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Left for Dead...The Resurrection Story....(AWD EE-20)
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dobryan
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Joined: March 24, 2006
Posts: 11053
Location: Brookeville, MD
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PostPosted: Sun May 29, 2016 5:52 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

Popcorn Very Happy
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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

Join the Vanagon Rescue Squad on the VanAlert app.
http://vanalert.com/

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371
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ServantOfElwood
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Joined: July 25, 2014
Posts: 200
Location: The Wet Side of WA
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PostPosted: Sun May 29, 2016 8:37 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

Popcorn
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The Ghost Ship - 1984 Westfalia 2WD
https://www.thesamba.com/vw/forum/viewtopic.php?t=602180
Install in reverse order of removal.
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Sat Jun 04, 2016 6:05 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

More of the gas filler mod pics.


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Because of having plastic tubing in the metal pipe that i was welding to the body, I had to come up with a way to keep it cool. Ice water should help. In the end I didn't see anything wrong with the plastic. Just welded very slowly and a lot of tack welds only.

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Sound dampener sprayed. lizard skin or something like that.

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Air line that will go to the gas tank. In retrospect i should have moved it up further to make sure new gas doesn't go down the wrong tube , but i think it will be ok.

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Action shot.

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End result of the inside panel. The duck tape is just there to keep dust and debris out of the flared tubing.

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A little of the piping entered the inside of the sleeping area, yet its on the corner and will not be noticeable at all.
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I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Sun Jul 03, 2016 4:43 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

For the longest time I really didn't like the rear side windows of the Vanagon. Always thought they were useless and helped create heat inside the van. Time and time again I watched my surfboards wax melt under the magnifying glass of the rear windows. Well, I say no more! No more Chinese wax job before a surf. Enough is enough!

All things deemed stupid are deleted in this build. Bye bye Windows.


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Because of the shape of the window frame, I needed to grind a little slot until I reached the flat area. Then a spot weld was added. The amount of spot welds was more then factory, so it will be strong and sound. Then the remaining window lip was removed and ground down all nice and smooth like.

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I was really OCD about alineing the window panel. Didn't want very much bondo at all. The welding took forever, because it was all spot welding and moving to the opsite area to reduce heat and warping.

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Also took care of the seams with a crud thug and lots of tlc.
_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Tue Jul 05, 2016 3:13 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

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Couldn't forget to make sure no rust appeared after all that work.

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Put in an additional strip of 14 gauge metal to make sure it was nice and firm incase something pushed in the panel. One strip for drives side. (Rear cabinet will also provide support.) and two strips for passenger side.

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Since I now have about 2 inches of newly made room on the inside window area, I decided to make a book shelf and wetsuits holders.

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I didn't want just a panel with sharp edges as the book shelf, so adding a solid metal rod to the top would help soften the edges and make it look good.

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Little grinding required.

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Welding it in place was a little difficult, but do able.

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End result with some heat/sound abatement stuff.
_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)


Last edited by 0cean on Mon Jul 18, 2016 7:09 pm; edited 2 times in total
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oldhuldy67
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Joined: November 25, 2008
Posts: 503
Location: somewhere with a southern exposure
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PostPosted: Tue Jul 05, 2016 6:47 pm    Post subject: Re: DO IT! Reply with quote

0cean wrote:
msinabottle wrote:
Get Grim. Get Tough. Get to Work.


Link


Get glory.

Best!



Lol.. Nice

It's been done...she rises, boys...she rises! Oh, wait...she sunk


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_________________
Currently:1980 Westy Westfalia Poptop (a total stock-look rebuild with all my favorite camping mods)
1967 stock Sunroof Beetle
Formerly:
1978 Westy Campmobile, the"EM50 Urban Assault Vehicle" code named "The Pickle"
1973 Squareback (sold on a lark)
1973 Super Beetle (crashed..walked away without a scratch)
1972 Standard Beetle (lost in a relationship..)
1966 Beetle (the Black Beauty, my Dad's)
1964 Beetle (the Beige Bug, my beginning beater, also my Dad's) Thanks, Dad.
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Thu Jul 07, 2016 5:43 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

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Spent some time working on the rear brakes I ordered on ebay. Apparently the "Remanufactured" brakes had rust under the poor spray paint job. Also replaced the seals, because i didn't trust that they had been replaced.

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Red stuff is anti-rust for brakes

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Same love for the fronts. They were sold as used, so i expected giving some TLC.
_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Fri Jul 15, 2016 5:08 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

So I really want a Back up camera for obvious reasons, yet don't need a view of straight back behind me. So the best place to view how close you are from the other guys bumper is from above. The problem is the camera is flat on the bottom and the rear hatch is curved metal near the top of the rear window. No problem... new welding skills come to the rescue.

Don't let the cat box scare you.. Its clean'ish.


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_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Sun Aug 21, 2016 6:52 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

Ok, for those of you who haven't closed your eyes for what I have done already, you may want to look else where. LOL.. J/K

I don't know how this happened, but i decided it would be great to have a 22-26 gallon diesel gas tank. The only way to make this happened in a Syncro is to cut into the cabin. So here we are. I'm still keeping structural integrity and in fact improved it with sub framing.


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Off goes the old gas tank holder.


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its so much easier working on the frame this way.


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Three layers of sheet metal tack welded together was a little concerning, so now they are one.


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Here is the sub framing that was added.


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The bracing is from one rear spring tower to the other. Little added stiffness. Overall, the rear is solid enough to easily support my weight on the edge of the opening. I'm happy with it.
_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Mon Aug 22, 2016 9:19 am    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

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Started making the inside cover for the fuel tank.

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Added a coupe of metal strips to the edge that will slide into the corrugated rear engine lid. When its done, there will be screws to make the whole piece fit together.

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More bracing and bottom to the area where the metal tabs will side into.

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Fits great and is strong.
_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Sun Oct 02, 2016 3:12 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

Next i welded in a couple of shackles to keep my warm water bottle from sliding all over the place. Essential for a after surf road side shower.


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Since i have taken away a lot of the storage under the rear seat, I needed to make up some room somewhere. There is a good amount of room under the van, so why not.

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The van has four bolts welded in place from the factory on the floor board. I don't know why they are there, but they work great as mounting points for the undercarriage compartment mod. The four bolts are strong enough to hold the entire compartment.

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The mounting points where welded in place to the compartment.

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_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Mon Oct 03, 2016 8:14 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

For some dumb reason I didn't make the shelf go all the way under the bottom of the undercarriage space. Don't remember why, but I had to fix it.

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Then epoxy primed it.

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_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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Robw_z
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Joined: April 28, 2007
Posts: 849

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PostPosted: Mon Oct 03, 2016 9:25 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

Popcorn Popcorn Popcorn

Nice attention to the small things.

-Rob
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rubbachicken
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Joined: October 05, 2004
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Location: socal
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PostPosted: Mon Oct 03, 2016 11:00 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

looking good jason,
i'll pop by for a look when i get back to san diego
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meet 'burni'


markswagen {mobile mechanic} san diego area all early VW's cared for.

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0cean
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Posts: 867
Location: California
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PostPosted: Mon Oct 03, 2016 11:22 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

rubbachicken wrote:
looking good jason,
i'll pop by for a look when i get back to san diego


Yeah, it would be nice to see you again. Come on by.
_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Mon Oct 24, 2016 12:27 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

Here is a favorite mod. Extra storage space box thing from Rocky Mountain Westy. Its a great place to sit wail changing into a wetsuit. I found this and a under the seat drawer from Rocky Mountain Westy in the samba ads pretty cheap. The air compressor will also go in the new storage space as its to big to fit in the storage bin under the van.


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Tight fit, yet it will work out good.

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The fit for the storage box was awful, but I didn't care because it can be made to work with a lot of cutting.

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The weld marks on the top of the door are bracing I added so its a lot stonger. Hay, you never know if you will gain some weight.. Laughing

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More to come soon about the box.
_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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xoo00oox
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Posts: 2021
Location: East Nassau, NY
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PostPosted: Mon Oct 24, 2016 1:15 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

When do we get to see the AWD goodies?
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0cean
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Posts: 867
Location: California
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PostPosted: Mon Oct 24, 2016 1:47 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

Its going to be some time. I'm further along with this build then I'm posting, yet I keep modifying the body so much, its taking wail to get there. The first AWD part, the cable shifter will be coming in the next month or so. Lots of work for a guy on the side of his house. Laughing
_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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0cean
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Joined: February 29, 2012
Posts: 867
Location: California
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PostPosted: Mon Oct 24, 2016 1:54 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

Couple fun filled pics.


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_________________
I'm not a mechanic, I just play one on the internet

Cluster Rebuild:
http://www.thesamba.com/vw/forum/viewtopic.php?t=569920&highlight=

Left for Dead the Resurrection Story Build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=613669
(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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xoo00oox
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Joined: February 11, 2010
Posts: 2021
Location: East Nassau, NY
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PostPosted: Mon Oct 24, 2016 2:57 pm    Post subject: Re: Left for Dead...The Resurrection Story....(AWD EE-20) Reply with quote

That's more like it! Do you have the engine and transmission yet?

Bytheway, love the idea of welding in tie down hooks. I'm always wishing I had them when I go to secure something in my van.
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