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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Sat Feb 27, 2021 5:08 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Started out this morning to take a look at the rear closing panels - I thought I was going to get away with just fitting the reinforcing panels on the back, but the usual story as I dug further, I realised it was quite rusty back there - still not as bad as our 72 though!
Looks like I’ll be needing to make a new panel order! The left side just needs the rear closing panel , but the right will need the closing panel, and the rear of the heater channel and underneath replacing aswell.
I thought I’d at least cut out all the rust so it’s ready for when I get the new panels - at least it looks a lot cleaner now 😀
I can’t even imagine having to do all that rear body repairs without splitting the body and chassis now!!
Also I removed the rear interior panels and bonus discovered the original interior material underneath in good condition 😀
Also found the usual collection of walnut shells and newspapers in the heater channel from the colony of squirrels that appeared to have taken residence in the car at some point !
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Thu Mar 04, 2021 2:00 pm Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Another bit done after work tonight. Every little bit counts!
Started to have as look at the firewall area and the end of the heater channels.
I have the whole firewall panel and I was tempted to drill out all the spot welds and replace the whole panel, but decided to save the old metal and graft in a repair instead. Not to bad, but should be ok with a smidge of filler over the joint- it is hard to get the edges exactly lined up.
Not sure what do about the heater channel - I’d like to save as much as possible but it is tempting to let in a whole repair section, but then it doesn’t match the profile of the very early channel, so think I’ll try and save as much as possible.
I have some angle irons coming to brace the gap tomorrow as the gap is spot on at 951mm and I don’t want to lose the alignment if possible.
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rod_vw Samba Member
Joined: December 20, 2006 Posts: 416 Location: Shropshire, UK
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Posted: Fri Mar 05, 2021 4:34 pm Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Here is how Steve Hook restored mine on the '46.
The car had been converted to RHD at some time in the past and was returned to LHD during the restoration.
But many of the sections were removed and restored separately. The restoration of the bracket that holds the dipswitch was just one of the little challenges as the original was totally destroyed by the dreaded rust moth!
_________________ Rod,
Please visit http://www.historicvws.org.uk
https://www.facebook.com/historicvwclub/
1946 Beetle (Back on the road after over 50 years! Last major outing - Hessisch Oldendorf 2022)
2016 T6 Selfbuild Camper and a LWB MAN TGE in build. |
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Sat Mar 06, 2021 1:27 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Nice - the acces must have been so much better than trying to do it in situ! |
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aa390392 Samba Member
Joined: March 28, 2007 Posts: 3602 Location: So.Cal
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Posted: Sun Mar 07, 2021 9:16 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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_________________ .
getting grumpy & less tolerant!
55 ragtop
56 delux sedan
56 Kabriolet |
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Sun Mar 07, 2021 1:01 pm Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Carried on with that side this afternoon - intention was to save as much of the original channel as possible - in the end I’m not sure if I’d have been better off replacing the whole channel - but there you go, I saved a whole lot of money on an expensive heater channel and the car still has most of its original metal in place
It took ages to cut and prep the pieces making sure everything fit and measured correctly (although I still cut short one bit - doh!)
I repaired the a post and then got the new heater channel section tacked and partially welded - will finish welding that later this week after work and then I’ll get on with the inner arch closing panel.
Getting there!
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Tue Mar 16, 2021 2:07 pm Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Got in a few hours after work tonight to stack the other side. I finished welding in the side above but got no pics for some reason.
The left side heater channel was a bit more solid but it still needs the end fixing and the section under the a post.
Tonight I repaired the end and also the inner firewall 😀
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Sat Mar 20, 2021 12:34 pm Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Had some time to look at the other a post and front heater channel this afternoon.
It took me ages to make the piece to fit the heater channel section under the a post and then I also had to repair another section.
Although I am saving original metal in the car I do keep wondering if I should’ve just splashed out on a pair of new heater channels! Too late now though!
Here s the pics 😀
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Mon Mar 29, 2021 1:38 pm Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Managed to take a look at the firewall closing area - still quite a bit to do round this area but getting there.
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Mon Mar 29, 2021 1:45 pm Post subject: Re: 52 Split Crotch Cooler Rebuild |
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And tonight I decided to look at my sorry front end!
It’s obviously been hit at some point and both front inner wings have been beaten out and are quite crumpled. A new later front valance had then been ‘welded’ on - they hadn’t even bothered to fully remove the old one!
So I removed everything carefully- I’ll have to make sure everything is fully aligned by fitting the bonnet and wings on while I get it all lined up and tacked into place .
I did notice that my new inner wing is missing the fuse box pressing and bolt holes so will have to graft that in from my old one.
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Sun Apr 04, 2021 12:16 pm Post subject: Re: 52 Split Crotch Cooler Rebuild |
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So I managed to get on with front end 🙂 using the wings and bonnet as alignment, I got the inner wings cut and welded in. I’ll have to skim over some areas of the butt weld finishes as it’s quite tricky to get edges lined up exactly (especially when some areas have been hit, crumpled and then beaten out) .
I’ll get the front valance welded in and the rest of this area finished next 😀
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eurodub Samba Member
Joined: August 05, 2007 Posts: 1321
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Posted: Mon Apr 05, 2021 3:57 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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I always get a laugh, remembering a guy that wanted to buy my 1990 Bluestar with Westfalia pop-top, all built by me in my small garage at home, including the poptop conversion. After haggling with the price, and countless pictures sent, his reason was that the bus was not welded in a professional workshop.. however, the hours I've spent on it would make it twice that amount if rebuilt by a workshop.
The reality is that one can do a nice work even at home with limited equipment, with enough skill and devotion... (your case) so keep up the good work! _________________ 1960 1200 model 117 deluxe ragtop
1974 T2 Westfalia Campmobile
1976 MK1 Golf |
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Sun Apr 25, 2021 2:59 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Been quite busy and not far off with the welding on the body now 🙂
Here’s the front wheel well - I had to let in a repair to the front of this and then I got the new valance all welded in place aswell
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Sun Apr 25, 2021 3:27 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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I also finished the inner wings closing panels and repaired the rear sections
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Sun Apr 25, 2021 3:29 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Seat belt mounts for 3 point belts
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Sun Apr 25, 2021 3:34 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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The front holding nuts on the wing had obviously had water creep between the body and wing which had rotted out a few of the nuts , so I cut them out and let in some repairs from another repair panel I had left over 😀
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Sun Apr 25, 2021 3:39 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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The bar in the rear window had been cut out to make it look more ‘desirable’ back in the day lol!
Someone else at some point has welded in a repair but not the best job so I cut part out and tidied it up - it’sa bit better and with a skim of filler it’ll be fine - at least it’s welded in the inside now!
Before and after pics
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Wed May 26, 2021 8:46 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Havent updated for a while, but been up to a few bits a pieces
I had to fit the fuse box mount into the new inner wings - i cut the donor piece from my old inner wing and grafted it in.
I also finished stripping the pan right down and that has been sent off for blasting along with some other bits and the wheels for powder coating.
A very big pile of car parts - i hope i remember how they all go together!
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Wed May 26, 2021 8:48 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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I also warmed the welder up again and took a look at the rear valance - it is the original one, so worth saving despite it having taken a battering over the years. Someone had cut out exhaust outlets which i tidied and welded up -
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topnotch Samba Member
Joined: June 22, 2004 Posts: 132 Location: weymouth, dorset, uk
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Posted: Wed May 26, 2021 8:50 am Post subject: Re: 52 Split Crotch Cooler Rebuild |
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Whilst i was waiting for the chassis to be picked up, i thought i might aswell tackle one of the floor pan halfs - both sides are pinholed and have also had previous repairs - out with the old , in with the new!
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