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Supercharged Jungle Green 56
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vwhelmot
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PostPosted: Thu Jun 29, 2023 6:21 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

The roof slowly returned to shape and i was determined to use as little filler as possible, in fact the only area that i had no choice to apply was where i couldn't get underneath or behind the skin to work the metal out, like behind the inner strengthening rail but even then i used levers to pry the steel back so all in there is hardly any in the roof.

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Half way through i grit blasted the gutters and a pillar seams, messy job but had to be done. Any tiny rust spots in the roof skin was blasted off at the same time.

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Still loads to do by this point. I must have spent two months of evenings just on the roof alone.
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PostPosted: Thu Jun 29, 2023 9:18 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

Popcorn
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getting grumpy & less tolerant!


55 ragtop
56 delux sedan
56 Kabriolet
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vwhelmot
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PostPosted: Fri Jun 30, 2023 1:17 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

First coat of etch after every tiny rust spot had been blasted off and cleaned to an inch of its life.

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Layer of filler primer

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sinclair
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PostPosted: Fri Jun 30, 2023 1:46 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

Nice work Thumbs Up I spotted a very early chassis in one of those pics Shocked
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vwhelmot
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PostPosted: Fri Jun 30, 2023 2:51 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

I let the roof settle for a while and set about the quarter panels. I never really studied the state of the quarters until this point. Only when i quickly blocked them did i realise that they were dented in quite a few areas. I managed to get the dents out in the end.

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vwhelmot
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PostPosted: Fri Jun 30, 2023 2:52 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

sinclair wrote:
Nice work :thumbsup: I spotted a very early chassis in one of those pics :shock:


Cheers. Its a 47 floor pan.
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vwhelmot
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PostPosted: Fri Jun 30, 2023 3:43 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

Front quarter had a hole for an antenna which i was not going to use anymore, so i welded it up and carried on with the dent removal. The doors were a whole new story and were a big hassle, well one of them was.

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I was very careful when i blasted the doors. The right side passenger door was full of filler, no rust but just full of bondo. It being that they were the original doors to the car made me want to repair rather than replace.
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PostPosted: Fri Jun 30, 2023 3:48 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

The drivers door was dented but not half as bad as the other. I still had to cut the inner structure out to gain access to the skin. After panel beating it back into shape i welded it back in and smoothed all the welds. Test fitting it went fine.

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vwhelmot
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PostPosted: Fri Jun 30, 2023 4:06 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

The right side was a right thorn in my side. After blasting it and cutting out the inner like i did with the other side i quickly realised that the skin had been badly dented and just been pushed out and filled. The moment i started working the metal it gave me no end of tin canning. No matter how many times i shrunk it another spot would tin can. I would later cut the whole skin off just to see how stretched it was and i couldn't believe how bowed the skin was. Anyway, i bought a replacement and that turned out to be a bit of a dog too. I tried repairing the rust issues and eventually gave up on this panel too.

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Like i said i didn't end up using this door as it too started giving me trouble when i started blocking it.
Finding good rust/dent free oval doors is a bit of a problem here in the UK, i ended up getting another one from Bob at BBT and thats another story...
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vwhelmot
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PostPosted: Mon Jul 17, 2023 1:44 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

The door saga continued for a while. I sourced another door from BBT and when it arrived i was greeted with a bent window frame which pleased me no end.


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I ended up cutting out the frame and pulling it back into its original position and using donor pieces from the other doors that i had now accumulated.

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Fixed another crease

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Modified the drain hole to the correct three hole type for my year


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Installed new oversized hinge pins

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vwhelmot
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PostPosted: Mon Jul 17, 2023 1:46 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

Fully blasted and primed


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So now i had two perfect doors
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PostPosted: Mon Jul 17, 2023 1:53 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

The other OG rear wing was in a sorry state so i set about making it nice again. No filler was used on this panel either.


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It needed a lot of panel beating but it turned out to be a nice wing in the end.
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vwhelmot
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PostPosted: Mon Jul 17, 2023 3:38 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

After many hours of blocking etc the shell was ready for paint. I made my own paint booth and bought a decent gun. I managed to match the original colour off the glove box door as the dash is still wearing its original paint from the factory.

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I made some panel stands

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vwhelmot
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PostPosted: Mon Jul 17, 2023 3:51 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

More painting, colour sanding and polishing followed. Doors back on and set the gaps.

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PostPosted: Mon Jul 17, 2023 11:07 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

Applause amazing painstaking craftsmanship - you'll be able to see the twin's faces in that paint Laughing
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PostPosted: Tue Jul 18, 2023 1:15 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

Very Happy The twins already love going for a drive in car dad bug.

The engine was something that i wasn't expecting to completely rebuild as it was running really nicely. No noises or rattles or smoke, it ran fine. It had a few oil leaks which tbh every vw bug owner expects a little one at least. Anyway as i delved deeper into the block the more issues i found. I started off with buying a sebring exhaust that was made for a 356 so i set about modifying it to fit my 30hp.

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As you can see, the original inlet manifold had suffered , people don't realize how heavy the judson supercharger is and really its only a matter of time before something will crack under the strain. i made a proper charger support that bolts to the block and gives the added strength.
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PostPosted: Tue Jul 18, 2023 8:31 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

VERY COOL! Loving the fabbing skills!
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PostPosted: Wed Jul 19, 2023 6:05 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

Thanks Jim

I started buying parts to build a new motor and was lucky to find a NOS case which is unstamped but has a produced date of aug 60. I also bought a NOS set of Kolbenschmidt B&P , NOS 30hp cylinder heads and some more nos goodies. Soon after i changed my plan and came up with the idea of building an Okrasa bottom end and keeping the judson instead of going down the twin carb route. As far as i`m aware, no one has done this before so i thought i`d give it a go. So not long after i managed to buy a pair of genuine Okrasa 30hp heads that were apparently ready to go but as you will see later they weren't.
I wanted to get hold of a nos standard crank and phoned around my usual contacts until i got hold of Ian at Wolfsburg performance here in the Uk. Ian had a nice used standard crank but then mentioned that he had a lovely original Okrasa 64mm item in stock with a NOS set of main bearings to suit. I was sold instantly so that was sent over too. Little did i know that that would turn into a bit of a saga too.


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Made my own valve spring compressor


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NOS Case

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OG Okrasa heads and crank

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Sent the whole turning assembly for balancing and for small end replacement.

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PostPosted: Wed Jul 19, 2023 7:23 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

This is getting good! Keep the updates going. I am loving this! Picture heavy threads are the best!
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PostPosted: Thu Jul 20, 2023 1:43 am    Post subject: Re: Supercharged Jungle Green 56 Reply with quote

Next stage was to figure out how to connect the dual port manifold up. VW dual port end castings are decent, they are lightweight and they can be modified to flow well so i thought why not use a pair of those plus i was keeping the whole factory look and feel too which is a bonus. People don`t realize when they look at the motor, 30hp middle and late bug outer, it confuses straight away. I started to properly build the motor after the bodywork was finished and used the old block as mock up . I removed all the old gallery plugs from the new case and drilled and tapped it for full flow too. Also found a nice 356 oil filler/breather tower which i modified to fit to the case.
The manifold took a huge amount of work, the supercharger had to be in exactly the same place as before because its a tight fit under the decklid so trying to work all that out took a while. I`m just glossing over it with these pictures but you get the idea.


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