Alex J’s rebuild

[ashman40]

Appreciate the feedback.

I've never opened up a heat exchanger and the only ones I have seen in cutaways were the later style with the non-round internal cores. I'm surprised yours have round tubes at their core. Good for you.


I'm considering the removal of the underside my center tunnel. I need to replace the fuel line and possibly reinforce the clutch tube. I considered doing by cutting a couple access holes in the sides of the tunnel but opening the bottom would make it so much easier and allow me to clean and coat the inside with a anti-rust treatment.
Your descriptions make me feel more confident I can do it. Thanks!
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AshMan40
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'67 Beetle #1 {project car that never made it to the road }
'75 Beetle 1200LS (RHD Japan model) {junked due to frame rot}
'67 Beetle #2 {2019 project car - Wish me luck!}

[Alex Juszczyk]

Ashman40 a couple of things to bear in mind, when I was working and welding this the underside was flipped and pointing up. Cutting out would be easy enough in situ if the car was on a ramp for example but welding it a lot easier with gravity on your side. Just something to bear in mind as I don’t know your project. I would not make access holes, that would effect rigidity. Have you got a progress thread?

I think I was just very lucky with the inner tubes, I started hacking at them before I looked for advice 😅 I’m not sure if they are early or late or repo items 🤷🏽‍♂️ They were VW stamped. realistic I should of probably sold the hole unit as I think I’m going to have to make up a custom exhaust and intake manifold to do what I’m planning....

[Alex Juszczyk]

Slowly slowly getting there

[offtherailz1]

Coming along nicely.

What’s your pan sitting on?
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“ My worry is, that if I die suddenly, my wife will sell everything VW for what she thinks I paid for it.”

Cuppa tea man, living in a latte world.

1973 1303, one previous owner, my Dad
1975 1303, Fourth owner, mum 1975 to 2014, me from 2017
https://www.thesamba.com/vw/forum/viewtopic.php?t=711269&highlight=
https://www.thesamba.com/vw/forum/viewtopic.php?t=740901

[offtherailz1]

Coming along nicely.

What’s your pan sitting on?
_________________
“ My worry is, that if I die suddenly, my wife will sell everything VW for what she thinks I paid for it.”

Cuppa tea man, living in a latte world.

1973 1303, one previous owner, my Dad
1975 1303, Fourth owner, mum 1975 to 2014, me from 2017
https://www.thesamba.com/vw/forum/viewtopic.php?t=711269&highlight=
https://www.thesamba.com/vw/forum/viewtopic.php?t=740901

[Alex Juszczyk]

Thanks offtherailz1

It’s a scissor lift that I’m using the wrong way round, box section frame built on top with pipe insulation on the frame so I don’t mess up the underside 🙈
You can tilt either way to a decent angle for other jobs too.

https://www.ebay.co.uk/itm/284116694593

[offtherailz1]

Thanks for the link, I thought that’s what it was. I have one saved in my eBay list, nice to see it being used on bug for reference.
_________________
“ My worry is, that if I die suddenly, my wife will sell everything VW for what she thinks I paid for it.”

Cuppa tea man, living in a latte world.

1973 1303, one previous owner, my Dad
1975 1303, Fourth owner, mum 1975 to 2014, me from 2017
https://www.thesamba.com/vw/forum/viewtopic.php?t=711269&highlight=
https://www.thesamba.com/vw/forum/viewtopic.php?t=740901

[Alex Juszczyk]

She’s on the floor!!!!
I haven’t put any of the gubbins onto the backing plate or the callipers onto the front discs. All that sort of fitting will get done in the garage once the body is back on.

[Dodgy]

Wow, fast work! 👍
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'75 1303 (current project) owned since 1989!
'72 Squareback - full resto completed 2008 - now sold
356 Speedster kit, completed 2005 - now sold

[Buggeee]

Those wheels are awesome.
_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Alex Juszczyk]

Dodgy; thanks mate! I had a look at your current project and looks like your steaming on to. My pans looked in a similar situation to yours, but your repairs are lovely work!

Buggeee; 😏 Yh I have to admit I do have a soft spot for those centre lines, I picked them up when I had her on the road. Originally when I collected her she had a pare of cookie cutters on the rears and steels on the front. Hopefully the beefy tyres will raze her off the ground a bit too.

[Alex Juszczyk]

I totally forgot how much body work there is to do 😂
Started on the roof a short wheel back, have only given it a lighter sand, clean off and then rubbed a thick layer of bees wax over by lightly heating. Once it’s closer to being on the road il heat up and remove excess wax.

[Alex Juszczyk]

Please excuse a lack of content, just feels like I’m constantly cleaning 🤪

[Buggeee]

That is time consuming labor for sure. Looks like you are about to crest the hill though and start welding. It's closer than you think, keep rolling.
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1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Alex Juszczyk]

But Looooooads of other bits buggeee 😅

Anyways

Rivited new panel in place so there was a decent inner overlap, welded top and bottom seams then the holes where rivits were. Ground back then went over with a sander till any proud/excess weld was gone. Slapped a load of metal filler over which really wasn’t necessary but most of it will come off when I come back to it.

And today Iv been prepping the area in front of your feet, the bit that sits on the top hat, so basically that’s a new panel, hope to get it in tomorrow. Iv cleaned back further than pictured. Where the spots are is also ground back but I still need to remove a bracket each side.

[raydog]

Didn't read the whole thread, but just keep in mind, those coil overs are gonna give a stiff ride.
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Come on, It's not rocket science. KISS

[Alex Juszczyk]

Thanks for the heads up raydog, il be mostly driving motorway or competing on tarmac or occasionally slower grass stuff.
I’m not too clued in on the many of the part, but I was thinking it might take some preload weight off from the spring plates....? Yes, making a stiffer ride but also making it ride higher? Iv set the shock to its “softest” setting too.

[Alex Juszczyk]

Well it was a little tricky to get into place but thankfully there were a number of fixed points to work to.

I ran out of time, it still needs a lot of cleaning up but it’s getting there 👍🏼

[Alex Juszczyk]

[Alex Juszczyk]

One side of the heater channels are now in, this side was a bit trickier that what the other side will be as I also replaced the area where the runner boards attach.

Again needs lots of tidying 😅