Discussion in 'Restorations' started by exuptoy, Jul 5, 2012.
WHS coming on a treat , i say cut the panel to suit the van NOT the van to suit the panel , owen nw
Cheers chaps, nice thought Owen!
After reading what Kruger had written last night I went to have a GOOD look at the work required on the remaining part of the Y section horn that I made the end for. I decided to chop the horn off and fabricate the new one to match what had been removed.
The inner is equally bad but it can wait until tomorrow. this was today. ;D
Not looking too good. Right decision I reckon.
I was a bit concerned at replicating this. But as they say faint heart never won fair maiden and all that.
Not too shabby I reckon. What you think?
and a quick pic with the accelerator post tacked in. I was worried that the angle would be all wrong but I needn't have panicked.
Started the day with this rot and wasn't sure where to start.
Chopped out the best I could and made myself a template from cardboard and set about cutting a 2mm plate to shape.
Welded in place.
The only problem is when I welded in the plate, I realised I hadn't put the throttle shaft through the plate before assembly, so I now need to remove the master cylinders out to get the shaft in place, but thats tomorrows work.
Removed the remains of the tie plate from the top of the chassis section and found a couple of holes (may have caused them by tearing the plate lol) so cut out and made a plate to fill the hole. Well, at least my weldings improving. O0
Cut out the grot beneath the brake pedal shaft and rebuilt with fresh metal.
Only offered up the Y piece to see how it looks. Much better!
Good work dude , had the same problem myself with my bus except it began at the front beam hanger - half the front beam was bolted to nothing .
Cheers dude. The beam mount part of the chassis is gonna need work as well, but now I have material fore and aft to weld to so it's the same thing as you've had to contend with too one way or another.
Quite pleased really though with how it went today it looks a little scruffy BUT when I looked back at what I started with I am stoked.
Cheers for the K+ too O0
^ You should be - you've made a great job of it.
Good effort there pal, patching the old flaky metal there would have been a can of worms, except the worms had escaped!
Keep up the good progress whilst the weather is warm!
Well done dude
If id discoverd that lot hiding id have put down the grinder and gone to the pub to calm down
Wow, good work!
Biggest thing for me is this is my first resto and I'm not sure whats right and whats not. My next one should be easier. lol
You guys are a massive help though, especially with the advice and measurements when I'm stuck. :mwave:
I thank you all.
great work, thats looking much better now
Todays work then.
Cut out the perforated double joggled edge along the side of the arch and cut up a spare seatbelt anchor repair so I could replicate the joggled edge. Then welded on both sides so I could grind the top welds right back without fear of loosing the weld integrity.
Looking much better.
Spoke to my m8 Darren who runs a machine shop called Fairfield Tool and Die to make me a pair of spacers to house the throttle assembly shaft. He has made numerous one off parts for my streetfighter like adapting the steering stem on a set of Hayabusa forks to fit my GPZ, so I know his work is second to none. Also if anyone needs anything machining, I can get it done at a very good price. Just drop me a pm.
The last one of these was worn in an elongated fashion due to the throttle pedal linkage causing lateral wear.
I then clamped up the Y section arm and offered my inner valance up so I could get the measurement of the inner section of the arm so I could weld in the inner box section wall. Then marked where the arm was to come to then welded it all in place.
So happy. This means I can weld in the closing panel over the top of the Y section tomorrow then once the arch is finished I can get the floor panel in place.
Speeding along now.
More cracking work, especially considering it's you first resto
Cut a plate for the top of the tub and stuck it in. There was a lot of thin metal there tho so took me a while to fill it in on the front corner. Same procedure, weld above then below then grind back the top.
Cut up another seat belt repair patch to get the edge for the tub. Need to clean this up!
Due to the curve of the door, I had to make 3 cuts and kick the edge to follow the line.
Welded in place then cleaned up.
Cleaned up the little patch required along the seat runner and sorted that.
Cut a piece of 2mm plate and tacked it across the Y section but it was fouling the pedal a little, so I notched the top to clear it. Seamed around the plate then put 6 plug welds for a little more future proofing.
Dropped the floor in place and tacked it but not finished as I need to hang the door to jack the arch into the right place alongside the tub before it is welded along the arch.
Just been up the garage for an hour.
Bolted back on the door and jacked the arch out to where it should sit and spot welded it in place.
For a cheap arch, I'm quite impressed with the line of the door and the gaps.
Also jacked out the step a little so the door line was right at the step, even that looks well. The floor pan originally looked like the line on the edge was out but now the floor has been jacked, the angle looks correct. You can see in the last pic of yesterdays work how the floor looked off. That was the reason I stopped where I did. I'm kinda glad now.
the door shuts look good mate
Cheers Dale. The only issue I have is to get the door to catch on the second latch I really need to slam the door real hard. I assume this could be a poor quality door seal?
Todays work was to get the floor in place and the tub/floor join repair sorted.
The floor was tacked into place from yesterday so that was fine however there was still some manipulation required to meet the tub repair section and that panel was a real pig and had to be cut, reshaped and forced into place. Got there in the end though.
Welded the back of the panel.
Welded the join to the floor panel.
and the finished article.
brilliant resto , my fave this year by miles , only you will appreciate this bus properly when its done , no one else will feel the pain .
keep it up dude , it will be worth it when you get to camp in it .
Cheers Poptop. Nice to hear. 8)
As it's my first VW, sometimes I worry whether the finished article will be good enough (and what I am doing is right) but at least I know the rot will be gone and I suppose the finish will be in the prep and paint.
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