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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32634
Location: Reading Pennsylvania
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JerryMCarter1
Samba Member
Joined: January 07, 2007
Posts: 6199
Location: N.W. Phoenix
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 Posted: Thu Oct 13, 2011 4:16 pm Post subject: |
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Hmm very good Dave
How much money ?
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Experience always triumphs over hearsay and You get to select which theory to believe |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32634
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32634
Location: Reading Pennsylvania
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JerryMCarter1
Samba Member
Joined: January 07, 2007
Posts: 6199
Location: N.W. Phoenix
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| Posted: Fri Oct 14, 2011 3:03 pm Post subject: |
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ballsy worka holic!
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Experience always triumphs over hearsay and You get to select which theory to believe |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32634
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32634
Location: Reading Pennsylvania
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JerryMCarter1
Samba Member
Joined: January 07, 2007
Posts: 6199
Location: N.W. Phoenix
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| Posted: Sat Oct 15, 2011 8:52 am Post subject: |
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get-er Dave
Jerry
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Experience always triumphs over hearsay and You get to select which theory to believe |
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djkeev
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Joined: September 30, 2007
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Location: Reading Pennsylvania
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DrummerDaveB
Samba Member
Joined: March 25, 2005
Posts: 504
Location: Louisville, KY Area
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| Posted: Fri Oct 21, 2011 1:50 pm Post subject: |
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Looking great.
Im going to be tackling the running board fastening panels soon on my 79 vert.... Except I dont know how to weld, so it's gonna be SUPER fun. 
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79 SB Vert, in pieces.
Kadrons, SVDA. |
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torsionbar
Samba Member
Joined: December 11, 2010
Posts: 2215
Location: earf
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| Posted: Fri Oct 21, 2011 2:06 pm Post subject: |
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| djkeev wrote: |
The next "easy" project will be this fender, it is the ONLY after market fender on the car and it's the only one that is rusted out!!! It is amazing how thin and light this fender is compared to the OEM ones. It's like tissue paper in comparison. |
it's almost comical how bad most aftermarket parts are for these cars. i too had one aftermarket fender on my '79. it was rusted completely through in a grapefruit sized spot. i could poke straight through it with one finger, it was just rust held together by the paint.
the correct '75 - '79 fenders are actually tricky to find for some reason, at least the rear ones. i found tons of early ones for sale, but really had to search to find a late rear fender available locally.
nice work on the rust repairs so far.
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| Max Welton wrote: |
[air cooled vw's] are no longer suitable for the general public. The owner has to be be able to maintain the car. And that is after fixing all the deferred maintenance items and ill-conceived modifications. If you can't do those things you are pretty much screwed. |
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JerryMCarter1
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Joined: January 07, 2007
Posts: 6199
Location: N.W. Phoenix
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| Posted: Fri Oct 21, 2011 5:01 pm Post subject: |
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got beer in that frig???
Jerry
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32634
Location: Reading Pennsylvania
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JerryMCarter1
Samba Member
Joined: January 07, 2007
Posts: 6199
Location: N.W. Phoenix
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| Posted: Fri Oct 21, 2011 5:28 pm Post subject: |
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shiieeesh
your 2500 miles from me !
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32634
Location: Reading Pennsylvania
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| Posted: Sun Oct 23, 2011 12:06 pm Post subject: |
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Well, today's challenge is the cheap after market fender rusted through!! 
Shouldn't be too hard to fix, I have some left over sheet metal from fixing the front inner splash area. It already had a curved 90 degree bend so it needed minimal work to start with. I cut it to shape and did some additional bending to make it follow the fender curve. I did cut it and weld it on the bottom lip to make the bend a little tighter as needed.
Next I cut out the fender to the ends of the patch panel I'm making.
I then welded in the patch panel at the fender lip area.
I then sliced the panel in multiple places in order to make it fold over with out kinking and rippling as too much metal gathers together.
I used my torch and heated up the metal to red and gently pounded over each finger until the shape was formed but I had multiple over lays to deal with.
Next I used the dremel with a thin slicing blade to trim the first finger to be slightly smaller than the cut out I made in the fender.
I welded in the first set of fingers. Then using heat to make the metal red hot and soft, I formed the bend a little better and softened any sharp edges where the cuts ended. I cut between the next finger and the first finger and the fender making clearance for a butt weld without overlap. I then welded up the union between the first and second set of fingers.
I did each finger in a similar fashion..
After grinding off the welds it's ready for some final shaping and putty!
Keep in mind that heat and proper hammer hits can do miracles when making metal fit into a funny shape!
Let's see, Sunday, 3PM, lets take a look at that rusted door bottom!!
Dave 
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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JerryMCarter1
Samba Member
Joined: January 07, 2007
Posts: 6199
Location: N.W. Phoenix
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| Posted: Sun Oct 23, 2011 1:27 pm Post subject: |
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DAMN - GIT ER ---- DAVE
Looks like a few fenders I have had to do !
Jerry
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32634
Location: Reading Pennsylvania
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| Posted: Sun Oct 23, 2011 5:24 pm Post subject: |
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So, on to the Right door!
This door was severely rusted on the bottom, front to rear. Because of this I ordered a new panel from M&T manufacturing.
I wire brushed the door and upon examination determined that I really don't need all of that new panel. I elected to install a new inner bottom curve and 1/2" of new metal. I took some dimensions on the height of the door from the upper door panel lip and drew a line across the door.
I then used my angle grinder with a cut off wheel and cut just above the line I drew, removing the old rusted bottom.
Inside I found a reinforcement piece I didn't know was there and fortunately had not cut with my cut off wheel!! It gets welded to the bottom of the door.
I then cut the new panel so it was 1/2" from the bottom and welded it to the door. Ground off the welds and ended up with this. Still need to go back and repair a few welds and weld the edges. I also need to rebuild the weather strip flange on the bottom and a bit up the sides of the door.
A good day over all!! I then went into the house to celebrate my twin grandson / grand daughter's 3rd birthday!!
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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slione
Samba Member
Joined: June 18, 2011
Posts: 180
Location: NJ
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| Posted: Sun Oct 23, 2011 7:40 pm Post subject: |
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Great work Dave!! Thank you for documenting all of your work. For those of us eager to learn about welding, this is both educational and inspirational! 
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1974 SB Vert  - Getting there, slowly but surely |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32634
Location: Reading Pennsylvania
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EXJAY
Samba Member
Joined: October 04, 2009
Posts: 1109
Location: Myrtle Beach, SC
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| Posted: Mon Oct 24, 2011 4:50 am Post subject: |
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 nice work! Damn, I need to get a fridge for the garage
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EXJAY
'74 Superbeetle (Family owned since new)
'73 181 Thing (sold) |
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I love buying from East Coast Vendors!!! 
)
