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My Wedding Transportation (Maybe)

Printed From: West of Scotland Volkswagen Club
Category: General Chat
Forum Name: Restos and repairs
Forum Discription: Share what you've done to your v-dub and how you did it.
URL: http://www.vwscotclub.co.uk/forum/forum_posts.asp?TID=13782
Printed Date: 23 July 2018 at 6:40pm
Software Version: Web Wiz Forums 9.74 - http://www.webwizforums.com


Topic: My Wedding Transportation (Maybe)
Posted By: whamcars
Subject: My Wedding Transportation (Maybe)
Date Posted: 08 March 2018 at 4:50pm
Hi, this is my first post. I'm going to log the rehab of my '70 1500 beetle here. I'm getting married in June this year and have promised my bride to be that my beetle will be my transport on the big day

Here it is in all it's glory
https://flic.kr/p/GmT8Z3" rel="nofollow">

Everything you see was done in the early '90s by the previous owner. I forget how long I've owned it, must be about 20 years. In that time I've fixed it a bit, driven it a bit and parked it a lot
https://flic.kr/p/EQrGM6" rel="nofollow">

Sadly, although the p.o. threw money at the car he didn't know much about them and did no work to it himself. So it was in very poor condition when I got it. It should really have been scrapped but I was young and full of enthusiasm. So I fitted pans and heater channels and repaired the bulkheads and fixed all the stuff that you can't see. Unfortunately this left all the exterior panels with massive amounts of filler in them from the expensive respray the p.o. got done. I knew it was going to cost a fortune in repair panels and I was worried that I might not get it spot on, so in the back of my mind I was thinking about re-shelling it. So once in a while I'd check ebay, gumtree and facebook

I spotted this on facebook and had it bought it for £350 the next day. It's an '85 Mexibug
https://flic.kr/p/24uAWz8" rel="nofollow">
https://flic.kr/p/24qAMxf" rel="nofollow">

The plan is to use the red bug as a donor for the Mexi shell and then put the Mexi shell onto the '70 pan

While I was waiting for the Mexi to be delivered I made this. It's mostly salvaged from the huge trampoline we had in the back garden that got destroyed in a storm
https://flic.kr/p/24qAXB3" rel="nofollow">

I tested it by moving my T4 into the corner of the garage
https://flic.kr/p/21JEKWL" rel="nofollow">





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Wham Cars Retro Workshop



Replies:
Posted By: whamcars
Date Posted: 08 March 2018 at 5:00pm
After a jet wash I was able to see what I'd bought a bit better
Original factory fit quarters
https://flic.kr/p/GmTmkq" rel="nofollow">

Factory horn, still on its bracket
https://flic.kr/p/GmTmJG" rel="nofollow">
https://flic.kr/p/24qAY3y" rel="nofollow">
https://flic.kr/p/24qAY3y" rel="nofollow">

Original, but rusty, metal
https://flic.kr/p/24qATLC" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: malky39
Date Posted: 08 March 2018 at 5:35pm
Sound like you will have you time filled from now until June
☺️. I too will be using my bug as transport to my wedding this year also in June


Posted By: gayle
Date Posted: 08 March 2018 at 8:23pm
Take it the floor of the mexibug is gubbed then? Good luck for this project :)

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Highly medicated for the safety of the masses


Posted By: whamcars
Date Posted: 08 March 2018 at 9:35pm
I’m going to be busy. That’s for sure. I hope yours is in better condition than mine

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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 08 March 2018 at 9:54pm
Originally posted by malky39

Sound like you will have you time filled from now until June
☺️. I too will be using my bug as transport to my wedding this year also in June


Good luck. Have you got a build thread?

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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 08 March 2018 at 9:58pm
Originally posted by gayle

Take it the floor of the mexibug is gubbed then? Good luck for this project :)


The pan’s not too bad. I managed to sell it on eBay. The pan on the red bug has had a lot of work done on it. New brakes, drop spindles, new steering box and a narrowed beam. Plus it’ll speed up the conversion from lhd to rhd

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Wham Cars Retro Workshop


Posted By: malky39
Date Posted: 08 March 2018 at 10:08pm
Originally posted by whamcars

Originally posted by malky39

Sound like you will have you time filled from now until June
☺️. I too will be using my bug as transport to my wedding this year also in June


Good luck. Have you got a build thread?


No build thread, wouldn't be much to show Ed might disagree though, my bug is running and usable it more bits I want to sort rather than they are really need to be done. Rusty spots, ride height sorted and if funds allow the interior sorted aswell. MOT is first on the list as it due next week


Posted By: whamcars
Date Posted: 09 March 2018 at 7:19pm
Can anyone tell me how to edit photo's? I've got a duplicate in one post that needs to go

TIA

Time to split the body from the pan
https://flic.kr/p/21JEJf9" rel="nofollow">

So close
https://flic.kr/p/24qAUNN" rel="nofollow">

Down safely. I can move it with one hand now
https://flic.kr/p/GmTisS" rel="nofollow">

I'm very happy with the condition of the body. It's a little rusty but it's had next to no work done to it. The same can't be said for the pan, which has been "repaired"
https://flic.kr/p/21JEyvE" rel="nofollow">
https://flic.kr/p/23pNndL" rel="nofollow">
https://flic.kr/p/21JEwzq" rel="nofollow">
https://flic.kr/p/21JEvu9" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 09 March 2018 at 7:33pm
I couldn't figure out where I should start with the metal work. In the end I decided to remove the rusty front bulkhead. Looking at the options I could fit a poor quality pattern part or pay for a genuine vw part which would need converting to RHD anyway. so I decided to try and repair and convert the one that's already on the car

The drilling of many holes
https://flic.kr/p/ESfBpT" rel="nofollow">

I shouldn't have drilled along the top. I should have cut the boot floor about an inch behind the edge so that it coulkd be seam welded back in. But I only figured that out after I'd got the bulkhead out
https://flic.kr/p/ESfTpD" rel="nofollow">

I ground these welds down with a finger grinder. I don't know of any other tool that would have done such a neat job. It's one of my favourite tools
https://flic.kr/p/GoGBm7" rel="nofollow">

So close, but the school run stopped me in my tracks. Ah well there's always tomorrow
https://flic.kr/p/ESfASF" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 09 March 2018 at 7:54pm
It's out. It looks fit for the skip. Years ago that's where it would have ended up but not today
https://flic.kr/p/24uFYa3" rel="nofollow">

Cleaned
https://flic.kr/p/EUsV6t" rel="nofollow">

I decided to start with something easy. Pitting and rust holes on the top rear. Trying to weld up holes like these is a recipe for extreme frustration. So I removed the bit that's sticking out
https://flic.kr/p/EUsUzZ" rel="nofollow">
https://flic.kr/p/24uG1NQ" rel="nofollow">

Inside it looked like this
https://flic.kr/p/24uG1m7" rel="nofollow">

Repair piece made
https://flic.kr/p/24uFZEN" rel="nofollow">

Once I was ready to weld I gave the inside of the box section a good clean then a couple of coats of Screwfix cold galvanising spray
https://flic.kr/p/23cpRD2" rel="nofollow">

It's been a while since I did any tack stacking. A couple of them look quite nice. The rest are just ugly. Oh well I'll get better as I go on
https://flic.kr/p/24uFYCs" rel="nofollow">

Done
https://flic.kr/p/24zYgDi" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 09 March 2018 at 8:14pm
This is the outer edge of the bit that sits on the napoleons hat, where it joins the heater channel
https://flic.kr/p/GseBWA" rel="nofollow">
https://flic.kr/p/21PXW95" rel="nofollow">

Checking I've still got a right angle
https://flic.kr/p/GseB93" rel="nofollow">
https://flic.kr/p/21PXVrU" rel="nofollow">

The other side of the bulkhead base has a lot more rot. So I'll remake it in sections
https://flic.kr/p/F2iRUK" rel="nofollow">

The camera battery died so I just cracked on
https://flic.kr/p/23ABQp5" rel="nofollow">



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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 09 March 2018 at 8:23pm
There were a couple of areas of rot right in the middle of the bulkhead so I tackled them both at once

Hole
https://flic.kr/p/24BARTJ" rel="nofollow">

Patch. This little bit of metal took forever to make. I understood what I needed to do but without a shrinker/stretcher I couldn't figure out how to make the metal do what I wanted
https://flic.kr/p/23jeMPB" rel="nofollow">

In the end I used the pick end of a hammer on a dolly and gave it about a million hits
https://flic.kr/p/21Vq5Zu" rel="nofollow">

Some big gaps to fill but I’ll get better
https://flic.kr/p/23ABN1N" rel="nofollow">

The payoff for all that effortBig smile
https://flic.kr/p/F2iaCH" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 10 March 2018 at 12:56pm
The second repair to the middle of the bulkhead
https://flic.kr/p/24MqSpH" rel="nofollow">

Nearly there
https://flic.kr/p/GDFnVm" rel="nofollow">

I managed to grind right through the patch while I was smoothing out the welds. I had a go at filling the holes but I just made more holes. So I made a filler piece and welded it in. And then I ground right through that too. I ended up cutting the whole mess out. The smooth bit is the filler piece
https://flic.kr/p/24Jx1vP" rel="nofollow">

I decided to do something else as I was getting wound up by the mess I was making
https://flic.kr/p/24EMSVy" rel="nofollow">


My first line was too low. By going higher I could get rid of hidden rot and the mess over on the left
https://flic.kr/p/24Jx4VV" rel="nofollow">
https://flic.kr/p/23DLWx1" rel="nofollow">

That turned out pretty nice. It will only need a couple of mm of filler to get it flat. I try to do no filler repairs but I'm still learning and I don't always get it right
https://flic.kr/p/23nsfKD" rel="nofollow">



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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 10 March 2018 at 1:22pm
I've given up on the bulkhead for the time being. I ground through it again! It seems the bulkhead is made from 0.6mm steel. Add to that the fact that I haven't picked up a welder for about six months and it was bound to go wrong

I decided to have a look at the engine bay. It still had the factory tarboard fitted. So I had no idea what was lurking
https://flic.kr/p/24RkwiC" rel="nofollow">
https://flic.kr/p/24RkuUA" rel="nofollow">
https://flic.kr/p/23xSLFH" rel="nofollow"> https://flic.kr/p/23xSLFH" rel="nofollow - P1060536 by https://www.flickr.com/photos/146139339@N02/" rel="nofollow - snedboy sneddon , on Flickr

I thought about keeping the tarboard but it was a bit chewed up
https://flic.kr/p/24Rktzm" rel="nofollow">
https://flic.kr/p/24Rkueh" rel="nofollow">

That looks alright. I removed the tags that held the tarboard on
https://flic.kr/p/24WCWAF" rel="nofollow">
https://flic.kr/p/24WCW9P" rel="nofollow">
https://flic.kr/p/23RWFyS" rel="nofollow">

The body had been stored on trestles before I got it. Looks like the engine bay sides took the weight
https://flic.kr/p/24WCUtV" rel="nofollow">
https://flic.kr/p/24WCVET" rel="nofollow">




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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 12 March 2018 at 12:35am
I moved round to the nearside rear wheelarch. I wanted to make sure the wing mounting flanges were good so I ground the paint back and found mostly good metal
https://flic.kr/p/Fpo1HM" rel="nofollow">

There was a broken bolt in the bottom wing mount
https://flic.kr/p/24RksQL" rel="nofollow">
https://flic.kr/p/24Rks8U" rel="nofollow">

I've given up on stud extractors. I must have tried loads over the years. They're usually a waste of time. Just get the drill bit centered and then go up the sizes until you can get the correct size tap started in the hole
https://flic.kr/p/23xSJFF" rel="nofollow">


Looking at the front of the arch there was a fair bit of corrosion. So I started cutting
https://flic.kr/p/23xSHTi" rel="nofollow">

I ended up with a hole that needed three different bits of metal to fill it
https://flic.kr/p/FhA2EK" rel="nofollow">

First bit in
https://flic.kr/p/22bFUFm" rel="nofollow">

Second bit in. I realised I hadn't made the first bit big enough so I added a bit. I couldn't find a decent pic of this area on the net and I didn't take a pic before I chopped it. I looked in my other beetle but it's so rotten, it's literally coming apart at the seems. In the end I cleaned back the seam sealer on the other side of the car and used that as a reference
https://flic.kr/p/22bFTUm" rel="nofollow">
https://flic.kr/p/FpnYY4" rel="nofollow">
https://flic.kr/p/FpnY8r" rel="nofollow">

Attempting to recreate the factory welds
https://flic.kr/p/22ix8LL" rel="nofollow">

The completed repair. The weld blobs are from the factory so I kept them
https://flic.kr/p/FpnYyX" rel="nofollow">



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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 12 March 2018 at 1:05am
I got stuck in to working on the car without really thinking about what I was doing. So I decide to do a bit of prep work. When I welded up the red '70 the glass ended up like sandpaper with all the grinding flash. I tried to polish the marks out but it was still a mess

Sections of old paddling pool pinned to the window rubbers. I tried gaffer tape but it just wouldn't stay put. The headliner will just have to fend for itself
   https://flic.kr/p/Fpo28e" rel="nofollow">
https://flic.kr/p/254uXh4" rel="nofollow">

At the same time I removed the door trims. Inside the doors looks amazing. Not a spot of rust

Dirty but not rusty
https://flic.kr/p/Fpo1ii" rel="nofollow">
https://flic.kr/p/FpnZR6" rel="nofollow">
https://flic.kr/p/FpnZoc" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: KennyC
Date Posted: 14 March 2018 at 7:39pm
1985 Mexican, 1200cc, in that colour (looks like LA7Y Zinngrau/Pewter Grey) with those wheels and a grey headlining....
That looks like a rare special edition “50 Jahre Kafer” “Jubilee Beetle”
One of 3150 built to commemorate the last Beetle officially sold through the VW dealerships in Europe.
Did you say the chassis sold?? (I saw it on eBay)
These cars came with Golf GTI steering Wheels, Golf GTI style trim on the seats and green tinted glass...
There’s less than 10 in the UK I’m told....
If you’re on FacePest, check out the “50 Jahre Kafer” page
Will be worth more when finished in it’s original spec I’d guess
Have fun in the garage :-)
Ken.
(Lockerbie)


Posted By: 93fxdl
Date Posted: 15 March 2018 at 1:12pm
A good source of info on repairing panels
http://forum.retro-rides.org/thread/70135/panels

All done using basic equipment
Ttfn glenn
http://forum.retro-rides.org/thread/70135/panels" rel="nofollow - tinbashing

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If it ain't broke, fix it till it is. If you can't fix it with a hammer, you've got an electrical problem. Lack of funds is the mother of ingenuity


Posted By: gayle
Date Posted: 15 March 2018 at 1:14pm
Agree on the LA7Y paint code. It's the same as my Scirocco

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Highly medicated for the safety of the masses


Posted By: whamcars
Date Posted: 16 March 2018 at 8:07pm
Originally posted by KennyC

1985 Mexican, 1200cc, in that colour (looks like LA7Y Zinngrau/Pewter Grey) with those wheels and a grey headlining....
That looks like a rare special edition “50 Jahre Kafer” “Jubilee Beetle”
One of 3150 built to commemorate the last Beetle officially sold through the VW dealerships in Europe.
Did you say the chassis sold?? (I saw it on eBay)
These cars came with Golf GTI steering Wheels, Golf GTI style trim on the seats and green tinted glass...
There’s less than 10 in the UK I’m told....
If you’re on FacePest, check out the “50 Jahre Kafer” page
Will be worth more when finished in it’s original spec I’d guess
Have fun in the garage :-)
Ken.
(Lockerbie)


I think you're right. A lot of what is on the "50 Jahre Kafere" page matches what's on the car. Unfortunately the pan is sold and I don't drive LHD cars so it won't be going back to original


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 16 March 2018 at 8:10pm
Originally posted by 93fxdl

A good source of info on repairing panels
http://forum.retro-rides.org/thread/70135/panels

All done using basic equipment
Ttfn glenn
http://forum.retro-rides.org/thread/70135/panels" rel="nofollow - tinbashing


That is a good source. Here's a couple more

A total metal master

https://www.garagejournal.com/forum/showthread.php?t=182565

Inspiration for anyone welding a beetle

https://www.thesamba.com/vw/forum/viewtopic.php?t=629294&postdays=0&postorder=asc&start=0&sid=f4c3cff73dbec11c7ec82b7390f36184


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 28 March 2018 at 5:01pm
I haven't posted for a while. I've been having a nightmare getting my taxi through it's Hackney test. Anyway there has been some progress on the beetle

The next bit to be fixed
https://flic.kr/p/22ix82E" rel="nofollow">

Rot cut away to reveal more rot
https://flic.kr/p/FVuGFa" rel="nofollow">

I won't cut any more out until I'm happy with the fit of the first repair panel
  https://flic.kr/p/FVuAHZ" rel="nofollow">

Ready to fit
https://flic.kr/p/FVuzUK" rel="nofollow">

I had to cut the quarter panel to gain access to the rotten inner panel
https://flic.kr/p/FVuER8" rel="nofollow">
 
spot welds drilled out
https://flic.kr/p/FVuC2F" rel="nofollow">

Inside the quarter was nice and clean
https://flic.kr/p/FVuDhM" rel="nofollow">

Second repair patch made
https://flic.kr/p/FVuyza" rel="nofollow">

Patch number three. This is for the side the running board mounts to
https://flic.kr/p/22PKCAW" rel="nofollow">

It just needs the captive nut for the running board welded on
https://flic.kr/p/22PZrsq" rel="nofollow">

I could see that the jacking point reinforcement was a bit crusty so I cut away part of the heater channel closing plate to gain access
https://flic.kr/p/25zAj5g" rel="nofollow">

The jacking point reinforcemnt is rusty but saveable
https://flic.kr/p/22PKBZL" rel="nofollow">

Saved
https://flic.kr/p/HrL2p5" rel="nofollow">
https://flic.kr/p/22PKBs3" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 03 April 2018 at 7:58pm
Heater channel wire brushed back to shiny metal. The black pitting will get a coat of Aquasteel rust converter
https://flic.kr/p/HDXQYj" rel="nofollow">

When I think I'm ready for primer I wipe down with a clean white cloth. Judging by the colour of this it needs more scrubbing with celly thinners
  https://flic.kr/p/HDXQ17" rel="nofollow">

With everything cleaned and primed I lined the jacking reinforcement up with the holes in the sill
https://flic.kr/p/25J1XQm" rel="nofollow">

Checking the alignment
https://flic.kr/p/HDXP73" rel="nofollow">

Zapped. It took a lot of heat to plug weld this properly
https://flic.kr/p/25J1X5d" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 04 April 2018 at 3:51pm
More
https://flic.kr/p/24qJu8H" rel="nofollow">
https://flic.kr/p/Gaj4Ti" rel="nofollow">

Checking the running board lines up with the new captive nut
https://flic.kr/p/25KED8Q" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 14 April 2018 at 10:03pm
The next piece of the puzzle
https://flic.kr/p/Gvmf1t" rel="nofollow">

Primed
https://flic.kr/p/Gvmeav" rel="nofollow">

The back of this got primed too. It creates a bit of soot when you weld but what else can you do?
https://flic.kr/p/255miMC" rel="nofollow">
https://flic.kr/p/255mi2Q" rel="nofollow">
https://flic.kr/p/255mhzs" rel="nofollow">

Nearly there. Just the bottom of the rear quarter left to weld in
https://flic.kr/p/255mhg1" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 14 April 2018 at 10:26pm
The wing mounting flange on the quarter was a mess. There should be a captive nut where the hole is
https://flic.kr/p/G8K9MP" rel="nofollow">

Repair piece
https://flic.kr/p/2333f57" rel="nofollow">

Now for the tricky bit
https://flic.kr/p/2333ex5" rel="nofollow">
https://flic.kr/p/25J1Za5" rel="nofollow">



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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 25 April 2018 at 4:35pm
I clamped the panel in place and marked where I thought the captive nut should go
https://flic.kr/p/26t9dzj" rel="nofollow">

And then bolted the wing on
https://flic.kr/p/26wxZNR" rel="nofollow">

Captive nut ready to be welded in
https://flic.kr/p/26wxZ2v" rel="nofollow">
https://flic.kr/p/26t9cCQ" rel="nofollow">
https://flic.kr/p/26wxYbT" rel="nofollow">

I clamped the panel back in and test fitted a bolt. It only went in about half way and stopped. I had a mini panic as I'd seen repair panels with a stud fixing for the bottom wing mounting. But they were for older cars. I was sure later cars used a captive nut and bolt. A quick internet search showed I was right and a wee bit of clearancing had the bolt going all the way in
https://flic.kr/p/23LWKwC" rel="nofollow">

So with that all looking good it was time to weld it in. I got about half a dozen tacks done and ran out of gas




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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 25 April 2018 at 4:51pm
It's less than two months 'til my wedding. There's no way I'm going to finish the car in time.

On to plan B
https://flic.kr/p/26t9b5Q" rel="nofollow">

I started by replacing the exhaust. I bought a replacement from Heritage. The fit wasn't brilliant. My tail pipes ended up a bit wonky and needed tweaking to get them lined up with the bumper (even now they don't sit quite right). Time will tell how good it is
https://flic.kr/p/23YuKUb" rel="nofollow">

The old exhaust was on the car when I got it 20 years ago
https://flic.kr/p/26wxWPp" rel="nofollow">

The heavy duty stainless tail pipes from Heritage polished up well. These are 20 years old and well worth the money
https://flic.kr/p/25a8adv" rel="nofollow">




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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 01 May 2018 at 4:30pm

I tried jacking the low tailpipe up while I pushed the high one down. That didn't work. Then I had an idea. This way I could lever up and down at the same time
https://flic.kr/p/H5kHvn" rel="nofollow">

Better
https://flic.kr/p/23YuJYd" rel="nofollow">

Time to fit the upright wings from the mexi bug. It was nice to finally see the back of the sloping wings and Rossi headlights the car came with
https://flic.kr/p/25mL6bn" rel="nofollow">

The lower front holes on both sides didn't line up with the bolt holes on the body. Strange. I'm pretty sure the wings are original VW Mexico
https://flic.kr/p/25CRkNm" rel="nofollow">

The headlight mounting tab on the pass side wing had rotted away
https://flic.kr/p/25CRj7A" rel="nofollow">

The drivers side one was good so I made a copy
https://flic.kr/p/25mL5DR" rel="nofollow">
https://flic.kr/p/23YuGSE" rel="nofollow">
https://flic.kr/p/26J9ptH" rel="nofollow">

To try and keep it looking factory I plug welded the tab from below
https://flic.kr/p/26J9owH" rel="nofollow">
https://flic.kr/p/26J9nZv" rel="nofollow">

It looks like it's going to work
https://flic.kr/p/JAFymJ" rel="nofollow">

The screw head lines up with the rust stain on the paintwork. Success!
https://flic.kr/p/26J9nwg" rel="nofollow">





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Wham Cars Retro Workshop


Posted By: TheDocmeister
Date Posted: 14 May 2018 at 10:32pm
Some lovely fab work going on there Sir!

 Handshake


Posted By: whamcars
Date Posted: 24 May 2018 at 5:05pm

Originally posted by TheDocmeister

Some lovely fab work going on there Sir!

 Handshake


Cheers Smile

I've got too many bumper holes and not enough horn grill holes
https://flic.kr/p/26J9n2t" rel="nofollow">

No need for a cardboard template here. I marked straight onto some sheet steel. I also marked where the horn grill will go
https://flic.kr/p/27pTA9S" rel="nofollow">

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I'd been using the finger grinder at max power with 40 grit belts and I kept breaking through on either side of the weld. On this I used 80 grit followed by 120 grit with the power turned right down. This gave much better results
https://flic.kr/p/27pTz7b" rel="nofollow">

Even so, with a bright light held behind the wing There were two pin holes but I managed to weld them without a problem
https://flic.kr/p/27pTyBd" rel="nofollow">

With everything smoothed off there was a slight bulging along the length of the filler patch. After about 100 goes at heating and quenching it I was getting nowhere. I got on the web and found a discussion on The HAMB. One recommendation was ; heating a small spot at a time and then beating the spot with a wooden mallet/slapper with a block of wood behind the wing and then cooling with compressed air. This worked fine but It's a really slow process
https://flic.kr/p/27pTy5m" rel="nofollow">
https://flic.kr/p/27pTxBY" rel="nofollow">

I cut the horn grill hole out of a scrap wing and used it as a template to mark the good wings
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To me it looks a bit wonky but the bars on the horn grill are parallel with the straight edge of the wing so it must be right. Right?
https://flic.kr/p/28e1sZf" rel="nofollow">
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Wham Cars Retro Workshop


Posted By: bawheid
Date Posted: 06 June 2018 at 7:32pm
Just saw the latest on fb. Looks great, very impressed indeed!


Posted By: whamcars
Date Posted: 17 June 2018 at 9:01pm
Originally posted by bawheid

Just saw the latest on fb. Looks great, very impressed indeed!


Ta

Once I had both wings fitted I could see that the drivers side grill hole was way off. I had to weld a piece in so I could move the hole
https://flic.kr/p/28ihsy8" rel="nofollow">

With all the welding done I got on with the filling and sanding. This seemed to go on forever. Once it was done my cleaning crew got to work. You can tell the wee one is thrilled
https://flic.kr/p/LaqTEY" rel="nofollow">

I decided to try Rustoleum paint. I sent my filler flap to Avenue Coatings and they did a great job of matching the colour. Although it did take them four weeks. After three coats the paint was patchy and you could see the colour was really uneven. I had thinned the paint too much. So for the next two coats I added a lot less white spirit. That made the difference and it started to look a lot better. But at sixteen hours between coats I didn't have time to do any more
https://flic.kr/p/26VHHDH" rel="nofollow">
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https://flic.kr/p/25xiaKA" rel="nofollow">


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Wham Cars Retro Workshop


Posted By: whamcars
Date Posted: 17 June 2018 at 9:41pm


The car had no front indicators so I decided to put them in the headlight bowls. I had a box of LEDs that I bought to light the rear floor area of my taxi after endless complaints from customers not being able to see where they were putting their feet getting in and out of the taxi. This then led to complaints about the lights being too bright. So I knew they would make good indicators. The only other thing I needed was a new flasher unit to let the LEDs work with the old style bulbs in the rear lights. I got one from Classic Car Leds

I started by doing a test fit on an old headlight
https://flic.kr/p/28ihX6t" rel="nofollow">
https://flic.kr/p/28ihWE8" rel="nofollow">
https://flic.kr/p/28ihW98" rel="nofollow">

I found a clear, orange, model paint at the local HobbyCraft. So I lightly sanded the LEDs and then applied three coats of paint
  https://flic.kr/p/26VHGNz" rel="nofollow">
https://flic.kr/p/JDqd5n" rel="nofollow">

The wiring on my headlights had always been a bit messy but looking in my donor T4 I found the correct headlight connectors with enough cable on them to rewire the headlights
https://flic.kr/p/28ihVBg" rel="nofollow">

My good mate Ivan came over from the USA for the wedding. We always used to work on cars together (He's building a twin turbo V8 Ford Focus back in America). So he was happy to come over and help out. With the help of his son Connor we gave the wheels a spruce up with some satin black paint
https://flic.kr/p/28ihTLx" rel="nofollow">

With all the lights working and the wheels painted I was getting close to finishing my job list. I needed to turn the car round. So I jumped in, started it up and pushed the clutch down. At about halfway down the clutch pedal went soft and I couldn't get any gears. The clutch cable snapped! Getting the old one out was easy but the bowden tube was seized solid and took a good few hours to remove so I could feed the new cable in
https://flic.kr/p/JDqfhD" rel="nofollow">




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Wham Cars Retro Workshop


Posted By: gayle
Date Posted: 17 June 2018 at 10:17pm
Did you spray the rustoleum on or did you use the roller method?

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Highly medicated for the safety of the masses


Posted By: whamcars
Date Posted: 17 June 2018 at 10:19pm
With the clutch cable fitted I tried the pedal. It didn't feel right and no amount of adjusting would make it go into gear. Somehow, while I was fitting the clutch cable I had managed to dislodge the clutch release bearing. This was on the Wednesday before my wedding on Saturday. I had put so much work into the car I'd had enough. So I went and told Jade my OH the bad news. "No way" she said. "you're finishing it." So Ivan came over and we started to take the engine out
https://flic.kr/p/JDqeq8" rel="nofollow">

With the bearing out we couldn't figure out how the retaining clips fitted. A quick google showed us the way. But the Youtube video we watched showed the spring clips fitting much deeper into the bearing. I suspected that I had a missmatch of parts. So I drilled the bearing to let the clips sit further in
https://flic.kr/p/JDqe3e" rel="nofollow">
https://flic.kr/p/JDqdCX" rel="nofollow">

On Thursday morning Ivan was back to help me refit the engine. He's a trooper and I can't thank him enough (he was on his holidays)

Wedding day
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https://flic.kr/p/27dck3s" rel="nofollow">
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https://flic.kr/p/LaKMCu" rel="nofollow">

All that's left is to say thanks to Simon, Gary, Alan, Iain, Connor and Ivan for all their help


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Wham Cars Retro Workshop


Posted By: 93fxdl
Date Posted: 18 June 2018 at 2:24am
Congratulations on everything
Ttfn Glenn

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If it ain't broke, fix it till it is. If you can't fix it with a hammer, you've got an electrical problem. Lack of funds is the mother of ingenuity


Posted By: whamcars
Date Posted: 19 June 2018 at 3:16pm
Originally posted by gayle

Did you spray the rustoleum on or did you use the roller method?


I rollered it on. It was quite orange peely but this sank down a lot after a week. It still needs flatting down but it’ll do for now

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Wham Cars Retro Workshop


Posted By: KennyC
Date Posted: 19 June 2018 at 9:12pm
Well done in making the deadline....!
I like your cameraman’s braces/camera strap combo making a “VW” sign on his back!!!
(even reads “VW” when doing a handstand!!)



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