: 2602 Location: Madeira Island - Portugal
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Fri Aug 09, 2013 3:12 am Post subject: |
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no chance of that mate, I'm still at it. I need to update this thread, but I have finished the rear valance, replaced the rear bumper mounts and what they attach too. done a lot of work on the engine lid and have just stripped the inside/seats etc, plus the sad homemade wiring. _________________ If you can't join them, beat them! |
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HUGO bOSS Samba Member
Joined: April 27, 2008 Posts: 2602 Location: Madeira Island - Portugal
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Sun Aug 11, 2013 2:05 am Post subject: |
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channels aren't to bad, I'm hoping to just remove the bottom plates blast and repair them, might need new bottom plates, we will see! _________________ If you can't join them, beat them! |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Sun Aug 11, 2013 2:55 am Post subject: |
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sanded, blasted and primed the valance.
the inner panel there, was bent, rusted and needs alot of work
I wanted to trim the valance down to give more room for the exhaust system, so i rolled the edge under and then needed to extend the inner panel to meet it.
but first, an't it pretty.
so, started fixing the inner panel
here it is welded in place
first i had just folded the end over but that looked shit, so i did a little hammering and stretching, much better.
I'm going to make this panel bolt on, rather than weld it back on, will make pulling the engine even easier.
With the valance sorted, i took the spot weld drill and cut off wheel to the rusty thing that use to be a bumper mount.
this part of the car has cleverly been designed to create as much rust as possible
not much left of the old one
also removed the inside engine tray so I had full access to both sides of the panel
thought i'd have a crack at some fab work
this was fun, had to make some cuts to get the metal to bend in the right places, then weld back together, then grind.
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Sun Aug 11, 2013 3:27 am Post subject: |
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chop chop!
Baja spec.
fitted in place
welded up
on to the other side, something like 36 spotwelds on these pricks
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Sun Aug 11, 2013 3:52 am Post subject: |
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got onto the right side, had to replace more than the other side as the damage went up a bit higher up.
so the replacement had to be bigger
i can not tell you how long this took to make, ages, just ages.The indent where the valance overlaps took some thinking and a lot of hammering, pretty pleased with how it turned out.
and just when i thought i was getting there, i offered the panel up to the car and it was not bent enough
so i pushed until, crack! back to the welder.
as you can see in the first pic, the panel was not long enough by 5-6cm, i did this just to save a bit of metal
oh well , the plan was to join it at the bottom then let in a small patch on the side, but as i was trying to fit the replacement, i found i'd cut it too short.
I spent another night extending the panel to fix my fuck up.
at lease I got to practice my welding more.
This is the finished thing.
then tacked in place and test fitting the fenders etc
and welded in
spent alot of time smoothing it out as best i could
really hard to get a good photo with the reflections, not perfect but the bumper mount will cover it anyway
I took a photo in primer but it just looked completely flat.
I was very happy with this finish, as i was stressing about it a bit with all the angles etc.
everything still seems to fit _________________ If you can't join them, beat them! |
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HUGO bOSS Samba Member
Joined: April 27, 2008 Posts: 2602 Location: Madeira Island - Portugal
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Posted: Mon Aug 12, 2013 3:24 pm Post subject: |
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Nice work going there...
What kind od gas are you using on the welding? Looks in the spots welds that you need a litle more gas... In the begining I use the same gas that they use on gas drinks (coca cola, beer, etc...)... _________________ http://www.thesamba.com/vw/forum/viewtopic.php?t=538182 |
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63Ragtop NZ Samba Member
Joined: December 04, 2007 Posts: 895 Location: West Auckland
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Posted: Tue Aug 13, 2013 3:17 am Post subject: |
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gasless MIG, doe's the job.
my brother-in-law has a real nice new gas rig, might see if I can use it for the more visible areas.
haha, the old sodastream trick? as long as it works! _________________ If you can't join them, beat them! |
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jmw1982 Samba Member
Joined: May 19, 2008 Posts: 298 Location: Weymouth, MA
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Posted: Sun Aug 18, 2013 6:30 pm Post subject: |
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nice work! _________________ ________________________________________
'60 Beetle Indigo Blue |
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