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58 kombi Rocker repair
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Mitch Case Premium Member
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PostPosted: Tue Nov 09, 2010 9:08 pm    Post subject: 58 kombi Rocker repair Reply with quote
This is a 58 kombi that belongs to a friend of mine. We finally got around to fixing the hammered rocker. In a past life this bus took a hard hit on the passenger side wiping out the doors and rocker plus some of the qtr. The old doors were welded to the body and that really didn't do the bus any favors. Our goal was to just fix the rocker. Things went a little awry and now the bus is getting a face-lift.
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Mitch Case Premium Member
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PostPosted: Tue Nov 09, 2010 9:11 pm    Post subject: Reply with quote
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Mitch Case Premium Member
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PostPosted: Wed Nov 10, 2010 7:20 pm    Post subject: Reply with quote
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Mitch Case Premium Member
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PostPosted: Wed Nov 10, 2010 7:22 pm    Post subject: Reply with quote
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http://www.thesamba.com/vw/forum/viewtopic.php?t=269607&highlight=
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http://www.thesamba.com/vw/forum/viewtopic.php?t=428154
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Mitch Case Premium Member
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PostPosted: Wed Nov 10, 2010 7:27 pm    Post subject: Reply with quote
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Mitch Case Premium Member
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PostPosted: Wed Nov 10, 2010 7:32 pm    Post subject: Reply with quote
We got a piece from Wolfsburg West for the repair. It works but the edge is a little more round then the squared off factory metal I will need to build up the edge with some weld and grind it down a little.
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Mitch Case Premium Member
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PostPosted: Wed Nov 10, 2010 7:38 pm    Post subject: Reply with quote
The rocker was a farily straight forward repair cut off the old hammer the floor into submission and clamp weld clamp weld repeat
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Mitch Case Premium Member
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PostPosted: Wed Nov 10, 2010 7:47 pm    Post subject: Reply with quote
For the C pilar I dug through the stash and came up with some OG metal this is harder then it looks to do as you have to be able to get the door on and off with the new piece in place it took a lot of on and off on and off to get it close. Once we striped the qtr it was ovious were going to have to do something with it. The metal was just garbage.
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Culito
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PostPosted: Wed Nov 10, 2010 9:47 pm    Post subject: Reply with quote
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Wow, looks like somebody blasted that thing with a shotgun! That's a lot of stud weldin'.

Nice work so far!
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Saul Koll
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PostPosted: Wed Nov 10, 2010 9:52 pm    Post subject: Reply with quote
Cool, thanks for the work pics.
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BarryL Premium Member
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PostPosted: Thu Nov 11, 2010 7:55 am    Post subject: Reply with quote
Intense and some critical fit areas. Wrinkle city on that ground down area.
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Mitch Case Premium Member
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PostPosted: Thu Nov 11, 2010 8:15 am    Post subject: Reply with quote
No studs here. That was an option but you would have to shrink it and hammer it so much that it really wouldn't be the best option. The tape is where we cut that whole panel out. I cut it so all the welds would be hidden behind the chanels of the inner structure.
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PostPosted: Thu Nov 11, 2010 8:26 am    Post subject: Reply with quote
You are truly an artist Cool
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PostPosted: Thu Nov 11, 2010 8:45 pm    Post subject: Reply with quote
The lowest cross brace was missing off the car possibly when the previous owner was hammering on it it may have come loose. I built one out of some 20 guage metal I picked up 18 seems to be to thick and 22 is like paper. I thought it looked pretty nice. I crimped the ends so it would sit flush against the new sheet metal more like factory.
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Mitch Case Premium Member
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PostPosted: Thu Nov 11, 2010 8:51 pm    Post subject: Reply with quote
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No turning back now
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You can see the braces better now
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Mitch Case Premium Member
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PostPosted: Thu Nov 11, 2010 8:53 pm    Post subject: Reply with quote
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PostPosted: Thu Nov 11, 2010 9:00 pm    Post subject: Reply with quote
I used a piece of paper to make my template for the new sheet of metal. I added a 1/4 to 1/2 inch around the edge so I could flange the metal and do a lap repair on the edges. There will be a small section of but welding but I kept it to a minimum. Hope fully the flange will also cut down on the warping. I would have liked a whole qtr panel but Gearson wasn't an option due to shipping costs and England would hav taken to long oh well were on our way now it will be a better repair then trying to fix that mess that was there.
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Mitch Case Premium Member
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PostPosted: Thu Nov 11, 2010 9:02 pm    Post subject: Reply with quote
You can see how the new sheet will fit behind the old one
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ol36er
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PostPosted: Fri Nov 12, 2010 11:46 am    Post subject: Reply with quote
Good Work...keep the progress pics comin!
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PostPosted: Fri Nov 26, 2010 8:30 pm    Post subject: Reply with quote
already looks 20x better Cool
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