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halbug
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Location: Germany
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halbug
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Posts: 455
Location: Germany
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WrennMetallWerks
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Joined: December 06, 2007
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Location: Rescue ca
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halbug
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Joined: March 09, 2006
Posts: 455
Location: Germany
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TRS63
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Joined: December 17, 2017
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Location: Stuttgart - Germany
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Ian Godfrey
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Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
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 Posted: Thu Dec 28, 2023 1:53 pm Post subject: Re: Ghia coming home |
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| No tips, but i am enjoying the pixs. Thats a lovely solid steel bench to work on, that heavy flat surface is excellent. |
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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| Posted: Thu Dec 28, 2023 1:11 am Post subject: Re: Ghia coming home |
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First time I'm building something new from a sheet of metal, not repairung it.
Home style bending, the anti slosh plates served as templates
The tank frame attached to the new lower.
My plan is to spot weld from the inside and CUSI weld the seam again from the outside to seal. So the plan...
But lower sider walls are first and they are a the next challenge for me. And as always, if you have comments or tips please let me know. I just do as I think... never done before.
Cheers
_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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TRS63
Samba Member
Joined: December 17, 2017
Posts: 999
Location: Stuttgart - Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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Ian Godfrey
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Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
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| Posted: Mon Oct 16, 2023 1:26 pm Post subject: Re: Ghia coming home |
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No going back now, good luck with the brazing, I'm looking forward to seeing the pictures.
Are you adding any 'anti slosh' baffles while the tank is open? |
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halbug
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Joined: March 09, 2006
Posts: 455
Location: Germany
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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| Posted: Tue Sep 26, 2023 10:00 pm Post subject: Re: Ghia coming home |
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| Ian Godfrey wrote: |
to stretch that area I would quickly heat up a small section (30 - 40mm circle) to cherry red with oxy acetalene and work that area with a ball peen hammer. I'd start in the middle and work out a bit at a time
to cold form it you would need something behind it which you can't do 
Or, when you cut the top of the tank you could possibly support the creases with some wooden blocks  |
Ian, i agree, I should wait until I open the top of the tank.
_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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| Posted: Tue Sep 26, 2023 9:56 pm Post subject: Re: Ghia coming home |
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| Rome wrote: |
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| Not sure about the sender. I love to re-use the mechanical gage. Either bending the sender's arm or extending it. Not sure... I am open to suggestions. |
I noticed that VDO makes an adjustable-arm sender. https://www.google.com/shopping/product/4866271455...eQQ9pwGCAU
The description states that the mounting flange for the tank is an SAE (Society of Automotive Engineers) US auto industry standard, so that it should fit the flange on your modified tank. |
Rome, thank you! This is interesting. This unit is also adjustable in length of the sender arm. And it was new to me that VW used an SAE recommended flange for the tank sender.
I will experiment with a mechanical gage first. If it does not work, this unit is definitely on my list to check out closer.
Cheers
_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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Ian Godfrey
Samba Member
Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
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| Posted: Mon Sep 25, 2023 2:46 pm Post subject: Re: Ghia coming home |
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to stretch that area I would quickly heat up a small section (30 - 40mm circle) to cherry red with oxy acetalene and work that area with a ball peen hammer. I'd start in the middle and work out a bit at a time
to cold form it you would need something behind it which you can't do
Or, when you cut the top of the tank you could possibly support the creases with some wooden blocks |
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Rome
Samba Member
Joined: June 02, 2004
Posts: 9641
Location: Pearl River, NY
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| Posted: Mon Sep 25, 2023 5:10 am Post subject: Re: Ghia coming home |
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| Quote: |
| Not sure about the sender. I love to re-use the mechanical gage. Either bending the sender's arm or extending it. Not sure... I am open to suggestions. |
I noticed that VDO makes an adjustable-arm sender. https://www.google.com/shopping/product/4866271455...eQQ9pwGCAU
The description states that the mounting flange for the tank is an SAE (Society of Automotive Engineers) US auto industry standard, so that it should fit the flange on your modified tank. |
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halbug
Samba Member
Joined: March 09, 2006
Posts: 455
Location: Germany
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| Posted: Mon Sep 25, 2023 4:47 am Post subject: Re: Ghia coming home |
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To clear the fuelpump I need to create some clearance on the tank underside. All I need is a channel, bridge, bend or however you want to call it... its a channel, like a half pipe about 45 degree to normal (green). I want to form or "hammer" it into place.
How do I go about it, so that the two bends (red arrows) do not crease right away? Anyone here any idea?
I know that there must be someone reading this that can help  Please feel free to comment.
Cheers halbug
_________________
Stealth Ghia Transformation: http://www.thesamba.com/vw/forum/viewtopic.php?p=7226044&highlight=#7226044
My Berg5: https://www.thesamba.com/vw/forum/viewtopic.php?t=730276&start=0 |
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halbug
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Posts: 455
Location: Germany
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Ian Godfrey
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Joined: September 25, 2006
Posts: 1137
Location: Melbourne Australia
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| Posted: Sun Sep 17, 2023 2:34 am Post subject: Re: Ghia coming home |
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I haven't brazed with CUSi3 but I understand you need pure Argon as a shield.
Tig might be another approach to keep the warping to a minimum?
it is a bummer that the top of the 2 tanks are quite different.
I mechanical gauge would be Kool, maybe extend it so it reads accurately near empty and thats what matters  |
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