670 replies to this topic

[big-jay]

cracking effort here pal!

Thanks Buddy !

[Baldspeed Racing]

nice and tidy work there dude, love how clean the sealer looks at the mo

[big-jay]

nice and tidy work there dude, love how clean the sealer looks at the mo

Thanks,

Took a lot of effort to clean it up, but was well worth it !

[big-jay]

Parts update,

After what seems like months of searching, I finally managed to track down some factory MPi companion bin pockets. They,re mint with no damage what so ever, and also have all four seatbelt covers, so I'm well pleased with them.

Here's a couple of pictures -



No damage to the screw holes -





I've also just ordered a door bottom repair piece from M-Machine, so I'll be cracking on with that this weekend. Got two weeks off starting next week so hopefully i can get the welding finished and then get her off for some paint !

[mk2 choker]

Absolute quality work mate! I've been reading through this build for a while now and im about to start a project for my son and the first phase is putting all the rust/bodged repair work right.. and being a (forgive me folks ) vw bloke I got no idea where to start, logic says ground up.. so just a couple of questions.... 1. Ground up is that a good place to start? 2. What size plate did you use when you were just patching and not using heritage panels, 2mm? And 3. Patience where can I get some of that from?

[big-jay]

Absolute quality work mate! I've been reading through this build for a while now and im about to start a project for my son and the first phase is putting all the rust/bodged repair work right.. and being a (forgive me folks ) vw bloke I got no idea where to start, logic says ground up.. so just a couple of questions.... 1. Ground up is that a good place to start? 2. What size plate did you use when you were just patching and not using heritage panels, 2mm? And 3. Patience where can I get some of that from?

Hi bud,

Thanks for the kind words, I'm glad you're enjoying the build.

To answer your questions,

1 - I'd say ground up is definitely the way to go about it. Start with the floor, get that solid and work from that. Ideally you want to leave the front end and doors until last, as this is where you want to spend the extra time getting the alignment and gapping of the panels correct.

2 - It all depends on what area your looking to patch. If you're referring to me patching the inner wing, then I would be using 0.9mm gauge steel. In places like the heelboard and toe board, you would use slightly thicker 1.2mm. It's definitely worth doing a bit of research into this before you start.

Saying that though, I don't really like patching, hence my reason for cutting out my patched up R/H inner wing and putting in the full panel. My biggest regret was not replacing full panels, I would have liked to have fitted complete rear quarters, a complete new floor, rear arches and a complete boot floor, but there's not a lot I can do about that now. Just be sure to have a good look around the car before you start and decide whether you want to patch or replace. Of course, a lot will depend on how far your going with the car, compete restoration or a quick tidy up. Anyway that's just some food for thought really !

3 - Let me know if you find out, many a times Ive had to restrain myself from attacking it with a BIG hammer

Jay

[Marco1972]

Absolute quality work mate! I've been reading through this build for a while now and im about to start a project for my son and the first phase is putting all the rust/bodged repair work right.. and being a (forgive me folks ) vw bloke I got no idea where to start, logic says ground up.. so just a couple of questions.... 1. Ground up is that a good place to start? 2. What size plate did you use when you were just patching and not using heritage panels, 2mm? And 3. Patience where can I get some of that from?

FH warden is where we get our sheet steel from he has loads of off cuts in all the thickness you will need and box section if you need to brace your shell

F. H. Warden (Steel) Ltd. Landor Street, Saltley, Birmingham, B8 1AE.
Telephone : 0121 327 7575
Fax : 0121 327 7212
Email : [email protected]
Office Hours : 08.00 - 17.00 Monday To Thursday, 08.00 - 16.30 Friday.
Works Hours : 07.45 - 16.15 Monday to Friday

Edited by Marco1972, 25 July 2014 - 04:05 PM.

[mk2 choker]

Cheers jay, I'll be posting some pics up soon of a sledge, I haven't even start yet and my patience is wearing thin lol and thanks marco I'll look them up, being a steel erector our firm aint light on heavy gauge stuff but when it comes to sheet metal there pants lol

[Jacks]

This is one of the best restoration freds iv seen good job mate

[big-jay]

This is one of the best restoration freds iv seen good job mate

Thanks a lot jack.

Edited by big-jay, 27 July 2014 - 07:54 PM.

[big-jay]

Update,

Haven't got much done unfortunately as I'm still waiting for my door repair panel to arrive. Hoping it will be here tomorrow, then I can start making some real progress.

Heres what I've been doing in the mean time though.

Purchased some lowered shock mounts -



Cleaned up the small bracket that the shock mount bolts into and zinc primed it -



Welded into place -



Then I wire brushed the hinge brackets and left them to soak in some Deox Gel for a while -



Zinc primed -



And welded into place -





That's all for now but have been doing some more sealing today so I'll put some pictures of that up when I've finished it tomorrow.

Edited by big-jay, 28 July 2014 - 08:22 PM.

[big-jay]

Update, Part 1 of 2.

Got a fair bit done over the last couple of days, lots of pictures, I'll start with the sealing I've done.

Scuttle closers sealed -





Bottom of toe board masked up -



Sealer applied -



Smoothed the sealer out and removed the tape. Then I masked up the top of the toe board and the R/H flitch -





Sealer applied -





Smoothed out and tape removed -







Then I sealed up the bulkhead -













I also removed the last of the bitumen from the back seat pan -



That was Mondays/Tuesdays progress. Today's progress to follow as I can't fit it all into one post !

Edited by big-jay, 31 July 2014 - 04:11 PM.

[big-jay]

Update, Part 2 of 2.

Today's progress.

Finally received my door panel repair piece, unfortunately it's a magnum panel, should of asked before ordering from M-Machine as I presumed it would be one of their own pressings. I've had to do some extensive repairs to the door frame as it is really quite bad, but I'm very happy with how it's came out.

Anyway here's a few pictures, the repair panel -



Chopped out the rotten bottom of the door -



Trimmed the repair panel to fit -



Tacked in place -



Then tried the door skin on to make sure the repair panel was positioned correctly -



Happy with that, I removed the skin and fully welded the repair -



Next to repair was the bottom corners of the frame. Made a repair piece and clamped it into place -



Tacked in -



Fully welded -



Same procedure for the other corner, clamped in place -



Tacked in -



Fully welded -



Next was to replace the flanges, cut out the rot -



CAD template made -



Transfered to steal -



Clamped and tacked into place -



Fully welded -



Same for the other side, cut out the rot -



CAD template made and then transferred to steal -



Clamped and tacked into place -



Fully welded -



Tidied up the welds and run a roloc disk over them -





Flipped the frame over and done the same thing, light skim of filler over this and will be as good as new -





Drilled the three drainage holes in the bottom of the door -



Removed all of the magnum black paint and wiped down the whole frame with some solvents to remove the old waxoyl and grime -





Zinc primed the bare metal and applied Deox Gel to the rest of the frame flanges -



I'm going to leave that wrapped in cling film until tomorrow now to give it time to do its stuff. I'm also going to leave the weld on the back as it keeps it nice and strong, just going to run a small bead of sealer over the top to tidy it up. I'll grind down the weld on the front face of the door and apply a light skim of filler, just waiting for some sanding belts to arrive for the power file before I can do that though !

Last job I did before coming in was to apply a sound deadening matt to the door skin -



More updates to follow tomorrow, hoping I can get the front end over the weekend !

Edited by big-jay, 31 July 2014 - 04:15 PM.

[Ben_O]

Nice sealing jay!

[big-jay]

Nice sealing jay!

Cheers Ben !