66 Squareback

[andybla]

No need fot that, Tram; Thx guys!

Did not do much last weekend as it is freezing here up to -6°C, that would be -43°F... freezing my toes off, even with two pair of socks

Have scanned the templates and working to put it all together, remember, this is merely a guidance as i just created these as how i felt was best to suit my situation

[andybla]

first one

Note: templates are scanned in A3 format, sizes in centimeter (CM) or millimeter (MM), i have live measured the template so when you should print it, these measurements should be the same when you measure this. These measurements were made with a thick marker so the side of the marker where the arrow is pointing is the measurement point...

Also note: The "raw" shapes i have, are bent in a metal workshop, really doesn't cost much if you have a good drawing of what you want, all metal i'm letting produced is 1mm thick

Info
http://s000.tinyupload.com/?file_id=06776363229717355495

Template
http://s000.tinyupload.com/?file_id=07492968631968633507

[bobnorman]

Wow. Great work! Your metal working skills are remarkable! A great inspiration to get others motivated for sure. Glad to be following your work.
_________________
Air does not freeze. Air does not boil.

http://www.thesamba.com/vw/forum/viewtopic.php?t=289807

[andybla]

The backplate bend, outer side + actual shape, i have pleated this because they were to large for the scanner, just print them and stick them together with some tape

A1 left meets A2 left
B1 right meets B2 right

You just place the straight side against the notch and start at the outer point of your piece of metal
A1 right is your start point
B1 left is your start point

Side A is inner, B is outer

I started with a piece of metal
L 65 cm
W 13,5 cm

In the middle a notch
L+R 5,5 cm
notch bottom W 2,5 cm
notch top W 1,5 cm
notch depth 0,75 cm

After shaping you need to straigthen the start and end of your piece because you obviously have still that notch there
At the bottom this is 2 cm
At the top see line on picture and B2, continue that line

http://s000.tinyupload.com/?file_id=21124447426547448943

http://s000.tinyupload.com/?file_id=07314111069342365915

A1
http://s000.tinyupload.com/?file_id=38421942561834860599

A2
http://s000.tinyupload.com/?file_id=99551327468147660999

B1
http://s000.tinyupload.com/?file_id=39818426969464152586

B2
http://s000.tinyupload.com/?file_id=72613935837362986719

[andybla]

The rear apron shape, just the top of the image is important, also see attached image, just place it according to your needs

http://s000.tinyupload.com/?file_id=58453580711841966526

http://s000.tinyupload.com/?file_id=60958793765405792049

[andybla]

Air shape 1, print this out and place against current air shape to get an idea, this template is not complete because i had my old one to look at and measure for further help

left side should be 0,5 cm extra, right side, see info here above, i would advise to cut the 8 blue lines
1 on the left diagonal
2 on the left vertical
2 on the right horizontal
3 on the right, the sort of triangle 1 horizontal and 2 diagonal

Note: i cut off the notch at the right later on as it wasn't needed eg less work


http://s000.tinyupload.com/?file_id=38308850726022070487


Air shape 2 i just had a straight Z piece shape
L 32 cm
W 5,5 cm
Z shape 2 times 1,6 cm
not much of a template, just use the old one as a template and measure

[andybla]

Those were all i have.
Questions just ask

[andybla]

Got a bit tired of the passenger side, so i did some stuff for driver side this weekend, enjoy

Made the inner corner + exhaust opening, the inner metal has some surface rust, not bad after 52 years

Don't mind the messy cuttings, still figuring out how to proceed

exhaust openings L + R almost ready, looking good me thinks

[MonT3]

You’re doing awesome on your build. I like your detailed so don’t let up as you’ll have that side put back together in no time. I really like how you handled the rear apron as well. Looking forward to your next update and keep the exceptional work!
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MonT3
67 Squareback
64 Squareback
63 Squareback
Engine rebuild
Trailer rebuild

[Bobnotch]

[Mike Fisher]

Something like my Harley-Davidson mufflers bolted to a stock exhaust would fit good on your car. They are higher than a header exhaust & fairly quiet.

_________________
https://imgur.com/user/FisherSquareback/posts
69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
two 57 oval ragtops sold
'68 Karmann Ghia sold

Society is like stew. If you don't keep it stirred up you end up with a lot of scum on the top! - Russ_Wolfe/Edward Abbey

[andybla]

Hi guys, thanks again for the good feedback

@Mike, looking good , yes that is the idea, putting a dual exhaust, engine is allready done, stock engine but a bit more bling, good enough for now. Mine has a vintage speed exhaust.

[andybla]

And so the story continues

Spring has started, days are getting a tiny bit warmer

So eventually i decided to go all the way like the other side, but first of all needed some extra solidity so redid the corner piece, and also the inner support was gone so restored that one too...

After that i drilled out the holes and removed the sheet metal after taking carefull measurements

Next i made new sheet metal comparing the old

Next up, tighten and weld everything together

[Bobnotch]

Looks like the left side is going to go quickly together. Nice work.
_________________
Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120

[oxsign]

This thread is so much fun to watch and follow. Great work!!! I keep going back and looking at the pix you've posted of the work already done. I just bought a welder and i'm nervous about welding in some floor sections and here you are literally rebuilding a car, HAHAHAHA.
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1971 Squareback, fully bagged, 1776.
Build thread here.....
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

[MonT3]

Amazing work! Metal surgeon for sure!
_________________
MonT3
67 Squareback
64 Squareback
63 Squareback
Engine rebuild
Trailer rebuild

[Clatter]

WOW!

How did I miss this one?

Excellent..
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Bus Motor Build

What’s That Noise?!?

[andybla]

Thx again for the positibe feedback, tips are always welcome, i'm willing to learn from mistakes

@oxsign: what i can recommend is using 0,6mm wire, i think it's 0,02inch? With 0,8mm there is more current flowing, creating holes faster.

And the thing i do when doing spotwelds, but without a spot welder, i drill one side in the spot weld with a larger diameter bore, creating a funnel, just enough to not drill through. After that i just filll it up, you will end with a larger spot but backside will be nice and clean if done right

good luck

[andybla]

Hi everyone, i haven't got any much time to do this project... every free half hour i got in my life, i try to do something

The plan was to finish this, again, at august for le bug show in Spa, but not gonna make it, again... What makes working on this a pita But am looking into something temporarily that drives and brakes

At the moment, i'm welding together the sill assembly...

[bkeith85]

Geez. I was over here with a big head because I made a new cargo floor for mine.
But this is impressive. Nice work, man.