Hebmuller door build.

[Hebster52]

In March this year I brought home from my better pair of split doors from the storage to start convert them to Hebmuller specs... I had bought the repairpanels for the bottom halves from Virtanen Restoration panels way back in 2011...

[/s]
_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

Before I started to do the rustrepair on the doors I wanted to make most of the parts needed for the conversion.
Started by making a bunch of cardboard templates.

Then cut the parts in sheetmetal.

Tackwelded them into shape.

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

When the rear corner pieces were done I made the inner pieces for the front corners.

Eyeballing the shape....

Made a template and a hammerform to shape the right curve into the pieces..

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

Earlier last winter I allready made the window channel rails and bought 4 bars of bakelite to make into window gliders.

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

In late March I then had the main parts needed.

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[finster]

always interesting to see your fabrication work
just out of curiosity - are bars of bakelite readily available these days or are they a dark web item?
_________________
"we're here on Earth to fart around" kurt vonnegut

nothing lasts, nothing is finished, and nothing is perfect...

[Hebster52]

Also as Hebmullers have the vertical bar for inner handle in both doors I had to make a copy of the one I got in the passenger door.
Early Hebs don't have inner handles so no need for the small piece in the middle.

The bars are welded on Heb doors with some extra support so I also made those.

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

[Hebster52]

After I got all the small pieces it was time to take the bull by the horns and tackle the rusted bottoms of the doors.
I was most worried with one as I needed to replace also the hingemount area on that one. Decided to start with that. With help with measurements and so on from fellow enthusiasts both here and elsewhere I managed to repair both doors without any bigger issues.

Mika's panels were the saviour to make this possible without bigger problems!

Off course I had to make an appropriate door hinge jig too!

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

When everything was prefitted and looked good I could start assembling the parts in the first door.

When the innerpanel was tacked to the door I went to the barn to testfit the door to the body.

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

At this point in mid April I started thinking that the first pair of window glider rails in 1mm sheetmetal felt a bit flimsy so I decided to make a new set out of 1,5mm instead.

Also realised that I only had one good glider rail for the bottom window sash...

And because these aren't available in every parts dealers shelves I thought what the H. It's just sheetmetal. I'll make one for the other side..

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[RUNKLE]

.

[Hebster52]

May was spent with other projects but in June I got inner panel welded and started working on the second door.

Before I could start on the second door I had to straighten out the outside as it had severe dent issues... Used the first door as a template as it was in hood condition compared to this...

First paintstripped it.

Then I could start fix the shapes and remove the dents...

It required a lot of patience and persuasion until I was satisfied with the shape..

After this I fitted the bottom to this door too.

Final check of shapes...

Also had to fix the small lock mechanism holder on one door.

Now this is a warming sight with both doors done on the inside.

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

Next in this jigsaw puzzle was then to start fitting the outer panels too.

I started with the one that had needed a lot of work in the first place so I could use the better door as a reference.

And when that was fitted I did the same with the other.

After I was happy with the fitment of the two panels I fully welded the corners of the inner panels. These corners are nowadays welded allready when you order these from Virtanen. Mine are from one of his first ever made batches.

After this I finally primered the insideparts while there still is easy access to these areas.

And then there was nothing more than to weld the panels!

After welding them the doors finally were structurally solid enough to cut off the window frames!

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

Now the real conversion can begin! Fitted the upper inner structures and they did fit just with minor adjustments!

Then started with the first patch!

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

Not really happy with the patch so will probably make both new.

Today I finally tackled a tiny big obstacle that have been a bad excuse to not weld the inner structures to the doors yet.

But the door wedge rubber holders turned out good in the end.

Next is to weld the inner structures and finish the outer skin.
_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

[VW_Jimbo]

Very cool! Love seeing the metal work! Those outer door skins turned out AWESOME!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[Hebster52]

Working on final pieces on the rear corners.

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD

[Hebster52]

This small detail I observed last week while researching door details. Seems like this very early had a different design on the doors upper rear corner compared to later in production.
Now I'm torn......

_________________
~Kris~
"The Hebster52" my Hebmuller replica build
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD