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didget69
Samba Member
Joined: July 22, 2004
Posts: 4927
Location: Raleigh, North Carolina
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 Posted: Wed Mar 17, 2021 6:18 pm Post subject: Re: The Warthog |
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Nice, riveted parts, Cyber-Punkass look going on there...
I live ~ 30 minutes from Chris' shop - heard every word. There was a disturbance in the Force.
bnc
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I never found the need to impress people with any mechanic certifications, trophies or track wins... unless it was for Mom to post on the refrigerator door. |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12855
Location: North Carolina
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| Posted: Wed Mar 17, 2021 7:01 pm Post subject: Re: The Warthog |
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| mondshine wrote: |
Keep up the good work!
I hope to see you and the Warthog in July where the rocks are flat and the Things are many.
Good luck, Mondshine |
Thank you sir, I hope to meet you there.
| didget69 wrote: |
Nice, riveted parts, Cyber-Punkass look going on there...
I live ~ 30 minutes from Chris' shop - heard every word. There was a disturbance in the Force.
bnc |
Careful Bryan, publicly admitting to knowing me may cause precipitous decline in social status. 
Disturbance in the force is correct, it might be the cause for tomorrow’s impending storms. Curiosity got the best of me, I had to see if all those riveted patches were indeed an attempt at some sort of cyber/steam punk vibe but as it turns out... Holy Hell...
The fan shroud even felt flimsy when trying to remove it, I wonder why?!?
It missing a huge chunk of it’s internal structure. This (T)hing must have run for years with an imbalanced fan & no generator strap.
In the meantime, I grabbed the lower pulley tin & gave it the spa treatment. I thought about painting it but, that ... THAT, jeeze. 
So I ground the rivets off & began to work it straightish again.
Once flat, I fired up the MIG & Bzzt, whirrr... dammit, out of wire again. 
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12855
Location: North Carolina
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| Posted: Thu Mar 18, 2021 7:10 pm Post subject: Re: The Warthog |
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With a new spool of filler stuffed in the old buzz box, I began my quest to fill in the rivet holes.
First off, I clamped a (pre-‘84) penny to the tin to use as a backer.
And then filled the holes in.
And then I somehow lost a bunch of pics. Oh well, here it is after grinding down the weld, priming, & painting it.
Since this was one of those “rare” parts, I left the EGR hole & made... A BUTTON!
Not really, but it sure as hell looks like it. Anyway, I lost pictures of how I made this piece but it will just drop into the hole & then the tabs will be folded out to clamp it in place.
Since this shroud is one of those rare pieces, I thought I’d torture myself a bit by trying to stitch up some of the cracks
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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olspeed
Samba Member
Joined: May 01, 2008
Posts: 489
Location: In the shadow of Denali, I still don't give a damn how they do it outside
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| Posted: Thu Mar 18, 2021 9:22 pm Post subject: Re: The Warthog |
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Looks like you are a glutton of punishment! looks like a lot of work there.
Have to admit I love your beastie even better than Ghiapet, I have really good memories of mine before it got squished by a drunk woman in an Eldorado. I most likely would have sold my Ghia and just kept the Thing if that wouldn't have happened.
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66- Ghia
76-Beetle |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12855
Location: North Carolina
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| Posted: Fri Mar 19, 2021 11:01 am Post subject: Re: The Warthog |
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| olspeed wrote: |
Looks like you are a glutton of punishment! looks like a lot of work there.
Have to admit I love your beastie even better than Ghiapet, I have really good memories of mine before it got squished by a drunk woman in an Eldorado. I most likely would have sold my Ghia and just kept the Thing if that wouldn't have happened. |
Most definitely, but I surely hope I will have as many fond memories with this one as I did with the Ghiapet. It’s gonna take a lot of good ones to offset this damn fan shroud.
Speaking of fan shroud, I continued grinding rivets & popping off patches to see what lurks beneath. In addition to all the fu#%*^g rivets, RTV was relied upon to keep the patches in place.
And, well...
Sweet Jesus.
All you can do is carry on carrying on.
Once those were all fused back together, I kept finding more to contend with, like yes another patch up under the edge of the oil cooler tin...
Which was holding the rear face to the internal vanes.
So that made me look for more attachment points for the vanes.
A quick (but ugly) tack.
Then up under the oil cooler housing.
And then there’s these rivets holding the oil cooler housing to the shroud...
So I drilled a few holes.
And plugged them up.
The shroud is now a helluva lot less flimsy.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12855
Location: North Carolina
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| Posted: Sat Mar 20, 2021 6:51 am Post subject: Re: The Warthog |
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My next project was to replace the missing air deflector/structural reinforcement on the shroud. I grabbed an old rusty non-doghouse shroud for a donor & after comparing it to a doghouse shroud, it was just different enough that I didn’t want to use it. Here is the non-doghouse shroud with a Beetle doghouse shroud and the Thing shroud.
Not wanting to cut up an otherwise good shroud, & since the piece looked simple enough, I figured I could just whip one up, probably in less time than it would have taken to extract one from a shroud. One of my favorite go to pieces of donor metal is an old oil drum, so I lopped off a section & passed it through the English wheel to flatten it out (yes, I may be the only idiot that uses an English wheel to make sheet metal flat again.). Apparently the phone wasn’t fond of this action.
After carving it out, a bend here, a twist there, a few folds here & there, & a few perforations, I came up with this.
I then measured the good shroud & matched it to the Thing shroud & clamped it in place.
And then fused it all together.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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kent70ghia
Samba Member
Joined: June 15, 2020
Posts: 176
Location: Tacoma, WA
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| Posted: Sat Mar 20, 2021 7:58 am Post subject: Re: The Warthog |
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Chris,
I admire your skills, that is a great fix, making the new defector. |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4416
Location: Stuck in Ohio
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didget69
Samba Member
Joined: July 22, 2004
Posts: 4927
Location: Raleigh, North Carolina
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| Posted: Sun Mar 21, 2021 7:13 am Post subject: Re: The Warthog |
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Chris has more patience than I...
bryan
_________________
I never found the need to impress people with any mechanic certifications, trophies or track wins... unless it was for Mom to post on the refrigerator door. |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12855
Location: North Carolina
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| Posted: Sun Mar 21, 2021 9:13 am Post subject: Re: The Warthog |
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| kent70ghia wrote: |
Chris,
I admire your skills, that is a great fix, making the new defector. |
| Buggeee wrote: |
| Well played |
Thanks y’all!
| didget69 wrote: |
Chris has more patience than I...
bryan |
Eh, I don’t know, this is one of those times where my OCD is winning over my ADD.
Speaking of OCD, there was one more missing hunk that I needed to address.
So I picked up some of the trimmings from the deflector & placed it in the press sandwiched between an old clutch cable & a couple more pieces of scrap & pumped away.
Which gave me a sorta matching profile.
I then trimmed it a bit more to get it to fit into place.
Dammit, sorry folks, it has been suggested by my better half that I should take her to get something for lunch, I’ll be back to finish sharing my exploits of the day...
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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olspeed
Samba Member
Joined: May 01, 2008
Posts: 489
Location: In the shadow of Denali, I still don't give a damn how they do it outside
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| Posted: Sun Mar 21, 2021 10:06 am Post subject: Re: The Warthog |
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Hey Happy Wife happy life!
All I can say is I would have gave up on that and took her to lunch after finding all the rivets. 
_________________
66- Ghia
76-Beetle |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12855
Location: North Carolina
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| Posted: Sun Mar 21, 2021 1:54 pm Post subject: Re: The Warthog |
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| olspeed wrote: |
Hey Happy Wife happy life!
All I can say is I would have gave up on that and took her to lunch after finding all the rivets. |
Speaking of happy life, after lunch we took a nice relaxing stroll through, get this...junkyard!  Her car got hit front & rear in two separate incidents & I found a donor in the same color so we made a “date” of pillaging a Jetta wagon.
Anywho, once I got it aligned, I clamped it in place.
And scribed the outline.
After paring it down, I secured it to the shroud & tacked it in place.
Then made it one with the shroud.
And then whittled it down to its final shape.
Upon cleaning up some of the welds, I found a few more cracks & sealed those up too.
& filled in another hole.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4416
Location: Stuck in Ohio
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12855
Location: North Carolina
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| Posted: Mon Mar 22, 2021 10:50 am Post subject: Re: The Warthog |
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I tossed the fan shroud into the blast cabinet & spent Waaayy too much time hosing it off. Upon removing it, I got to see fractures that were hiding under paint & RTV, yes, someone used RTV to seal up everything. This becomes very apparent as the blast media just bounces off it.
So let’s see, the sheet metal surrounding three of the four fan backing plate retaining bolts was cracked...
This f&^#*ng shroud is like having most of your chips in, getting called, & having to go all in, I have too much in to walk away now.
But WAIT! The hits just keep on coming! I flipped the damned thing over & found these too.
“But it’s that rare, one year only...”
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4416
Location: Stuck in Ohio
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12855
Location: North Carolina
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| Posted: Wed Mar 24, 2021 11:43 am Post subject: Re: The Warthog |
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| Buggeee wrote: |
| Dude walk away. That metal is so fatigued. What the heck happened to that poor shroud? Bury it in the back yard. |
NEVER!!!
I am all in on this POS. In fact, after more welding & grinding and even more welding & grinding, I cleaned the shroud once more in the blast cabinet & then grabbed a tub of Bondo to... aww FAWK THAT, if anyone is looking that close at the engine, they can just get the hell over it.
I shot it with some self etching primer & then painted the damned thing.
Last night I blew a wad on replacement pans & a bunch of miscellaneous bits & pieces so I could start bolting shit back up. I tossed some new cylinder tins on, painted the intake manifold, & slid some new intake boots on. The fresh-out-of-the-blaster end castings didn’t look quite right so I lightly burnished them with a wire brush.
I then removed my newly found collection of washers...
And then cleaned the exhaust with a wire brush & shot it with some BBQ paint.
I bought a new fan blade but found that it was so lopsided that I couldn’t get it true so I scrounged & found a good original & bolted it up after cleaning & painting another repurposed backing plate.
I then found all of the missing thermostat components & a good Hoover bit & after seven or eight times of installing & removing the shroud, I dropped it in place & cinched it down.
Yeah, the generator now looks nasty, IDGAF.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4416
Location: Stuck in Ohio
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kent70ghia
Samba Member
Joined: June 15, 2020
Posts: 176
Location: Tacoma, WA
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| Posted: Wed Mar 24, 2021 2:39 pm Post subject: Re: The Warthog |
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| Man on a mission, I am sure Chris wants to get out exploring again like he did in the Ghiapet! |
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toxicavenger70
Samba Member
Joined: July 28, 2019
Posts: 871
Location: CO
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| Posted: Thu Mar 25, 2021 8:24 am Post subject: Re: The Warthog |
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I have to be honest, I love your threads! You put a lot of time and effort into sharing the (T)hings you are working on. I know taking pics slows down that process tremendously.
So thanks for doing it!
P.S. That shroud would have went into a cathole and pissed on it if landed at my house. It would be a one year only cathole. lol |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12855
Location: North Carolina
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| Posted: Fri Mar 26, 2021 8:45 am Post subject: Re: The Warthog |
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Thanks y’all!!!
| toxicavenger70 wrote: |
I have to be honest, I love your threads! You put a lot of time and effort into sharing the (T)hings you are working on. I know taking pics slows down that process tremendously.
So thanks for doing it!
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No, thank you!
I started doing the build threads to share some of the techniques & other things that I have experienced so that others may learn from (especially what NOT to do.) that I really wish that I had known years ago, & I’m still making shit up. They now have progressed into a way of sorta keeping me on task as I tend to be easily distracted by the next project & it also helps to keep track of what I have done. I’m glad that others may find it interesting if not useful.
Yesterday, I was trying to find a spacer for the generator for the front pulley that was MIA on the Warthog. The one that I found was whipped but I tried to see if it would fit... big mistake, the little bastard slid right in & then wouldn’t come out & there wasn’t enough to grab it so I wrapped a piece of one of the tin patches around the armature to tack weld to it.
I missed but the wire stuck & I was able to coax it out.
And then I found another.
I also managed to find the proper fan nut.
The woodruff key was missing on the fan side too.
Since the Ospho had a few days to cure, and since it only neutralizes rust but does not prevent it long term, I decided to blow some paint into the frame horns. I started by folding another old shop towel into a coat hanger & threaded it into the frame horn.
I then found an old can of paint & dumped half of it in each tube & used the coat hanger to mop up the excess & schmear it around the rest of the inside.
Ehh, not great, but it covered. I then began to bolt up the transmission mount. I’m using a solid mount kit but this thing transmits ALL noise into the car, so I made & had inserted some rubber pads (the sidewall out of a tire & a bicycle inner tube) while it was in the Ghiapet.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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