Latest project, 1967 VW beetle restoration.

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Re: Latest project, 1967 VW beetle restoration.

Postby BTJustice » Mon Apr 09, 2012 6:18 pm

I dont know that updates will always be this regular but with another day off for the bank holiday I got more work completed.

Offside front wing came off first and the inner wing is better than the nearside;

Image
P1140469 by route9autos.co.uk, on Flickr

Same can be said for all of the offside body but strangely the floor and heater channel on this side look worse than the nearside.

With the last wing off and the tailpipes removed the car now fits perfectly (with the bonnet open and heater removed) across the garage. These stands are worth their weight in gold;

Image
P1140468 by route9autos.co.uk, on Flickr

Inside the car the sill and floor look not bad, just a bit scabby round the edges;

Image
P1140482 by route9autos.co.uk, on Flickr

Image
P1140483 by route9autos.co.uk, on Flickr

But going by the floor pan bolts there is a fair bit of rusted steel inside the heater channels. The top of this bolt would stick up inside the channel.;

Image
P1140485 by
route9autos.co.uk, on Flickr

Wings arent in the safest place but at least they look pretty;

Image
P1140488 by route9autos.co.uk, on Flickr

Next job is to strip out the interior then I can start getting ready to cut.

Dave.
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Re: Latest project, 1967 VW beetle restoration.

Postby BTJustice » Wed Apr 11, 2012 5:40 pm

Todays update;

First job was to dig out the donor heater channel so that I had an idea how much of the car will come off;

Image
P1140490 by route9autos.co.uk, on Flickr

As you can see there is a good bit of panel work still attatched to the channels from California and I plan to use as much of this metalwork as I can.

It also lets me paint the inside of the heater channels before fitting as I am never directly welding to the channel.

This is the grotty rear 1/4 before cleaning;

Image
P1140492 by route9autos.co.uk, on Flickr

And after;

Image
P1140494 by route9autos.co.uk, on Flickr


For some reason the weld inside the arch is a nice neat butt welded seam but where the panel is on the outside of the car its a messy overlap, spotwelded and sculpted in filler

Its not just a skim of filler, I think the artex on my ceiling is thinner (pound coin for reference);

Image
P1140495 by route9autos.co.uk, on Flickr

At least the dust saved me having to find a white pen to mark my line;

Image
P1140498 by route9autos.co.uk, on Flickr

At the front it dosnt look so bad......Yet;

Image
P1140501 by route9autos.co.uk, on Flickr

After a clean up the new panel should come higher than the previous repair which will make fitting easier and neater;

Image
P1140503 by route9autos.co.uk, on Flickr

Except the same sculpter has applied his skills to filling the front 1/4 panel;


Image
P1140504 by route9autos.co.uk, on Flickr

So here is where I left it tonight...... VERY dusty work so I think I will invest in a mask before my next session;


Image
P1140507 by route9autos.co.uk, on Flickr

I think before I go on I need to go and find my welder, buy some steel for patches and some other supplies.

Dave.
My all new film location website is here;
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Re: Latest project, 1967 VW beetle restoration.

Postby hungryjoe » Wed Apr 11, 2012 10:45 pm

This Prince Of Procrastination, salutes your endeavors.
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Re: Latest project, 1967 VW beetle restoration.

Postby Fireman » Thu Apr 12, 2012 5:47 am

Cool! 8)
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Re: Latest project, 1967 VW beetle restoration.

Postby BTJustice » Sun Apr 29, 2012 9:45 pm

I finally have a proper update for the thread.

I spent today cleaning off more of the filler, first of all on the front quarter.

Here is a quick video showing just how messy this job is for anybody who has yet to experience the fun of filler removal;

http://www.flickr.com/photos/route9autos/6979704176/

That left me with an almost bare quarter panel.

Image
P1140604 by route9autos.co.uk, on Flickr

All looks ok but there is a serious low area behind the wing mountin area which would explain all the filler. I cant work out if its accident damage or poor previous repair work.

I also got on to working out how far up the rear quarter panel the filler extended and I am now left with a filler free panel with lots of original red paint left on it.

Image
P1140605 by route9autos.co.uk, on Flickr

I then whipped off the door so that I could get better access to start stripping the paint and carpet glue from the inside of the car which has left me with a killer back ache as its a really awkward area to fold 6foot 3inch of dave into.

Image
P1140602 by route9autos.co.uk, on Flickr

Im not yet ready to start the proper cuts, I am still trying to decide on painting or investigating the galvanizing process for the heater channels.

Dave
My all new film location website is here;
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Re: Latest project, 1967 VW beetle restoration.

Postby Fireman » Mon Apr 30, 2012 5:47 am

You might have mentioned already Dave, so forgive me if you have - have you decided on a body & trim colour yet? :wink:
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Re: Latest project, 1967 VW beetle restoration.

Postby BTJustice » Mon Apr 30, 2012 12:18 pm

Body is staying black, thats a definate and Jo had yet to choose how she wants the seats and door cards. I have a feeling the interior will be red.
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Re: Latest project, 1967 VW beetle restoration.

Postby Fireman » Mon Apr 30, 2012 6:19 pm

Thanks Dave - looking forward to seeing the finished product, I like black & red. 8)
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Re: Latest project, 1967 VW beetle restoration.

Postby BTJustice » Tue May 08, 2012 8:48 pm

Done a bit of investigation work and it looks like galvanizing will be too expensive and require too much work so hope to visit an industrial paint suppliers this week or next. I have been told about brush on galvanizer and resin marine paints so will price these up as a DIY option.

Did get some more prep work done this evening.

Image
P1140736 by route9autos.co.uk, on Flickr

With the new panel on the floor I need to accurately transfer the shape of the new panel onto the car as a guide to where I will cut.

For that I need to make up a template.

First job is to cover the panel with tape. The bottom of the 1/4 panel will serve as a line to match with whats on the car and to double check measurements I will measure the door opening down from the gutter line.

Image
P1140737 by route9autos.co.uk, on Flickr

I then transferred the template onto the car as a cutting guide. I will need to check and re-check measurements before I cut but this will give me a really good idea of where to cut.

Image
P1140738 by route9autos.co.uk, on Flickr

I will also fit the door after tacking the sill in place before the final weld to check measurements.

Image
P1140739 by route9autos.co.uk, on Flickr

Unfortunately the new panel wont cover the bad previous repair but I will remove all of the past replacement panel, clean up whats there and make a new plate to fill the space.

I also got the front 1/4 panel and inner arch template in place and as hoped the previous repair line falls within the area that will be cut off.

Image
P1140741 by route9autos.co.uk, on Flickr

Image
P1140743 by route9autos.co.uk, on Flickr

Moved onto a template for the front bulkhead;

Image
P1140744 by route9autos.co.uk, on Flickr

Image
P1140748 by route9autos.co.uk, on Flickr

With the inner template and the outer template in place the top edges look pretty closely lined up. This will be checked before cutting by drilling a small hole at the top of the outer template and seeing how close it lines up.

I may remove some of the metal from the new panel in this area to make it easier to work with.

Once I sort out the right paint for the new panels I will start cutting.

Dave.
My all new film location website is here;
www.rewoundandfound.com

Check oot ma flickr page;
http://www.flickr.com/photos/route9autos/

For handmade jewellery, go to:
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Re: Latest project, 1967 VW beetle restoration.

Postby BTJustice » Mon Jul 09, 2012 2:54 pm

Its about time I started back at this resto and with 3 weeks holiday I have no excuses*

As it is a few weeks since I had got to the garage the inevitable tidying up needed done then I dug out the sill/heater channel I will be starting with;

Image
P1150332 heater channel by route9autos.co.uk, on Flickr

My plan is to coat the pans and heater channels with Jotamastic or similar resin paint prior to fitting (I will leave a couple of inches along the weld areas un painted) so I want to get the panels clean and double check their integrity.

Good old wire twist brush to start with on the underside;

Before;
Image
P1150333 underside before by route9autos.co.uk, on Flickr

After;
Image
P1150336 heater channel bottom after cleaning by route9autos.co.uk, on Flickr

Nothing is as good as finding metal as good as the day it left the factory.

I think for speed and ease I will visit a few shotblasters tomorrow to get a few quotes. Doing flat open areas is fine but the more intricate corners will not be very easy with the grinder and with the floorpans being such a large surface area I would be there about 2 weeks.

I had been hoping to have paint here to be getting on with but the Jotamastic supplier on ebay wasnt very forthcoming with information when I emailed him a few questions so I will see if I can find a supplier in Glasgow that I can visit and annoy before I hand over hard earned.

I really hope to have pans and channels done before I return to work but depends how much real life gets in the way.

Dave

*appart from a wedding, couple of weekends away and wanting to get out on my bike a few days.
My all new film location website is here;
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Re: Latest project, 1967 VW beetle restoration.

Postby Fireman » Mon Jul 09, 2012 4:51 pm

Did you watch the 'Beetle Crisis' marathon on tv last week I think it was - the guys were doing a rebuild on a 1302?

Not my cup of tea as far as a donor vehicle, but hey, at least they did it instead of me sitting on my fat a**e thinking about what I need to do to my classic. A top end rebuild that would take 6 weeks at a comfortable pace I rekoned - stripped off one of the V8 heads, did the business and now its sat for a year with me seriously thinking about finishing! ::):
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Re: Latest project, 1967 VW beetle restoration.

Postby BTJustice » Mon Jul 09, 2012 9:24 pm

I had seen the beetle crisis show and like you it wasnt really my cup of tea but good on them for doing it.

If you have a V8 sitting un driveable then get a move on man, its worth getting it going just to sit and rev the engine without going anywhere.

I cant really talk I suppose, I bought all the parts to build a new engine for my fasty and it still has the original in it.
My all new film location website is here;
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Check oot ma flickr page;
http://www.flickr.com/photos/route9autos/

For handmade jewellery, go to:
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Re: Latest project, 1967 VW beetle restoration.

Postby BTJustice » Tue Jul 10, 2012 3:45 pm

Dropped both heater channels off at a sandblasters today. It will cost me £70 to have both channels cleaned but it will save me many hours work and they will be cleaner than I would get them with the twist brush on the angle grinder.

I will use my random orbit sander on the floor pans as they are a less complex shape.

Visited a Trimite suppliers as well.

5 litres or epoxy primer is around £60 but I will need to buy 5 litres of hardener as they dont sell it in smaller batches so another £60! If anybody is thinking of buying paint, let me know and we could split the hardener.

Mates wedding tomorrow so no updates for a few days.

Dave.
My all new film location website is here;
www.rewoundandfound.com

Check oot ma flickr page;
http://www.flickr.com/photos/route9autos/

For handmade jewellery, go to:
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Re: Latest project, 1967 VW beetle restoration.

Postby BTJustice » Thu Jul 12, 2012 8:22 pm

So whie I was at my mates wedding the heater channels were blasted and ready for collection this morning.

Every time I think about getting rid of my Audi it prooves itself incredibly usefull.

Thats both Beetle heater channels in the boot.

Image
P1150409 by route9autos.co.uk, on Flickr

This is a good shot showing the sills/heater channels after sandblasting.

Sandblasting has left a rough texture over the panel but thats no problem. The only areas I need to work on to get smooth are the top of the sill as it passes the door opening, the rear 1/4 section and the door post section.

The santblasted texture will act as a great key for the paint system I have on the way.

Image
P1150414 by route9autos.co.uk, on Flickr

With a quick buzz over with a flap disk the sandblasted texture is smooth enough for a paint finish and rough enough to provide a key for the epoxy primer thats on the way.

Image
P1150416 by route9autos.co.uk, on Flickr

Looks like the rust is still munching its way through the old sills.

Image
P1150415 by route9autos.co.uk, on Flickr

I dont remember them even being soft when I was jacking the car up!

I have also ordered up Jotomastic epoxy boat primer so when it gets here the sills and floor panels will be prepped and painted in the hope I can get to cutting and welding by the weekend.

Dave.
My all new film location website is here;
www.rewoundandfound.com

Check oot ma flickr page;
http://www.flickr.com/photos/route9autos/

For handmade jewellery, go to:
http://www.weegemjo.co.uk
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Re: Latest project, 1967 VW beetle restoration.

Postby hungryjoe » Sat Jul 14, 2012 3:45 pm

Loving every minute of this. When's the next episode?
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