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hillmotorsports
Samba Member
Joined: December 27, 2014
Posts: 432
Location: Morrisburg, Ontario, Canada
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 Posted: Wed Mar 15, 2017 4:38 pm Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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What he said...^
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Rosemarie and Paul Hill
Morrisburg, Ontario
(With way more projects than spare time!) |
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cdnltded
Samba Member
Joined: March 13, 2015
Posts: 381
Location: Pincher Creek, Alberta
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| Posted: Wed Mar 15, 2017 6:39 pm Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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| hillmotorsports wrote: |
| What he said...^ |
X3 |
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joey1320
Samba Member
Joined: September 12, 2006
Posts: 2325
Location: Cleveland, OH
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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| Posted: Thu Mar 16, 2017 10:30 am Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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Thanks!
As this was originally a 1302S from 1972 it off course have Mcpherson front suspension with discbrakes and IRS with drumbrakes in the rear with 4x130 boltpattern....
I did want to change this to 5x205 so I could use 356 steelies on it..
So I decided to take a chance and ordered a pair of zero offset frontdiscs from Empi that was meant for standard torsionfrombeam drum to disc conversion...
And next I did a lot of research and digging at the local scrapyard for suitable brakecalipers....
Found that the early VW Polo frontcalipers are basically the same as on the ones used in the Empi disc conversions...
The disc worked perfectly on the 71-72 drumbrake frontspindles!! Tested first with original discbrake spindles but the bigger calipers did not work with the original calipermounts..
So, next was to figure out how to make a suitable adapter for the calipers to the spindles....
_________________
~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD |
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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| Posted: Thu Mar 16, 2017 10:39 am Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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Sat down with some CAD drawing...
A couple of different versions was brainstormed....
This was the final design...
And then I made a template out of 8mm hardboard for testing the fit...
Template prooved the design to work really nice so I sent the CAD to the local metalshop that lasercut the adapters in 10mm steel. I also machined the spindles at the connectingsurface to the adapters.
Tested to mount the fake 356 alu-drumcovers too.. The calipers fit inside without rubbing! 
_________________
~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD |
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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| Posted: Thu Mar 16, 2017 10:47 am Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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Off coures also needed to find some good 356 repro steelies for an affordable price. And I was lucky to find 4 repros and 2 originals...
The four repros met the anglegrinder... 
And now they are two 6x15" and two 7x15" instead of 4,5x15.... 
The offset on the wheels is pretty high at 45mm on both.. This just because the original early 356 body is pretty narrow and the donor superbeetle track is wider than the one on early beetles...
Here spindles are fitted to the frontstruts.
_________________
~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD |
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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| Posted: Thu Mar 16, 2017 10:53 am Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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The rear was a bit easier...
Just remove the 4x130 drums and put on one tiny spacer on the stubaxle. Then put on a 66-67 widefive drum and another spacer and finish with the lockingnut.
(yes, I have new drums to use later....)
_________________
~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD |
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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| Posted: Thu Mar 16, 2017 11:23 am Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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During all the other fabrication I also had some plans for detailling the inside...
The dash needed to get something that looks more original and real too....
I had a speedo in the garage that was a leftover from another project that I sold earlier...
But for the revcounter I had to find some repro that turned out to be 4 mm larger than the original... This was a dissapointment so I tracked down an NOS diesel VDO tacho with correct diameter.. Then just cut these two up too and made them one....
The face needed to be cut just a little bit to fit inside the real VDO housing.
Easiest way to get these to work together I decided to cut out the bottom of the repro tacho and weld it to the smaller housing...
I also always loved the center dummy gauge used in these early pre-A style 356's... So I thought I'd give it a try too....
Here just a paperprint under the chromebezel and glass....
To make this authenic I butchered an old splitbeetle clock to get a housing that I can put a dashlight in... 
Designed the layout and printed it on watertransferfilm.
Tested the first attempt on a jamjar lid...
Had to find better pliers to move the printed film without scratching it...
Next I then cut a thin steelsheet and formed it some concave to get some stability in it...
Then painted it a green very similar to the green on the speedo and tacho numbers etc...
And painted the edges around the face black so it would not be seen later if the transferfilm would not cover it all....
Here the film is moved over to the face.
And here the complete dummy gauge is assembled!
_________________
~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD |
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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| Posted: Thu Mar 16, 2017 12:33 pm Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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At an early stage I also scored this Formuling(?) steeringwheel..
No, hub or anything though...
An idea started to grow... I had a splitbus hornbutton laying around useless... And an old 356 fronthood handle logo too...
Bought a hub for Grant wheels
More CAD drawing...
Friend of mine then had a student in metalworking to mill a pair of alu parts....
Next I took disassembled the splitbus hornbutton and cut out the center so I could insert a new fronthood logo I bought for this...
Then taped a spraycan cap around the hornbutton...
And filled the form with clear artistic resin.
And filled the inside a bit too just to avoid possible cracks from inside...
Then I just started sanding by hand using anglegrinder, sandingpaper etc. etc. and finish with polish.
_________________
~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD
Last edited by Hebster52 on Sat Mar 18, 2017 12:39 pm; edited 1 time in total |
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joey1320
Samba Member
Joined: September 12, 2006
Posts: 2325
Location: Cleveland, OH
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germanx
Samba Member
Joined: July 29, 2010
Posts: 326
Location: Germany
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| Posted: Fri Mar 17, 2017 1:47 am Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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Hats off. Amazing!
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'73 Beach Buggy
'66 T1 Deluxe |
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brettsvw
Samba Member
Joined: November 22, 2007
Posts: 2145
Location: Florida
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BL3Manx
Samba Member
Joined: August 29, 2006
Posts: 6767
Location: Northern California
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| Posted: Sat Mar 18, 2017 8:29 am Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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| Amazing amount of skilled work, superb! Thanks for posting all that |
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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| Posted: Sat Mar 18, 2017 12:32 pm Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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Thanks!
The enginelid grill that came with the car was an original Speedster grill. Which was cool but also bad... Speedster enginelid is bent but coupe enginelid is flat.... So... Instead of trying to find a correct flat gril I decided to make this one flat.... Disassembled it and took my stretcher and straightened out all parts on the grill..
Half of the bars done.
Ready to assembly again. Now as a coupe grill..
Have seen lots of cool grillbadges so I also wanted(needed) some for mine... As mine never will be a real Emory Outlaw, just an Outcast, so I decided to make a tribute to Emory's instead...
Design printed on P-n-p film.
Aluminium sheet etched.
Finished badge.
Tested also an other badge I made a few years ago...
Also wanted to try make a badge from the logo of Widefive Outcasts forums logo as I liked the design and also suits the Outcast 356 replica...
Made this from 2mm thick brass plate
For the covers of the holes for rear torsionbars I thought this design would work... Also in brass.
_________________
~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD |
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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| Posted: Sat Mar 18, 2017 12:48 pm Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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At a weak point I happened to "score" a set of 16" repro centers..... I mean.. Pre-A's need 16" wheels dont they?
So I had to find some donorwheels for the wheelarches... Found a set of 6,5x16" VW Golf/Bora(=Jetta) wheels....
Had a shop narrow two to 5,5x16"
16" compared to 15"
_________________
~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD |
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cdnltded
Samba Member
Joined: March 13, 2015
Posts: 381
Location: Pincher Creek, Alberta
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| Posted: Sat Mar 18, 2017 12:48 pm Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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how do you make those brass emblems?
is it a acid etching style system?
everything is looking really nice very nice craftsmanship |
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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| Posted: Sat Mar 18, 2017 12:52 pm Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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Yes, basically the same technique as making circuitboards. I use so called Press-n-peel film. You design your picture in black and white, then print it mirrored and negative onto the pnp-film and transfere the print to the aluminium or brass plate with a cloths iron... Then cover the backside for not etching that. And dip the plate.
_________________
~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD |
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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rubenski
Samba Member
Joined: December 03, 2014
Posts: 100
Location: belgium
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| Posted: Thu Mar 30, 2017 6:26 pm Post subject: Re: Pre-A Coupe replica. (photoheavy) |
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| you got skills! |
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Hebster52
Samba Member
Joined: March 14, 2003
Posts: 1773
Location: Finland, Jakobstad
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