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'69 Baja - Dark Earth Version
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Dark Earth
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Joined: December 22, 2015
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PostPosted: Tue Jun 13, 2017 4:25 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

I Ride Sand wrote:
looks like i'm definitely not the only one giving the interior a fresh coat of paint and leaving it bare! Very Happy i've also shaved the clips off of mine, but rather than a cloth European style headliner i'm just hitting the recessed portion with black rubberized coating. i hate having a headliner in an offroad vehicle. collects too much dust, and never looks clean again after the first 100 miles of dirt road. the rest will be red, grey carpet, black seats and door panels. i look forward to seeing your build progress!


I'll be watching your progress as well. I'd like to see the rubber coating.
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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~ Anxious
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Dark Earth
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PostPosted: Sun Jun 25, 2017 10:07 am    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

I finally finished sanding all the headliner clips off.

Now back to the right rear quarter window rust.

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I cleaned some of the the rust away and opened up the rust holes.

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After some more cleaning, I found a couple more holes. Rolling Eyes

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I cut a piece of sheet metal and drilled a couple of holes in it. I fed some trimmer line down both large rust holes and through the sheet metal and tied a knot. Then I just pulled it up into place.

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Here's all the beads piled up.

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Then after sanding ...

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#Sleep
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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~ Anxious
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Dark Earth
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PostPosted: Fri Jun 30, 2017 6:26 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

Now for the rusty door hinge pillars. On the drivers side there is a lot of rust.

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I drew a reference line, with a sharpie, about where I think the final cut line will be.

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I made my first cuts well below the final cut line and ground the welds down fairly smooth.

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The fender well has a few patches I'll need to remove.

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That will have to wait until next time.
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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~ Anxious
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Dark Earth
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PostPosted: Wed Jul 12, 2017 10:03 am    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

Back to the door hinge pillars. Last time around I missed a spot that needed to be ground down in order for the hinge pillar repair panel to sit flush.

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Here's the last weld ground down.

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I started removing a patch from the left fender wheelhouse and found some bondo ...

... and some more rust Rolling Eyes

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I've been sucked into the VW Vortex. Laughing

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This minor hinge pillar job is gonna be a lot more in-depth than I first envisioned.
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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~ Anxious
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pullstart
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PostPosted: Wed Jul 12, 2017 1:27 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

Amazing some things hold together the way you find them sometimes, huh?
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4 seater Appletree buggy, road legal with 002 IRS, 3x3 Appletree kit, 6" over Dan's beam with 10" towers and Fox 2.0 shocks, '00 Subaru EJ25 with KEP stage 3 clutch and KEP adapter plate.

my build page: https://www.thesamba.com/vw/forum/viewtopic.php?t=662104&start=0
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Dark Earth
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PostPosted: Wed Jul 12, 2017 1:40 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

pullstart wrote:
Amazing some things hold together the way you find them sometimes, huh?


You're right about that !! Bugs amaze me how they keep going even with things wrong with them. It's truly a testament to the engineering of the car. I've encountered a bunch of problems in this build and I'm sure I'll find a bunch more. It was driven to my house under it's own power too Anxious
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Dark Earth
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PostPosted: Wed Jul 12, 2017 8:20 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

I sanded most of the bondo off to expose the patches.

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I went ahead and ripped the band aid off !!

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On March 15, 2017 I posted ...

I bought a new hinge pillar repair panel and it looks like it will take care of the rusty areas.

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Anxious It's gonna take a little bit more metal than that Anxious
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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~ Anxious
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Dark Earth
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PostPosted: Tue Jul 18, 2017 2:35 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

I bought a drivers side wheelhouse repair panel.

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I set it in place and marked a preliminary line with a sharpie.

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I will cut below this line to begin with.

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I marked a vertical line with a sharpie just beyond the edge of the rust along the heater channel.

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To keep more of the original metal, I drew an angled line. Unfortunately there's rust above the coverage of the wheelhouse panel.

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I drilled out the spot welds connecting the original door hinge pillar metal to the wheelhouse. I cut inside the lines I traced from the wheelhouse repair panel.

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I also cut out all of the rust above the wheelhouse panel line. I'll have to make a small patch for this area and for the rust hole in the heater channel.

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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~ Anxious
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Dark Earth
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PostPosted: Wed Jul 19, 2017 5:57 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

I marked out where I wanted to make my cuts in the heater channel.

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I then cut the rust out with a cutoff wheel.

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#Sleep

(This is pretty dry stuff, but if it helps somebody down the road it's worth it.)

Anxious

I drilled a hole in the patch to put a plug weld.

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I then tacked it in place.

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Here's the patch sanded down fairly smooth.

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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~ Anxious
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heywebonya
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PostPosted: Thu Jul 20, 2017 7:22 am    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

Very nice documentation and demonstrates the care and thoughtfulness in our hobby.

Great job!
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Dark Earth
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PostPosted: Thu Jul 20, 2017 10:46 am    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

heywebonya wrote:
Very nice documentation and demonstrates the care and thoughtfulness in our hobby.

Great job!


Thanks heywebonya !!

Sometimes the hard part is getting a decent picture Confused
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My Build: '69 Baja - Dark Earth Version

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Dark Earth
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PostPosted: Thu Jul 20, 2017 4:57 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

I bought a taller hinge pillar repair panel.

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The panel comes with a partial hinge pillar that's attached with one spot weld. I'm only using the sheet metal so I drilled the spot weld out.

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I set the sheet metal in place and marked out preliminary lines just like I did with the wheelhouse.

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I drilled out the spot welds around the hinge area.

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Then I drilled out the spot welds inside the car going up the inside of the hinge pillar.

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I drew a line below my final cut line, as I did with the wheelhouse, and cut the hinge pillar sheet metal out.

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Prior to cutting the sheet metal out, I butted a piece of square stock up against the hinge pillar with the door installed to help insure the pillar was pretty close to being in the right place. I welded it to the heater channel but not to the hinge pillar.

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~I'm almost done. I just lack finishing up.~ Anxious
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Dark Earth
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PostPosted: Fri Jul 21, 2017 2:00 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

I sanded a bunch of the rust off the hinge pillar and cleaned the sharpie marks off. I then set the new sheet metal in place and made marks with a scribe. You can barely see the marks in the picture. I'll be grinding right up to these marks with a die grinder.

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After looking closer I found another spot weld. I drilled it out before I started die grinding again.

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I set the new sheet metal back in place and traced the edge of the hinge pillar from the back side. I marked where the plug welds will go.

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I traced the hinge area plug welds off the old sheet metal where I drilled the spot welds out. I fudged a couple of the holes to the middle. I put several where the wheelhouse and hinge pillar sheet metal crimp together.

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I clamped the sheetmetal to the hinge pillar.

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I then plug welded the sheetmetal.

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I worked my way around the top seam bit by bit getting it as flush as I could. Then I sanded it down fairly smooth.

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I still have some more sanding to do on the inside, but It's pretty much done. It's not perfect by any means but it's a lot better than it was.
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Dark Earth
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PostPosted: Sat Jul 22, 2017 1:20 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

I cut out a patch and tacked it in place.

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I marked out lines on the wheelhouse.

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I set the trimmed wheelhouse repair panel in place.

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Looks like I'll need to do some more fitting.
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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~ Anxious
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Dark Earth
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PostPosted: Sat Jul 22, 2017 5:06 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

After a bit more fitting, this is what I ended up with.

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I'll weld it up when I get some more time. There's a pretty big gap where the butt welding clamps are. I'll use the old brass backing strip trick for the gap. It's not perfect but it's better than it was. After all it's just baja. Anxious
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Dark Earth
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PostPosted: Sat Jul 29, 2017 1:08 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

Famous last words ... "It's not perfect but it's better than it was. After all it's just baja "


I wasn't really satisfied with the hinge pillar repair I made. The key stock I welded in, to align the door, actually put a dog leg in the hinge pillar repair panel. The key stock kicked the hinge pillar towards the rear of the car .090". Not only did it put a dog leg in it, the fit where it met the wheelhouse wasn't good at all.

I tried to order another orange hinge pillar repair panel and they're out of stock right now. I bought a Klokkerholm panel and I'm now working to get it right (minus the key stock). I plan on putting a straight edge along the panel so it'll be straight. I just didn't want to see a dogleg every time I opened the door.

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The door probably won't be aligned when I'm done, like before I started the project, but I'll use a jack to stretch things out diagonally when I get to that point.
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Dark Earth
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PostPosted: Mon Jul 31, 2017 3:40 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

I threw some primer and paint on the hinge pillar.

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Then I welded the repair panel in place.

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Luckily most of it will be covered with carpet. Anxious
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Dark Earth
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PostPosted: Sun Oct 15, 2017 1:29 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

After a brief hiatus ... Back to the Baja.

As much as I enjoy sanding and welding paper thin metal, I've decided to change it up and do some mechanical work. I'll return to the interior painting project later. Besides, I haven't torn the car down all the way yet Anxious

I'm going to re-index the rear torsion bars to raise the rear a bit. To gain a little more travel, I'll notch the spring plates 1/4". I'll be removing a bit of material but the slopes will be gradual. I photoshopped some lines on the spring plate to show how much I plan to grind off.

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I'll actually be notching the inner plate of the dual spring plates because the inner plate is the only one that contacts the stop.

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I've decided to remove the rear trailing arms. I'll be doing some work on them later so why not get them out of the way of the spring plates right now ?

But, first ... the brakes have to come off. I bought a 36 mm 3/4" drive socket to loosen the rear axle nuts.

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When I removed the rear axles and CV joints, I kept the emergency brake applied so the rear drums and stub axles wouldn't turn. That helped break the CV joint bolts loose. I loosened the rear axle nuts at the same time. Surprisingly, they broke free quite easily.

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After releasing the emergency brake, I removed the drum.

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~I'm almost done. I just lack finishing up.~ Anxious
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dustymojave
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PostPosted: Sat Oct 21, 2017 3:03 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

Use anti-sieze on the axle threads when you put the nut back on to slow the rust creep and keep the nuts relatively easy to remove, On the splines too. I do't mean gob it on there, just a bit.
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Richard
Offroading VW based cars since 1965
Tech Inspection 1963 - 2012 SCCA/SCORE/HDRA/MORE/MDR +
Retired from building Bajas, Fiberglass Buggies and Rails in the Mojave Desert. Also Sprints & Midgets, Dry Lakes, Road Race cars. All types New and Vintage
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Dark Earth
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PostPosted: Sat Oct 21, 2017 8:30 pm    Post subject: Re: '69 Baja - Dark Earth Version Reply with quote

dustymojave wrote:
Use anti-sieze on the axle threads when you put the nut back on to slow the rust creep and keep the nuts relatively easy to remove, On the splines too. I do't mean gob it on there, just a bit.


Thanks dustymojave. I'll be sure to do that when I go back together.
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