First aircooled 65 single cab

ryans65 · Posted: Wed Mar 22, 2017 4:45 am Post subject: Re: First aircooled 65 single cab

The rust is fixable on the passenger dogleg, the drivers dogleg is a mess though. I think rather than attempt at patching the passenger dogleg I am just going to buy the KF inner and outer lower dogleg repair sections. It is an extra expense I wasn't planning on but I am trying to do this nose right the first time.

Pinetops · Samba Member Joined: March 24, 2007 Posts: 2987

Work looks really good so far, thanks for the updates.
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"A rolling bus gathers no rust."

SamboSamba22

Looking good Ryan, thanks for taking the time to share, I'll be diving into this very same thing soon, hopefully.
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The Bus Barn Ltd. Co.

Oct. ’67 Double Cab (’68 Crew Cab)
[url=http://www.vw-mplate.com/mplate-44412.png]Click to view image[/URL]
March '69 Delivery (Panel Bus)
[url=http://www.vw-mplate.com/mplate-44414.png]Click to view image[/URL]

ryans65 · Posted: Mon Apr 17, 2017 2:53 pm Post subject: Re: First aircooled 65 single cab

I need some opinions here before I start reassembly this week:

I have a new nose panel that would normally "tuck" under the lower windshield panel, not a nose panel like KF and some other places sell where it includes the lower windshield panel. My window frames are not rotted whatsoever so I decided not to go down that road but now I am thinking of the best route to take welding the new nose panel in. Here are my options:

-Trim the new nose panel just below the windshield frame and butt weld it up against the small leftover piece of the original nose, leaving the OG window frame and spot welds intact.

-Drill all of the spot welds where the OG nose panel meets the lower window frame and "slide" (?) the old sliver of nose panel out from underneath the frame, then "slip" the new nose panel under the old window frame section and use the now drilled out spot weld sections as the area to plug weld my new nose on.

-Purchase a KF nose with the lower frame included

I am leaning toward drilling the spot welds off the old frame and slipping the old nose section out and letting the existing window frame overlap the new nose, just how it was from the factory and plug welding it back in. Despite the hard work of drilling all the spot welds, I think it is the best route to take considering how much grinding and shaping will be required if I trim and butt weld the new nose on. Basically the more I think about it, I would like to avoid a huge weld seam all the way across the new nose... especially when I have gone this far already! Sounds like a lot of grinding and risk of warping.

Thoughts?

sgellis · Posted: Mon Apr 17, 2017 4:43 pm Post subject: Re: First aircooled 65 single cab

Drilling out the weld from the front will be difficult. Finding the spots and getting them cleanly drilled out and apart without making a mess of the windshield frame...

Getting a lower windshield frame will be easier.
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My 64 Kombi restoration
My camper interior build
My 54 standard restoration
The Nova Scotian Barndoor (YouTube)
The Nova Scotian Barndoor (CAD drawings)

glideking · Posted: Mon Apr 17, 2017 6:42 pm Post subject: Re: First aircooled 65 single cab

I would advise against trying to fit a nose under the old window frames in place. Getting a good looking tight fit of the new nose and old window frame will be very time consuming. It has been done that way though. I replaced my lower window even though it was ok. No regrets.
Kurt
_________________
"The more I get done the less it looks like I did anything"
1959 Single Cab Restoration"Funky Truck"
http://www.thesamba.com/vw/forum/viewtopic.php?t=5...highlight=
1965 21 Window Restoration Thread (From old photos)
http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=
1963 Panelvan build "Tyvanosaurus Wrecks"
http://www.thesamba.com/vw/forum/viewtopic.php?p=8351639#8351639

ryans65 · Posted: Tue Apr 18, 2017 4:52 am Post subject: Re: First aircooled 65 single cab

Thank you guys for the input! I think a lower windshield frame order is going in today. Seems like the best route when doing a full nose replacement, Kurt your videos have been so helpful during all of this I can't thank you enough for taking the time to make and most importantly share all of them.

SamboSamba22 · Posted: Tue Apr 18, 2017 7:43 am Post subject: Re: First aircooled 65 single cab

With both of you guys, Ryan and Kurt, how is the front section of the doglegs welded to the nose section? It looks like a butt weld, though both inner and outer doglegs being separate pieces, I'm just curious.
I haven't cut out my old rusty legs yet, I bought the half dog leg sections that is offered by Gerson, so I'm waiting to see how high they come up before removing anything.
I could totally watch Kurt's 3-piece dogleg seminar on the tubez, and plan too, once metal arrives.
I was hoping something would indulge my laziness.
_________________
The Bus Barn Ltd. Co.

Oct. ’67 Double Cab (’68 Crew Cab)
[url=http://www.vw-mplate.com/mplate-44412.png]Click to view image[/URL]
March '69 Delivery (Panel Bus)
[url=http://www.vw-mplate.com/mplate-44414.png]Click to view image[/URL]

glideking · Posted: Tue Apr 18, 2017 7:12 pm Post subject: Re: First aircooled 65 single cab

Thread hijack?

Doglegs at the front were four spot welded tabs only. They rely heavily on the floor and wheel housing for shape and stiffness. VW had very strong clamping frames to hold everything in perfect alignment for welding. We must spend hours trying fitting and clamping to gat a good door gap. Quality time well spent.
Kurt
_________________
"The more I get done the less it looks like I did anything"
1959 Single Cab Restoration"Funky Truck"
http://www.thesamba.com/vw/forum/viewtopic.php?t=5...highlight=
1965 21 Window Restoration Thread (From old photos)
http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=
1963 Panelvan build "Tyvanosaurus Wrecks"
http://www.thesamba.com/vw/forum/viewtopic.php?p=8351639#8351639

SamboSamba22 · Posted: Wed Apr 19, 2017 3:27 am Post subject: Re: First aircooled 65 single cab

No hijacking here.
Just reaching out for tips, suggestions, things to make it easier (Clecos) and the dos/dont's.
Carry on gentlemen!
_________________
The Bus Barn Ltd. Co.

Oct. ’67 Double Cab (’68 Crew Cab)
[url=http://www.vw-mplate.com/mplate-44412.png]Click to view image[/URL]
March '69 Delivery (Panel Bus)
[url=http://www.vw-mplate.com/mplate-44414.png]Click to view image[/URL]

ryans65 · Posted: Wed Apr 19, 2017 8:38 am Post subject: Re: First aircooled 65 single cab

Tried to put in a few hours last night after I fixed my F350 but that old jealous Ford was not letting me get any alone time with the single cab! Should have some progress pics soon.

ryans65 · Posted: Wed Apr 26, 2017 4:17 am Post subject: Re: First aircooled 65 single cab

Finally got the rest of the lower valence brackets cut off allowing me to start fitting fresh metal!

Despite this panel being held in by only vise grips, I am feeling very satisfied that I am in the rebuilding phase.

Image may have been reduced in size. Click image to view fullscreen.

My Freinds barn find 67 21 window I posted a few pages back ended up having a bad trans so in the "help each other out" spirit I have encountered with so many other aircooled enthusiasts I pulled my transmission and traded it to him for an IRS gearbox and other parts to do the swap. I wanted to do IRS originally so I am using this opportunity to do it while the truck is off the road plus he gets to drive his bus with a known good trans. First time this bus will be on the road in who knows how long! I believe the term for this is "mission creep." This is how my 91 BMW ended up with a V8, 6 speed, big brakes and completely repainted, started with a simple engine pull/ rebuild.

ryans65 · Posted: Sun Apr 30, 2017 6:33 am Post subject: Re: First aircooled 65 single cab

Drove my bug out to the shop, it needed some miles after being stored since October. Swapped the bus wheels on that and cranked the front beam down a little more. Perfect!

Started lining up the lower a pillar sections and outer a pillar support pieces. Immediately noticed the inner valence curve does not match the headlight support peice. This caught my eye before but now that I have the brackets and lower a pillars in place it is more apparent. My question is: is the inner valence curve supposed to match the curve of the headlight support?

Using Kurts method of hanging the doors to keep an eye on the gap for when the doglegs go back in. Door Gap on the pass side is still looking good, what a bear it is to hang these doors by yourself!

ryans65 · Posted: Fri May 05, 2017 7:16 am Post subject: Re: First aircooled 65 single cab

Gathering IRS swap parts, it's nice to have a good freind with a ton of fat chick and thing parts. Got a complete thing rear end to rob parts off of. So far I have a thing trans, axles, trailing arms and all the other bits and pieces to play with. In the Process of stripping, degreasing, rebuilding etc. moving along quite well with the IRS swap!

ryans65 · Posted: Wed May 10, 2017 4:30 am Post subject: Re: First aircooled 65 single cab

Happy to have made some progress, I ordered the KF inner valence as I was having trouble making the WW brackets line up with the valence itself... its hard to describe but there is pressing on the back of the WW valence that makes it impossible for the brackets to sit flush and that in turn messed up the angle where the brackets met the frame rails. The KF one popped right on no problem. Not really a bad part from WW just something that I was tired of messing with. Lining up the lower doglegs proved to be a challenge but I have the outers sitting at a place I am comfortable with. I beat myself up over the fit of the passenger one until I got it as good as I could get it but the passenger door is messed up on the lower edge so that made it harder to line it up. On to the pics:

Gap sort of "opens" toward the front but the door is sitting slightly low towards the latch side so it should even out a little.

KF inner valence, fit is perfect.

This one turned out really nice, just took my time and removed metal with the wiz wheel after my initial cut to get the right fit.

DONGKG · Posted: Wed May 10, 2017 5:15 am Post subject: Re: First aircooled 65 single cab

I haven't been wrecking my VWs especially my Split Bus lately. Been busy playing my guitars and covering those instrumental rock songs. But seeing your Single Cab gives me the reason now to revisit my VWs and drive then regularly!

BTW ~~ So So Cool Single Cab, Mate!
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'67 KG Cabrio (Mickey) ;
'66 Type 3 (Sharky 2)
'72 Type 2 Homey
'67 Splitty Bus
'65 beetle;'69 Country Buggy; '44 Kubelwagen (replica) TOOB MEMBER #20

ryans65 · Posted: Thu May 25, 2017 8:19 am Post subject: Re: First aircooled 65 single cab

Got some major parts fitted and tacked last night. Forgot my welding helmet again so I couldn't weld these permanently and finish the welds. I got to a point where I just couldn't adjust the lower a pillars any more to get them to fit any better. I've heard even the best lower a pillar sections require some modification to work so I just went with my gut and fitted them to the best of my abilities. KF lower valence is an absolutely perfect fit BTW.

kafer60

Looking good, I did the same on my 65. I used the KF inner valance and a WW outer and then installed a WW nose which was great. Have you measured how long the IRS axle need to be yet? I have to get the ones from Wolfgangs Int. (17") to make my IRS work. Keep up the good work
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