The Cal-look Lounge

Hi and welcome to my thread. This has taken me a long time to get together so stick with me as I will tell you the whole story of the car from when I first bought it over twenty years ago (christ has it been that long!). The car and I have lots of history, its been a big part of my life and its back now for good. All will be revealed.  Its a UK RHD 1300 deluxe and is originally from Dorset area. I recently met the bloke who I bought it off all those years ago and he told me that he had spotted the car while on holiday in someone`s back garden and he remembers making an offer on the car there and then. He had to return to North Wales and then go back down on the train with his wife to pick it up only to remember that there was no windscreen. He drove it back all that way with no screen! They are still married too  ;D
      My first bug was a white 1303 which I ended up restoring to show condition way back in 1997 and while that was off the road I needed a run around. I knew about the 64 as it was local to me, I always liked it, and one day when I was passing, there was a for sale sign on the window, £600 later and it was mine.  Happy days followed, I did many many miles in it, loads of memories, it was about the time when I first started going to the big shows like bug jam and vw action and the beetle bash.  It was at Beetle Bash 96 when I first had my taste of serious Cal Lookers, the Americans turned up , the sight of those cars left an indelible mark in my brain and from then on I wanted to build a car like theirs.  
      Fast forward a couple of years , my white 1303 was finished and although it turned out nice, I never took it to a show, not one. It was featured in the now defunct Total VW magazine but that was all. I never drove it for fear of a stone chip etc.  This was my first resto, I had no training in anything and I did 90% of the work.
(http://i98.photobucket.com/albums/l242/vwhelmot/Bug%20jam/454D5B04-56B6-4EE5-A6AE-383FBB04F5F0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Bug%20jam/454D5B04-56B6-4EE5-A6AE-383FBB04F5F0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Bug%20jam/45AC69B1-32A8-42E0-A62F-C05092F8AD42.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Bug%20jam/45AC69B1-32A8-42E0-A62F-C05092F8AD42.jpg.html)

These are a few shots of Fubar when I used to just have it as my daily driver, through the coldest of salt strewn winters and the warmest of summers.
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/02D18560-B527-4959-96EF-94FE40D853E3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/02D18560-B527-4959-96EF-94FE40D853E3.jpg.html)

It really was a fun car, it went through a few various engine combos, from a 1200 to a 1600 and then I built a 1641 and put two of the pistons in the wrong way around so the offset was wrong. It used to tick a bit but never failed!  ;D
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/48C0F321-BF0E-407C-8DDA-93546C92B294.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/48C0F321-BF0E-407C-8DDA-93546C92B294.jpg.html)

Plenty of updates to follow

So after three or four years of use, the usual signs of serious decay were starting to show. The previous owner had 'restored' the car , and remember this is from a time before the internet and before there was a source of proper quality fit repair panels. Veng and such like were only available off the shelf and to be honest , they were crap. Rear quarter repair panels were a particular favourite and door pillar repair were also awful.  These panels had been let in, so door fitment was shite, it used to leak too. So after a few winters, the car was suffering, soggy carpets and steamy windows :lol: I knew it was a matter of time before I had to do something about it.
    I started the first restoration while I still owned my 03 and was lucky enough in that I was renting a double garage so I had the space to do the repairs. This was still before the internet and quality panels were available to me, so I had to make do with incorrect shape everything from heater channels to bumper mounts. I used to finish work, head on up to my garage , do a couple of hours and then cycle home as I was now without a car.
  The first build wasn't really intended to be a show build and the quality showed, It never was anywhere near the standard it should have been, although I knew it had to look right.  Like so many others, Mr Seume`s bible was out and I couldn't put it down, I love gassers and the whole seventies vibe and style of drag race cars so my car was sort of styled in that manor. Stripped out interior, diamond pattern headliner, IDA equipped motor, lightweight race rims and a tiny bit of flake added to jazz it up. I painted it myself in my fathers garage which I decked out with plastic to keep the dust down,  I used to wet the floor and keep the door open , but those cellulose fumes used to really kick in! It took me a year to paint it because I had a load of trouble with my paint supplier giving me various shades of seablau so when it came to cutting the paint down I used to cut into a different shade of blue and create swirl patches all over. It was bloody awful.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B8826467-504A-4565-899D-1CA4830B53DB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B8826467-504A-4565-899D-1CA4830B53DB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F5A7083F-0A55-481F-8E14-C5E0A662E5B9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F5A7083F-0A55-481F-8E14-C5E0A662E5B9.jpg.html)

Priming the deck lid on the floor like all good show cars should be painted!
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/883BD152-8FEA-4A5A-B6DA-7646F3C2FE60.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/883BD152-8FEA-4A5A-B6DA-7646F3C2FE60.jpg.html)

The engine has a bit of history too. I`m not too sure about the finer details but basically I bought it from Luke at Terry`s Beetle Services as a complete 2110 motor. It had been removed from another looker, a 67 owned by Riki Ryat but was originally a 2007cc. There had been issues with flat cams etc but that's all I know. Our very own Keith Seume had something to do with a rebuild, its still got his name stamped on the case but I don't know much about why. Anyway, its been a good motor, its got some nice parts although even today I don't know who made the 82mm crank but I`ve been told its a Berg wedgemated one and I hope it is. Its got Denham 040 42x37.5 heads, eagle rods and an FK8 cam with cb rockers, a pair of Italian IDAs on Skat trak manifolds.  The motor looked scruffy as hell when I picked it up in my mates old Passat in London, back up the motorway in a twin engined family estate car ;)
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/73E813C7-F602-46A8-8003-ADA29A814A33.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/73E813C7-F602-46A8-8003-ADA29A814A33.jpg.html)

So after many hours making the scat tinware fit properly by cutting /welding etc  I had a motor which looked nice but not before it had been for a check up at John Maher Racing when he was still located in Manchester. Lets just say he had it a while, a long while. It was leak tested and an inlet valve was recut and put on the dyno. I was a bit disappointed when it made about 150bhp as I was expecting more but hey ho, it wasn't too important then.
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/34DC8527-D0C9-451E-9BED-2BB3D8E82441.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/34DC8527-D0C9-451E-9BED-2BB3D8E82441.jpg.html)
 I bought various bits for it , the ceramic coated exhaust, berg equaliser , berg linkage and a breather tower bought from Bernie and it looked nice with its black metalflaked paint.
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/79F2242B-B61B-4BE3-9EB4-EE39FDF0B893.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/79F2242B-B61B-4BE3-9EB4-EE39FDF0B893.jpg.html)

That was the engine I originally built for Riki Riyat's '67 – hence the name stamped on it. Not sure if it had been apart since, or not! That was a long time ago – probably 1998/9, if not earlier. It wasn't built as anything 'hot', more a torquey street motor, so 150bhp (a bit conservative, I suspect) was probably not far off. People get obsessed with high-bhp numbers but drivability was and usually is more important, especially as Riki didn't express any desire to go racing.

Here you go! 1999... Looks like I redid the engine as a 2110 using parts supplied. Original engine had a flat cam, I do remember that.
[attachment=1]

Bloody Hell  :o  Cheers Keith,    it was taken apart by Terry to install the FK8 as it had a different cam if I remember. It hasn't been apart since then. I plan to refresh it soon.

I remember reading the article on you 1303; I was writing the odd article for TotalVW at the time (and living in Dorset).  I remember thinking it was the best looking 1303 I'd seen anywhere in print since Dumper.  I still think it looks great.  I'm guessing you don't still have it?

Carry on with the story....!

Richard

Cheers Rich. You are right in thinking that I don't own it anymore. In fact it doesn't exist anymore as it was destroyed in a fire after I sold it. Sad really, it was a peach and full of nos and genuine parts as I worked opposite a now defunct VW dealership. I was mates with the lads that worked there and had access to the microphisch and store rooms. It would have done well on the show scene as it was but it never made an appearance as it was.
(http://i98.photobucket.com/albums/l242/vwhelmot/6F5E9760-5DC9-4454-9B05-85B6F75A5AB5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/6F5E9760-5DC9-4454-9B05-85B6F75A5AB5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/6FDE6D06-9EED-420C-AAEC-1DB38449EB1D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/6FDE6D06-9EED-420C-AAEC-1DB38449EB1D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/4A931BC9-D2F9-4A65-B292-F40ABC77D581.jpg) (http://s98.photobucket.com/user/vwhelmot/media/4A931BC9-D2F9-4A65-B292-F40ABC77D581.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/A582BA5B-A776-4BB0-B4AE-0C31997CE2D4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/A582BA5B-A776-4BB0-B4AE-0C31997CE2D4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CBA4F133-611B-40DD-B1FC-596D3004F52A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CBA4F133-611B-40DD-B1FC-596D3004F52A.jpg.html)

 This is how the car turned out after I completed the first resto, at the time repro BRMs were getting popular and I bought a set of mws ones which for the price were ok, and only available in one width. After stretching a set of zx 135s on the front , the rim lips were sticking out half a mile so I sent them off to get narrowed by Martin Taylor. Happy days, but it didn't really stick out from the crowd and I had seen Bernie Newburys black 67 with a couple of gold ercos and I thought maybe that could work. With no photoshop to see if it would work I just used a gold pen in my photo album! Old School :)
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/61BBD763-7D0D-4A1D-A459-C7D53F515348.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/61BBD763-7D0D-4A1D-A459-C7D53F515348.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/58B911EC-78C7-4638-81B1-C304DC5171A6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/58B911EC-78C7-4638-81B1-C304DC5171A6.jpg.html)

It made its debut at the Volksworld Show in 2003 and was parked in front of Ivans 67. It went down well and I scooped best engine which was nice but it didn't stand out with the copy brms.  A call was made to Paul at vw speedshop and he supplied me with a set of race weight ercos which I had him send direct to Martin Taylor so he could anodise them. He said he loved that job and was a breeze to do ( I`m a lying bastard) but when they arrived and I fitted them I thought they looked great.   The interior was pretty basic, I had a custom trimmed standard size headliner in alcantara fitted and a pair of glass buckets with alcantara covers, a set of autometer gauges and a flat 4 wheel.  I took it to bug jam that same year and it scooped BOS , I was a happy boy. I took it down the strip that weekend and netted a 13.2 which wasn't bad considering it was only my third run.
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BAAC2A64-A958-42A1-AA87-D54250AC229D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BAAC2A64-A958-42A1-AA87-D54250AC229D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F67223FC-86AE-433C-9AA4-8890663B634F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F67223FC-86AE-433C-9AA4-8890663B634F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9B9A1F5B-93D9-429F-B549-C64EFE7EA4B5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9B9A1F5B-93D9-429F-B549-C64EFE7EA4B5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1427F5A2-C7C9-498E-9CCD-C57BECFD5AAC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1427F5A2-C7C9-498E-9CCD-C57BECFD5AAC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0D56D4A8-2AC9-4344-BF91-02584EEB241B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0D56D4A8-2AC9-4344-BF91-02584EEB241B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/678B3E9D-9DBB-47BE-AAFE-32C20353FF48.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/678B3E9D-9DBB-47BE-AAFE-32C20353FF48.jpg.html)

It was at Bug Jam that year that Ivan approached me to see if I wanted a feature in Volksworld, and having read the mag since the start I was very happy to do so. It was a nice feature, made the front cover too. I suppose its crowning glory was to get it on a plinth at the Volksworld show in 2004, situated right in the main hall, next to some amazing cars, Brian Burrows Squarerra wasn't far away .

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A76D892C-EB7E-424F-91A0-9AB361E6CFEA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A76D892C-EB7E-424F-91A0-9AB361E6CFEA.jpg.html)

Notice in the background my old 1303 at the same show

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A7F70BB0-7E59-4ECC-B2BF-0499C5FF8A07.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A7F70BB0-7E59-4ECC-B2BF-0499C5FF8A07.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/184A18DE-A901-4057-985C-CF258470EC3B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/184A18DE-A901-4057-985C-CF258470EC3B.jpg.html)

It was also featured in Street Vw , a Japanese mag
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CFAEB092-55F4-490C-8986-8A9A400BA1BB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CFAEB092-55F4-490C-8986-8A9A400BA1BB.jpg.html)

So, after about three years of trailering it around all the shows, I got a bit bored to be honest, I had hardly driven the car on the road, having done only about 20 miles or so, and I had bought a 56 oval to play with so that was taking up my time. The 64 was just sitting in my garage doing nothing so I put it up for sale (which I would come to regret). At first I was optermistic with my asking price but I was in no rush to sell, so it took a while but it was sold to a bloke from Manchester for a fraction of what I spent on it, but I hadn't rebuilt it with the thought of making a profit. It was sold with the brms and I kept the ercos which I sold separately and ended up being fitted to John Walkets  blue looker. I think he had a load of piss taking 'Lyndon ' jokes come his way!     
   Anyway, it wasn't long before it found a new owner it being sold shortly after to Ian (48ida on here) and he got in touch with me for any build pics etc.  It wasn't long before he sent me some distressing pics. I will let the pics do the talking.


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DF058C64-C9E0-4E99-BF57-7A868FA79EDE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DF058C64-C9E0-4E99-BF57-7A868FA79EDE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/19CA9FDF-E018-4D22-A143-0B458398B3B9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/19CA9FDF-E018-4D22-A143-0B458398B3B9.jpg.html)

I was gutted to say the least, it hadn't been long since I found out that my old 1303 had been destroyed in a garage fire too.

After its disagreement with a Nissan Micra   :'(, it was taken up to Steve Gilberts One on One restorations for repairs, and if you know of Steve,  he does proper work, his Fridolin is one of my all time favourites, just for the detail alone, so I was happy that my old bug would return. Ian sent me some repair pics and the damage was extensive but repairable. A full front nearside quarter was needed.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/05067107-834E-4D12-830C-7E7A2B957680.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/05067107-834E-4D12-830C-7E7A2B957680.jpg.html)

  I think when Ian got the car back , he had fallen out of love with it and it was placed in the for sale section on various forums, wearing a set of Fuch alloys and a set of standard seats and different door cards etc , which I wasn't a fan of. It didn't look right to me on those wheels but everyone has different tastes. It sold pretty quick and then I lost touch with it for a while before a pic of it popped up on the net, now having changed owners again and living in Kent. Again it changed hands, each time something had changed, interior had been altered again with a set of Beard seats and aluminium panelling , the exhaust cut outs had been filled, a fire extinguisher had been screwed to the tunnel a set of centreline five spokes had been fitted too. All these differences but I felt it was still my car if you know what I mean.  
  It eventually got sold again and made its way up North in the hands of Mark Reynolds , remember , eight years had passed since I had sold it so I was expecting it to be in a bit of a state but when another pic turned up of the car in Europe wearing a cool set of rims and a nicely trimmed interior I was very pleased.  I contacted Mark through the lounge just to ask him that if he ever wanted to sell it to give me first refusal. To be honest I wasn't expecting a reply and didn't even have any cash to spend, so when he replied with a " come and have a look at it " I couldn't refuse!  Little over a month later, I was loading up BFJ999B on my trailer , I couldn't believe I had it back. This time its coming home for good.

I remember it at Deva one year - I'd brought my race car up and you'd got this. My dad and I looked it over several times, kept on spotting different things! I remember when Rob from Prowagen had it too but hadn't realised it was the same car, although i knew the plate was familiar!

When I first saw that car with the gold anodised rims I wanted to do my fastback the exact same colorsheme.
Maybe not original but better well copied then badly designed.
 :)

Anyone in their right mind would have got the car back home and used it as it was, a nice Cal look driver to have fun with on the weekends and maybe to drive  to a few shows etc. It was July last year when it returned so there was plenty of summer left to do just that. Not me, it was a case of I`ve got to strip it to see what the other owners had done to it. I didn't drive it far, only about 20 miles or so before I reversed it into the workshop for a full investigation. 
   I`ve been wanting to do a full show restoration for quite some time, in the past eight years or so I`ve been heavily into fast bikes mainly Hondas and even did a resto on a lovely little v4 which was featured in a bike mag. Anyway, I have wanted to challenge myself to build the car that I should have done in the first place, yes it would have been a lot easier to start with something more correct ie , a Californian or Swedish base car but I felt that the only car to build was BFJ. Now, don`t get me wrong , I wasn't sold a dud, it was a solid base, but and here`s the big but, it wasn't correct in any shape or form.  Almost the whole lower 6" of the shell was incorrect  pressings and panels of which you will see later.  Its been a pain in the arse trying to source good useable original 64 vw metal, from cross members to arches, but I want everything to be 100% right.  The theme of this build is clean, no seam sealer, just nice smooth body seams, exposed and not hidden with layers of filler and gunk.  I have the basic tools, and hve had to invest in a few new ones along the way, but anyone can do what I`ve done, I`m just lucky that I work in a Tool Hire and have the space to be able to do the work.  Commitment and being able to stick to a plan also helps, I`ve put my life on hold for the past year, every night I`ve been working on the shell for approx three hours , weekends I will do more but not every weekend as it can get a bit much sometimes.
  So here we go.  Up on the lift for the first time and I was a bit  :'( I don't know what I was expecting, it had been used after all  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/16735D08-7C89-45EC-8C6A-527784FE3588.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/16735D08-7C89-45EC-8C6A-527784FE3588.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D3347A6F-31B2-4BEA-840B-ABAC88027D18.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D3347A6F-31B2-4BEA-840B-ABAC88027D18.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4C71EC53-224A-489B-9830-69A17B406D64.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4C71EC53-224A-489B-9830-69A17B406D64.jpg.html)

There was some real suspect wiring going on. When ever I see earth coloured tape being used normally spells danger!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/37C64042-40C1-4DE7-B251-EF6B5D5B70AC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/37C64042-40C1-4DE7-B251-EF6B5D5B70AC.jpg.html)

This is how it looked by the way when I got it back. Looked nice.

(http://i98.photobucket.com/albums/l242/vwhelmot/600FF44B-6A7E-4641-BF68-2D7D8D5264B9_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/600FF44B-6A7E-4641-BF68-2D7D8D5264B9_1.jpg.html)

This was when the previous owner had it.

(http://i98.photobucket.com/albums/l242/vwhelmot/B778EEC8-D77D-46E0-B69D-4613DA6EC90C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/B778EEC8-D77D-46E0-B69D-4613DA6EC90C.jpg.html)

It wasn't long before the engine was out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/228F1DA2-98EC-4973-90B3-525BD7CE042A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/228F1DA2-98EC-4973-90B3-525BD7CE042A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/438E7983-052B-46F8-A44B-388F87D5A143.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/438E7983-052B-46F8-A44B-388F87D5A143.jpg.html)

It had been marking its territory!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4913CBA4-8431-4AF9-8AE3-E182D444F784.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4913CBA4-8431-4AF9-8AE3-E182D444F784.jpg.html)

Hey lyndon.

I remember being next to you in the line up at volksworld 2003, was my debut too haha.
really glad you got it back mate, and can't wait to have a look around it when its done.

Stoo.

Hi Stoo . I remember it well mate. Do you still have yours?

The interior looked like it had been hit by a Christmas tree.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/36B4A06C-FADB-4BE3-8AA5-094591DED7A5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/36B4A06C-FADB-4BE3-8AA5-094591DED7A5.jpg.html)

Luckily the sound deadening was easy to remove

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/05F2CFF8-1DF6-4F94-B555-E33DEF9C3693.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/05F2CFF8-1DF6-4F94-B555-E33DEF9C3693.jpg.html)

Sticky number plate found a new home

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0C5D8ABC-A08C-4F1B-BD06-684E665775BE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0C5D8ABC-A08C-4F1B-BD06-684E665775BE.jpg.html)

Body off

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8091DA76-3927-426D-857B-458123116FF1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8091DA76-3927-426D-857B-458123116FF1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A89941FC-EDF0-46A1-A8FD-1FA14FD1B62C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A89941FC-EDF0-46A1-A8FD-1FA14FD1B62C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8D560988-D9A6-4DF7-9883-5CBF86A7ADF2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8D560988-D9A6-4DF7-9883-5CBF86A7ADF2.jpg.html)

Cheeky surprise. No wonder it drove like shite  :o

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/54F456AC-CCD6-4A64-AD78-AB06E1C7B64E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/54F456AC-CCD6-4A64-AD78-AB06E1C7B64E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E8A9F4EF-F601-4D34-AC8A-3F5E5641FD17_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E8A9F4EF-F601-4D34-AC8A-3F5E5641FD17_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B632A1E3-5B4A-48B3-AB54-E5B481367017_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B632A1E3-5B4A-48B3-AB54-E5B481367017_1.jpg.html)

The only place I can use that is out of the way is high up on a mezzanine floor, so I had to fork lift the shell really high to get it over the railings. My arse was puckering up at that moment.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A5F361CF-CF31-4BB2-8063-909217FB24A4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A5F361CF-CF31-4BB2-8063-909217FB24A4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/41C3C25B-72B6-458C-B05B-71AD77C941D0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/41C3C25B-72B6-458C-B05B-71AD77C941D0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BF9A0CDE-E909-4936-812F-692AA1FEFC73.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BF9A0CDE-E909-4936-812F-692AA1FEFC73.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5BE9CCDA-7A1B-498F-B48D-C5FB2A283A54.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5BE9CCDA-7A1B-498F-B48D-C5FB2A283A54.jpg.html)

The first serious work was done on the chassis. The pans were shot , they were only the cheap shit thin ones and had split along the seat runners too, so they were cut off straight away.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/69F6BAF0-CC53-49E6-8766-F6B7DF29F7D9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/69F6BAF0-CC53-49E6-8766-F6B7DF29F7D9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3168B50C-ED78-4BE5-9606-154F924B0893.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3168B50C-ED78-4BE5-9606-154F924B0893.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E556328-46CD-417C-B987-64D7768341FC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E556328-46CD-417C-B987-64D7768341FC.jpg.html)

The frame head was in good order with no holes as I had blasted that the first time around and had protected it with plenty of red lead

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A660AA95-72E9-459D-92B9-7A7504BC6419.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A660AA95-72E9-459D-92B9-7A7504BC6419.jpg.html)

First bit of welding was to weld up the holes for the rear heater outlet cables and then the holes on the tunnel for the fire extinguisher etc

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1546451F-C6AC-4CDA-8712-62576A3E9A9A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1546451F-C6AC-4CDA-8712-62576A3E9A9A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7A89A812-3D09-4868-BF4B-E5E676CA08F2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7A89A812-3D09-4868-BF4B-E5E676CA08F2.jpg.html)

Then I blasted it myself. The perks of running a tool hire  ;)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EB4366A6-C5E5-468F-B60D-23ACB52E6907.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EB4366A6-C5E5-468F-B60D-23ACB52E6907.jpg.html)

Notice my quality Stevie Wonder welding for the intermediate mount  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EB4366A6-C5E5-468F-B60D-23ACB52E6907.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EB4366A6-C5E5-468F-B60D-23ACB52E6907.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7F9FF0B3-6E8C-45DF-8A4C-6E463D435C92.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7F9FF0B3-6E8C-45DF-8A4C-6E463D435C92.jpg.html)

Etch primed and a few coats of normal primer

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9FF9253C-CE97-4749-A1DB-0FC7623B737B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9FF9253C-CE97-4749-A1DB-0FC7623B737B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C6374554-F055-4F25-A274-4F1DD99B9BB5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C6374554-F055-4F25-A274-4F1DD99B9BB5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1D44C7C3-B228-4B32-A45E-601961AF308C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1D44C7C3-B228-4B32-A45E-601961AF308C.jpg.html)

Quality bit of VW welding, I think Helmut was having a shit day.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3F42710C-0DC7-436E-9A2E-B67ACD88727C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3F42710C-0DC7-436E-9A2E-B67ACD88727C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8CE38C0A-DF20-4243-A498-369EA5D44E6E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8CE38C0A-DF20-4243-A498-369EA5D44E6E.jpg.html)

The pans I have are WW ones (I think) and they needed modifying to remove the recesses for the LHD pedals , so I cut a section out and let in some fresh steel to make it flat.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D0C3C36C-007D-403C-B42E-D8E13E87D1CD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D0C3C36C-007D-403C-B42E-D8E13E87D1CD.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A7E0E1D4-BE86-4DD1-8896-94FE7D441459.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A7E0E1D4-BE86-4DD1-8896-94FE7D441459.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/120CE37D-30CA-4CDA-8FC6-49B0BB529177.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/120CE37D-30CA-4CDA-8FC6-49B0BB529177.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A7E0E1D4-BE86-4DD1-8896-94FE7D441459.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A7E0E1D4-BE86-4DD1-8896-94FE7D441459.jpg.html)

Plenty of trial fitting before welding them in
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/61A3FB28-8FFA-4875-B964-B81C6BB843A7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/61A3FB28-8FFA-4875-B964-B81C6BB843A7.jpg.html)

Looking good buddy. you seem to be pushing on with it now.

Yeah still got mine, and have been thinking about doing the same recently, could do with a re-detail....all those days racing around the streets are starting to show...!

WOW!

This thread went from good to excellent! Very nice cars! I remember the VolksWorld presentation really well and read it over and over again. It is so nice to learn that you have found your car again and is doing proper work on it once more.

Really looking forward to your updates. Please keep them coming!

Best rgs
BeetleBug

Cheers, these pics were taken from a year ago and a lot has been done since, so updates are good for now.

So the body was completely stripped and was solid all over but as everyone knows bare metal is the only way forward. The shell had so many coats of paint , I had splashed something like 25 litres of cellulose on it (remember I had problems with batches) and Mr Gilberts had painted over it with 2 pack. 2 pack paint is a bastard to blast off, its so hard it takes huge amounts of crushed glass to cut though. I had the bright idea of chemically stripping the main areas first with nitromors , the roof, quarters etc . It would then be easier to blast afterwards. Seam sealer is also a pain in the arse to remove as the glass just bounces off it so that has to be removed by hand too. Now here comes lesson number 1. Do not use a flame gas torch to melt seam sealer while the nitromors is doing its thing!!!    Mr stupid here managed to set fire to the shell inside my work. The flame shot up the rear quarter and in a second the whole roof was blazing away, six foot flames. I`m so lucky that there was an extinguisher close upstairs and managed to put it out before any damage. I could here the roof panels of the building starting to creak and sizzle too.  Proper scary shit!!

before the fire

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AA6C1E3D-8B72-4AD4-AE17-754F8682E50B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AA6C1E3D-8B72-4AD4-AE17-754F8682E50B.jpg.html)

just after, notice the burn on the roof of the building

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2E5131DE-28A9-4845-92A5-C73DADE9A6E8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2E5131DE-28A9-4845-92A5-C73DADE9A6E8.jpg.html)

Filled the whole place with corrosive powder. Nice.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5265E093-5C4F-4CE1-9311-F212896AEE2D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5265E093-5C4F-4CE1-9311-F212896AEE2D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2E9BE79A-FCB4-4FF9-A401-E04E78A2328C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2E9BE79A-FCB4-4FF9-A401-E04E78A2328C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BBB0EFB1-B86D-464B-8D75-F578ACC924B5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BBB0EFB1-B86D-464B-8D75-F578ACC924B5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D25A9500-633F-49AB-A6F1-AB1B217D5297.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D25A9500-633F-49AB-A6F1-AB1B217D5297.jpg.html)

So after the big clean up which took hours and hours, the fork lift was put to use again to take the shell to the corner of the yard so I could blast it.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/01863799-76AD-445B-ACD6-76F12196F9EA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/01863799-76AD-445B-ACD6-76F12196F9EA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D160D6CD-A0D7-479E-ADB1-3DC557CDB8DF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D160D6CD-A0D7-479E-ADB1-3DC557CDB8DF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/416E47FF-44AA-47AD-B887-716B4D885379.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/416E47FF-44AA-47AD-B887-716B4D885379.jpg.html)

A whole day and a half later I had this. Not a nice job but well worth it!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E5062BE6-C01B-4424-8A06-31639390BC02.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E5062BE6-C01B-4424-8A06-31639390BC02.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/97DB2045-4CF2-4D08-B48C-F7850018A4CA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/97DB2045-4CF2-4D08-B48C-F7850018A4CA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4BB26810-0AAE-4635-9D0B-C6DB7FD546D5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4BB26810-0AAE-4635-9D0B-C6DB7FD546D5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A2F58722-0218-49FC-BDBE-3E62FD465B60.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A2F58722-0218-49FC-BDBE-3E62FD465B60.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6AF0E3B3-E3FF-460F-9C71-9348B919FA5C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6AF0E3B3-E3FF-460F-9C71-9348B919FA5C.jpg.html)

Next it was forked up again to its home and the start of the metal work. This thread will concentrate just on that and not any of the detail shiny stuff that I have been doing in between as I want some of it to be a surprise for the debut in 2017.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BA26F078-3288-43D5-AF9B-CFA03334AFB7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BA26F078-3288-43D5-AF9B-CFA03334AFB7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9CC70ADB-D78F-460B-B57E-E9671C278918.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9CC70ADB-D78F-460B-B57E-E9671C278918.jpg.html)

I have worked from the back to the front  so I started with the incorrect bumper mounts. I used Hookys panels for these.  The first problem I encountered was the fact that there was no return lip on the inside as this had been lost in the previous rebuild, so I had to first guess how much of a lip there should be.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/229293FA-A8A5-4415-A660-2335DB3F12BF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/229293FA-A8A5-4415-A660-2335DB3F12BF.jpg.html)

The engine corner back panel was also very thin, and needed replacing so I removed the whole thing.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3C509C7B-A225-4EF4-A0B1-41623008FD50.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3C509C7B-A225-4EF4-A0B1-41623008FD50.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8481317F-E5E9-4819-A9BD-E7017EDA501A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8481317F-E5E9-4819-A9BD-E7017EDA501A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F8F9CDE2-03EB-4ADC-A546-C6A51849E1EE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F8F9CDE2-03EB-4ADC-A546-C6A51849E1EE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B8D77778-BB6D-4CAA-AD1F-9A311E3888A4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B8D77778-BB6D-4CAA-AD1F-9A311E3888A4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CECD22FC-047E-4F41-BB10-315B9954101E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CECD22FC-047E-4F41-BB10-315B9954101E.jpg.html)

Tacked in place

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/191E2843-6841-4B55-AB57-4135F2E76511.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/191E2843-6841-4B55-AB57-4135F2E76511.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3DBEE8EB-0431-46C4-BB7B-3DF456490369.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3DBEE8EB-0431-46C4-BB7B-3DF456490369.jpg.html)

It didn't line up at the rear but I sorted that not long after as you will see

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/20C93D54-2122-4798-B1F3-04DDCEEB2614.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/20C93D54-2122-4798-B1F3-04DDCEEB2614.jpg.html)

Semi welded

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8F9CD0BA-A32F-4DD5-9772-F4137FBDF338.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8F9CD0BA-A32F-4DD5-9772-F4137FBDF338.jpg.html)

The lip wasn't really the correct shape at this stage either.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E411BDD3-415B-4B53-A9BA-D6DCD45B08CB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E411BDD3-415B-4B53-A9BA-D6DCD45B08CB.jpg.html)

Part way through welding the corners.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4746FC44-CA35-4B63-8FCD-E14EC6B42481.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4746FC44-CA35-4B63-8FCD-E14EC6B42481.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1D3174F4-5417-4884-BF51-8AEDC4E18951.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1D3174F4-5417-4884-BF51-8AEDC4E18951.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/589294EA-6501-4827-9909-7BB6ACA1B83B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/589294EA-6501-4827-9909-7BB6ACA1B83B.jpg.html)


I then blasted it as the joining lip had some surface rust too

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7CF8CF4C-8CCE-4E89-A2CF-79A4E538AAE3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7CF8CF4C-8CCE-4E89-A2CF-79A4E538AAE3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F4E7AD6F-E7D8-451F-9AC3-B9DD95BA27CB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F4E7AD6F-E7D8-451F-9AC3-B9DD95BA27CB.jpg.html)

I spot blasted the body too as there was rust in between the two panels

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D6C7E379-5452-4945-92CD-F5BF7A204DF9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D6C7E379-5452-4945-92CD-F5BF7A204DF9.jpg.html)

More. Notice the shit welding under the floor. Best of show my arse!  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/76AC4BA9-713D-4FE0-9201-AD92B47CEA4D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/76AC4BA9-713D-4FE0-9201-AD92B47CEA4D.jpg.html)

Welded back in place. The tar board clips will be removed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FB1987BE-38A9-4423-8A21-3C5D28E54C40.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FB1987BE-38A9-4423-8A21-3C5D28E54C40.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7C262122-7F4B-4E83-BB3D-CD2128AED6C4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7C262122-7F4B-4E83-BB3D-CD2128AED6C4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AF8D5A8D-3258-4641-AE8C-35B2C5720D09.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AF8D5A8D-3258-4641-AE8C-35B2C5720D09.jpg.html)

This is the lip I`m talking about. Finished after I had installed the engine tray.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5B5996F4-A0F7-40ED-AD1C-40898F05F2EF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5B5996F4-A0F7-40ED-AD1C-40898F05F2EF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E7EF945C-79CF-4F95-A0EE-F9403C2156C2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E7EF945C-79CF-4F95-A0EE-F9403C2156C2.jpg.html)

Top work.
I really liked the work you did on your oval that I saw on vzi.
This car will be awesome
Lee

Thanks matey.
 The other side needed the same treatment in that I had to create a new lip.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8B9F1C62-DC70-4446-BE04-5B08B2175DF6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8B9F1C62-DC70-4446-BE04-5B08B2175DF6.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/153BCF16-191B-462E-8930-4E2D971F4784.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/153BCF16-191B-462E-8930-4E2D971F4784.jpg.html)

Now to weld in the rear panel and the two side trays , you need a valence to line things up. I managed to source a NOS one which was nice but I had to do something with the wing mounting nutserts first. Now VW in their infinite wisdom decided to use two different types of captive nuts. Unfortunately for me mine has the square recessed type and my car was a right mismatch of types as all these areas had been worked on previously.   
    I bought another valence on egay which included the sections I was after but it was bent and crusty.

Crusty

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/20E4A5DE-95C0-4A3D-90B9-C9AD552546B9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/20E4A5DE-95C0-4A3D-90B9-C9AD552546B9.jpg.html)

This is the section I was after with the correct nutsert

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/58E326F5-95AA-4F0C-A11E-D3D939BB90D5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/58E326F5-95AA-4F0C-A11E-D3D939BB90D5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EC50DCC8-B8C4-40F5-A1DC-48CE3E4D760A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EC50DCC8-B8C4-40F5-A1DC-48CE3E4D760A.jpg.html)

Cut the section out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/13E81C98-2C13-4FE4-9D0D-4F79A32F0528.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/13E81C98-2C13-4FE4-9D0D-4F79A32F0528.jpg.html)

Blasted

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B2CEA16F-1BCC-4246-A09A-5811FE74C8C0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B2CEA16F-1BCC-4246-A09A-5811FE74C8C0.jpg.html)

Tacked

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D0E4ADDB-FE39-475A-A5EB-031CD7E9B4DD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D0E4ADDB-FE39-475A-A5EB-031CD7E9B4DD.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/29BC2A28-3845-442D-822E-2C05ABD2BB36.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/29BC2A28-3845-442D-822E-2C05ABD2BB36.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/11AF5A24-5BF5-4AE7-A763-50C5F971AFF3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/11AF5A24-5BF5-4AE7-A763-50C5F971AFF3.jpg.html)

Using the NOS valence for fitment

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0DA35C97-3702-4D28-AA1F-2970443D6F9F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0DA35C97-3702-4D28-AA1F-2970443D6F9F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4EC9153D-BEED-4D44-A5DF-A74611931C97.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4EC9153D-BEED-4D44-A5DF-A74611931C97.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AF787F20-CB21-4A73-A841-F13B5220E89E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AF787F20-CB21-4A73-A841-F13B5220E89E.jpg.html)

These square serts would become a pain in the arse later as you will see

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/93413BCB-68F1-4028-9168-66327085C349.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/93413BCB-68F1-4028-9168-66327085C349.jpg.html)

Moving on to the other side and it was a similar story, the correct nutsert was missing so a section was cut out and genuine metal was let in.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3BC318FC-802F-4C79-A29B-C199FBDC3D32.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3BC318FC-802F-4C79-A29B-C199FBDC3D32.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/53C22C6A-C573-4D42-B191-22E0E31E0420.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/53C22C6A-C573-4D42-B191-22E0E31E0420.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3FC51AB0-FFE2-4703-AD8D-5FD72AC415C7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3FC51AB0-FFE2-4703-AD8D-5FD72AC415C7.jpg.html)

Again the NOS valence was used for reference.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F5566999-1EE9-477C-9B49-D84C51AC56DB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F5566999-1EE9-477C-9B49-D84C51AC56DB.jpg.html)

Nearly there

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5A5CD0CF-BEDB-42A8-8EC1-3588FD6116EA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5A5CD0CF-BEDB-42A8-8EC1-3588FD6116EA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/866807D5-EA14-4B63-B66D-ADE0D2939B78.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/866807D5-EA14-4B63-B66D-ADE0D2939B78.jpg.html)

I used an old steel wing , lines up nice

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9B91B645-1B15-4D5A-9734-154738700F86.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9B91B645-1B15-4D5A-9734-154738700F86.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/221C05A4-DF67-4454-BE99-5AC9D726AF13.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/221C05A4-DF67-4454-BE99-5AC9D726AF13.jpg.html)

Engine tray time. These are hookys ones which he made narrower for me as I`m running a bigger motor. At first there was a fitment issue but I sorted it without too much trouble. Welded from the outside so its a neater cleaner fit.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B8F10F3E-78D2-4DC7-9ABE-C347254EBE06.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B8F10F3E-78D2-4DC7-9ABE-C347254EBE06.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/17D426C4-F8FD-4985-A1D4-D8BEDDF5D6BF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/17D426C4-F8FD-4985-A1D4-D8BEDDF5D6BF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8FF420A7-C376-4617-98F1-D6AE86B16937.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8FF420A7-C376-4617-98F1-D6AE86B16937.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9D3A0D52-6947-4D76-94C0-335CC2A7455A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9D3A0D52-6947-4D76-94C0-335CC2A7455A.jpg.html)

Far neater

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A29375A3-098C-42DD-925C-781022F23A46.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A29375A3-098C-42DD-925C-781022F23A46.jpg.html)

Other side the same

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E638A8F0-C393-4E45-AF27-52EE4AC96B80.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E638A8F0-C393-4E45-AF27-52EE4AC96B80.jpg.html)

Made the access holes bigger for the 48IDAs , I`ve  made a pair of aluminium covers

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D3B2C113-7A26-4096-B188-B34ADB6435F5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D3B2C113-7A26-4096-B188-B34ADB6435F5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7A2811B4-71DC-4488-A32C-B992F8358512.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7A2811B4-71DC-4488-A32C-B992F8358512.jpg.html)

So both sides nearly done, the square top corner of the LH weber hole was adjusted after I welded in a section to make a curve.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CDED92A1-5CE7-4218-81AB-5CFD523A8CA2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CDED92A1-5CE7-4218-81AB-5CFD523A8CA2.jpg.html)

The next on the list was the rear cross members. Now as far as I`m concerned the only was to repair these are to cut them out completely and make them good before welding them back in again, rather than just trying to repair them in place. Its a neater job.  I had repaired mine before using a later square type member and it looked far from good.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3B04082F-89F2-4ED1-83EF-928B6F0F86B8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3B04082F-89F2-4ED1-83EF-928B6F0F86B8.jpg.html)

I managed to get a pair of members off the samba and got them sent over. I think 90% of the member arrived and unfortunately the missing 10% is pretty hard to replicate but its better than what was in the car.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2DFDE102-B80F-46D8-A0E2-975C792CCF4B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2DFDE102-B80F-46D8-A0E2-975C792CCF4B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8ADB4602-545D-4175-BA52-2F42F46E9458.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8ADB4602-545D-4175-BA52-2F42F46E9458.jpg.html)

There was part of the boot floor included which turned out to be a bonus

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/421DB98C-AE51-4C38-A362-750C7F2ED39D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/421DB98C-AE51-4C38-A362-750C7F2ED39D.jpg.html)

Started cutting out the old one

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/270D2F15-7A29-4A6F-A382-7AFBB56A8EA5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/270D2F15-7A29-4A6F-A382-7AFBB56A8EA5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8AAF4723-E86A-418F-B576-2BAD65C00387.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8AAF4723-E86A-418F-B576-2BAD65C00387.jpg.html)

Gone
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DB99700B-1D70-42A8-B61D-667218CF2551.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DB99700B-1D70-42A8-B61D-667218CF2551.jpg.html)

Straight away I tried the new old member and even the factory spot welds lined up

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FA8FF767-47A0-445E-B3AD-3DB30EC5560F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FA8FF767-47A0-445E-B3AD-3DB30EC5560F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E030E70-2BBE-4726-88E1-52C9A6EFAEFE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E030E70-2BBE-4726-88E1-52C9A6EFAEFE.jpg.html)

Now as it stands, no one makes correct repair cross members sections for mid sixties bugs so I ordered a pair of Virtanen oval repair sections as that was the next best thing. I could have made my own but to save time I went down this road.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0912FA05-3279-40F1-888B-EF6EEE281F59.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0912FA05-3279-40F1-888B-EF6EEE281F59.jpg.html)

It was quite a bit different

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3111AD30-3CC2-42D2-AFBA-FC0EBB9F0B26.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3111AD30-3CC2-42D2-AFBA-FC0EBB9F0B26.jpg.html)

Single mount hole as opposed to the dual mount of the earlier cars.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/15EE045D-D871-4895-AFD4-71262EA02798.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/15EE045D-D871-4895-AFD4-71262EA02798.jpg.html)

I drilled out the spot welds to separate them which wasn't easy.....

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5169433D-4A87-48C0-AE98-D2312497ABF8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5169433D-4A87-48C0-AE98-D2312497ABF8.jpg.html)

.... and then cut the Virtanen panel almost in half and tacked the old and new together

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/64C0DBCA-8493-4FE0-942F-90A7A707337A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/64C0DBCA-8493-4FE0-942F-90A7A707337A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F7568E29-E5A8-4324-B0A3-09991D95B150.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F7568E29-E5A8-4324-B0A3-09991D95B150.jpg.html)

Trial fitting

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3FC29C6E-3601-4B0E-9548-9742B7CEBD89.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3FC29C6E-3601-4B0E-9548-9742B7CEBD89.jpg.html)

fully welded and smoothed although not spot welded back in place yet.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/901C9B4D-D417-423F-AC72-BEED079A60CD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/901C9B4D-D417-423F-AC72-BEED079A60CD.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F57C54FD-4EBF-48E2-8498-1B6357BE1453.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F57C54FD-4EBF-48E2-8498-1B6357BE1453.jpg.html)

I then had a guide to make the outer from sheet

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0A9B5495-4069-4673-AEC4-B0BD2F7737F2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0A9B5495-4069-4673-AEC4-B0BD2F7737F2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/08E2B0B5-CA90-486A-B11F-EF99EB7DBB71.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/08E2B0B5-CA90-486A-B11F-EF99EB7DBB71.jpg.html)

I blasted the rust off before layering plenty of weld through primer , then welded the two pieces back together.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8C517073-19BC-436A-921C-3CEF5E793491.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8C517073-19BC-436A-921C-3CEF5E793491.jpg.html)

I would later go back and slightly modify it later but I don't have any pics

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/89CAEB35-D843-463E-8870-6352205D1E5F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/89CAEB35-D843-463E-8870-6352205D1E5F.jpg.html)

Checking fitment

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9A2F115D-890D-4A01-85BC-386B674C5FA4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9A2F115D-890D-4A01-85BC-386B674C5FA4.jpg.html)

I had to next think about the flange where it meets the body. Again there are no repair sections available so I had to fab this myself. I never liked the way the original panel was attached to the member, it didn't flow properly, you will see what I mean  ;)....


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/534C03F9-934F-483A-8723-ED7E908D64C2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/534C03F9-934F-483A-8723-ED7E908D64C2.jpg.html)

Smoothed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/188A35DE-6EB4-4809-AD0E-25F0C62E6C67.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/188A35DE-6EB4-4809-AD0E-25F0C62E6C67.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B4D26592-BE8E-4792-B99D-343BA64CF3CE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B4D26592-BE8E-4792-B99D-343BA64CF3CE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4D1B084B-413F-49CF-9BAD-B5BC624D454B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4D1B084B-413F-49CF-9BAD-B5BC624D454B.jpg.html)

Semi welded, flows nicer now

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/34D9B07C-14A1-4055-8BC9-937413C52EBC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/34D9B07C-14A1-4055-8BC9-937413C52EBC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A570FCBA-C282-419B-A6F2-AC1BFC840CD6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A570FCBA-C282-419B-A6F2-AC1BFC840CD6.jpg.html)

Blasted the rest of the member and trial fitted.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CF68BB7E-73A4-48D5-8D84-D2EE609D70B2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CF68BB7E-73A4-48D5-8D84-D2EE609D70B2.jpg.html)

VERY nice work!

Thanks  :)
This is a small section of the boot floor that was still spot welded to the cross member. Its got a complex pressing so I was happy I had it!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/44BD12A2-2DCA-4672-BB67-2EBD94E9BA33.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/44BD12A2-2DCA-4672-BB67-2EBD94E9BA33.jpg.html)

Blasted the whole member too

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/261F4C26-5295-4CFF-BBDA-EC27DDB540AD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/261F4C26-5295-4CFF-BBDA-EC27DDB540AD.jpg.html)

I didn't weld the member in yet as the boot floor needed fixing first. Again, there are no accurate sections available for this so I had to make my own. Sixties bugs have a strange raised area half way down , just above the body mounting section. Now I wasn't quite sure how this area looked as the other side wasn't right either so al I had was internet pics. I`m still not happy with what I made and since these pictures were taken I managed to source a genuine section , so I will cut it out and refit with OG metal. 

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BCDB1362-9E99-4E58-BDB6-A5777DE95927.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BCDB1362-9E99-4E58-BDB6-A5777DE95927.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D4E35579-C059-4BF3-9FC0-EF95745A2ECF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D4E35579-C059-4BF3-9FC0-EF95745A2ECF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D8E88F49-BC00-4DFF-90B4-60A80DD0DE17.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D8E88F49-BC00-4DFF-90B4-60A80DD0DE17.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A4F5FC77-248F-425D-AA42-5AAC38407A0B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A4F5FC77-248F-425D-AA42-5AAC38407A0B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DE133A74-8D5F-4EDB-B54F-C0F9BA5E453E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DE133A74-8D5F-4EDB-B54F-C0F9BA5E453E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8C17D86F-0B6D-4668-B490-D8DD428DA723.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8C17D86F-0B6D-4668-B490-D8DD428DA723.jpg.html)

Not welded in yet

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1A6FBC85-F469-4CA1-85AB-B2F75C59C436.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1A6FBC85-F469-4CA1-85AB-B2F75C59C436.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BB295922-32FA-42EC-85E5-7CFAD63CD904.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BB295922-32FA-42EC-85E5-7CFAD63CD904.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5D89CE97-1195-4E0F-955E-0BFD219BC2A9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5D89CE97-1195-4E0F-955E-0BFD219BC2A9.jpg.html)

Before welding it in I made a new lip and I made it big so I could cut it down to the correct size / height after.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F6B5FA2C-F7E9-4BE4-BDB1-278FA1195226.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F6B5FA2C-F7E9-4BE4-BDB1-278FA1195226.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5C12F291-3850-4CC7-901D-CE38661BF0EF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5C12F291-3850-4CC7-901D-CE38661BF0EF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/820C6A45-A927-4C56-96EF-6C0C2F207452.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/820C6A45-A927-4C56-96EF-6C0C2F207452.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0A36738E-07A6-4516-BFE4-15C9ACB654F3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0A36738E-07A6-4516-BFE4-15C9ACB654F3.jpg.html)

Eventhough the floor is all welded in and smooth, I`m going to replace a section of it with this after I`ve repaired it.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D3554808-BEC9-4CEE-B966-BB8D30A32941.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D3554808-BEC9-4CEE-B966-BB8D30A32941.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1470616C-8773-428E-8A4C-E77E76C8AA2F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1470616C-8773-428E-8A4C-E77E76C8AA2F.jpg.html)

Part way in

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E5B13F60-1CE8-4BFA-BF9F-07A39F7E903C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E5B13F60-1CE8-4BFA-BF9F-07A39F7E903C.jpg.html)

No filler

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/47037B99-9F22-4FCF-ACA1-63CBD4DC8F69.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/47037B99-9F22-4FCF-ACA1-63CBD4DC8F69.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3495F598-8DB9-418F-BAEF-14DF2EB38FE2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3495F598-8DB9-418F-BAEF-14DF2EB38FE2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/46998834-69EE-454E-B298-3D9CCF20022F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/46998834-69EE-454E-B298-3D9CCF20022F.jpg.html)

Corner slowly getting there

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4CB8F326-8532-436D-B078-F868D375E213.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4CB8F326-8532-436D-B078-F868D375E213.jpg.html)

Finished welds underneath

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DCDD5149-616F-4AC3-A7E2-D05527FDD5C2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DCDD5149-616F-4AC3-A7E2-D05527FDD5C2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5C074EC7-517F-4A51-A925-8D155240C6E3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5C074EC7-517F-4A51-A925-8D155240C6E3.jpg.html)

Corner needs finishing

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/33A00383-D0A9-4585-A6D4-8211B093B0A8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/33A00383-D0A9-4585-A6D4-8211B093B0A8.jpg.html)

Rewelded and smoothed off the welds here

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A3342EA8-7B8F-4584-8C44-25EC8A11FC18.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A3342EA8-7B8F-4584-8C44-25EC8A11FC18.jpg.html)

I`m not going to be running heaters so I cut off the pipe inlet and filled in the hole.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4ABFC5D6-190B-44FE-94A1-3AAEDBB9710E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4ABFC5D6-190B-44FE-94A1-3AAEDBB9710E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DB710F38-B13A-492B-BE74-D88DB3148E84.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DB710F38-B13A-492B-BE74-D88DB3148E84.jpg.html)

Made a new piece

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C61C15D8-806F-4307-8BA1-4538962356F3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C61C15D8-806F-4307-8BA1-4538962356F3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AEEDBBEB-E3D0-4243-BF02-38B3575FB597.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AEEDBBEB-E3D0-4243-BF02-38B3575FB597.jpg.html)

I then refitted the body to align and fully weld in the cross member

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D4D7305B-E451-4211-A08E-32FCA73AE9AC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D4D7305B-E451-4211-A08E-32FCA73AE9AC.jpg.html)

Pre welded

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BA4D5EA9-DA74-43C0-A9CD-54258DEE3EFC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BA4D5EA9-DA74-43C0-A9CD-54258DEE3EFC.jpg.html)

Cool

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D9A0AC51-C335-4717-8091-FC239A358D85.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D9A0AC51-C335-4717-8091-FC239A358D85.jpg.html)

All welded in and smoothed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/369572E0-D787-4384-94AC-25310F5FEC4C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/369572E0-D787-4384-94AC-25310F5FEC4C.jpg.html)

Bit still to do here

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BAA9362B-2BAB-4836-B213-E4EAA7FF00BA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BAA9362B-2BAB-4836-B213-E4EAA7FF00BA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/40F10887-180C-4CBB-AC72-FF05C571A60F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/40F10887-180C-4CBB-AC72-FF05C571A60F.jpg.html)

Happy days

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0E172120-EE2F-437F-9D91-0A8FA7A3A750.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0E172120-EE2F-437F-9D91-0A8FA7A3A750.jpg.html)

That's some seriously impressive work you are doing 8) You must have a lot of patience to make it all fit so well, looking forward to seeing how it turns out

cheers Richie

Cheers Ritchie, as I`m getting older, the more anal I`m getting!  ;D

This is the other side. Not happy days. This took a lot more work.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5072C4FB-C1D7-4C79-95D1-A6454EFA3814.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5072C4FB-C1D7-4C79-95D1-A6454EFA3814.jpg.html)

My previous fabulous Stevie Wonder fabrication.  #-o

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E3301F5-0B2C-4F82-A981-F36409A444FA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E3301F5-0B2C-4F82-A981-F36409A444FA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5EFFF3C7-9A16-40BB-AB4B-EF61D387EAE7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5EFFF3C7-9A16-40BB-AB4B-EF61D387EAE7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8D99EB97-A1A4-4C88-8D59-F1D9D86E71A3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8D99EB97-A1A4-4C88-8D59-F1D9D86E71A3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F560018D-2A28-41EB-8328-4AC5B70EBA4A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F560018D-2A28-41EB-8328-4AC5B70EBA4A.jpg.html)

The joining panel was truly goosed too. I`m not saying it wasn't solid and useable, but if you are building a show car, this is far from good enough.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BAF61DE0-7449-47BB-BF7A-A4B2C5C2B308.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BAF61DE0-7449-47BB-BF7A-A4B2C5C2B308.jpg.html)

The boot floor was a mess too.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/42338C7B-07AE-4258-AEA3-DA31EE4537D6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/42338C7B-07AE-4258-AEA3-DA31EE4537D6.jpg.html)

Cut it out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/ED9AA790-D773-4076-B5E6-EC1E3ED82E50.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/ED9AA790-D773-4076-B5E6-EC1E3ED82E50.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3766FC36-C44A-4424-8416-0A19BAFA3EA3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3766FC36-C44A-4424-8416-0A19BAFA3EA3.jpg.html)

I could have repaired the original cross member but I decided to install the one I had from SoCal.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/22854914-A55D-4603-9EFD-788C42D8DEA9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/22854914-A55D-4603-9EFD-788C42D8DEA9.jpg.html)

My hoodride parts project is coming along nicely  ;)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/944A879D-2DA7-41DE-9BD8-7C4259D8F6FA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/944A879D-2DA7-41DE-9BD8-7C4259D8F6FA.jpg.html)

Again, I started off with this.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/701EE311-FDEA-419A-93CC-2F6B5EF5CF86.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/701EE311-FDEA-419A-93CC-2F6B5EF5CF86.jpg.html)

Using Mikas panel again

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FA5A6A36-591A-4CBF-B312-E9DE6F508A91.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FA5A6A36-591A-4CBF-B312-E9DE6F508A91.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1B5BE8AC-8574-4A21-89CF-F77B51F0CE0C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1B5BE8AC-8574-4A21-89CF-F77B51F0CE0C.jpg.html)

This was a bit more tricky in that the cut went through the corner of the pressed rib.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8E1BA760-DDF2-41D4-9D32-85FE6B73C299.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8E1BA760-DDF2-41D4-9D32-85FE6B73C299.jpg.html)

See what I mean

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/736EE7BE-3048-4AD8-8AA2-36400419CBD1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/736EE7BE-3048-4AD8-8AA2-36400419CBD1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4BD5CD32-1F68-43AC-89E9-3FD0546AB747.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4BD5CD32-1F68-43AC-89E9-3FD0546AB747.jpg.html)

Smoothed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C8F78B81-167A-4BC7-8B87-44BD5F3F74FC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C8F78B81-167A-4BC7-8B87-44BD5F3F74FC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/56EEA23C-1C73-473D-8B03-46DBDAAFBC71.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/56EEA23C-1C73-473D-8B03-46DBDAAFBC71.jpg.html)

Started to make the outer

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/99BFA317-B5CC-42D3-9E32-2EAF4630FC69.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/99BFA317-B5CC-42D3-9E32-2EAF4630FC69.jpg.html)

Took a bit of time . I modified the other side to the same as this.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/99738C15-956A-4F29-8997-F247744A16D9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/99738C15-956A-4F29-8997-F247744A16D9.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/393157E3-15CA-470F-8C3D-E356CA585AFD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/393157E3-15CA-470F-8C3D-E356CA585AFD.jpg.html)

Separate workshop was a bit full.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E129611E-2639-47EA-805A-AEE776230212.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E129611E-2639-47EA-805A-AEE776230212.jpg.html)

Check the fit

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/10DD0C5C-E794-406A-BE50-09C41907EE16.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/10DD0C5C-E794-406A-BE50-09C41907EE16.jpg.html)

Ready for blasting

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DC2A802B-AFD9-4751-8D14-65B41C065ED3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DC2A802B-AFD9-4751-8D14-65B41C065ED3.jpg.html)

guide coat to show the highs and lows

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/28CDB06A-0E66-474C-A1A9-E5712D43B234.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/28CDB06A-0E66-474C-A1A9-E5712D43B234.jpg.html)

Bare metal

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BBD4F141-F236-4A17-85BB-4BA7DAE907E9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BBD4F141-F236-4A17-85BB-4BA7DAE907E9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/280592E9-A42A-4AAA-8770-79048CA3BA5E_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/280592E9-A42A-4AAA-8770-79048CA3BA5E_1.jpg.html)

Weld through primed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AA90892B-50DF-4E31-AADD-193CBE86CAEE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AA90892B-50DF-4E31-AADD-193CBE86CAEE.jpg.html)

Finished

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7DB83338-EA07-49E5-9BAC-DD8AB4FC6151.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7DB83338-EA07-49E5-9BAC-DD8AB4FC6151.jpg.html)

well, I suppose with a little more practice and effort you might just get things to an okay kind of standard...

haha.....seriously dude....absolutely incredible workmanship and detail, I don't believe anyone else has come close to this.

VERY much looking forward to seeing more of this .

Jick

I'll box up my car and ship it, just need the address   ;D

This is excellent!

My boss saw me snooping this thread at work today. Not a car guy, but totally impressed!  :D

Yes, guys are totally right!

Danny Gabbard and now You have set the bar for metalfinishing for me at least! Pleasure to follow a build with this kind of detailwork

Cheers for the compliments!  The key is to enjoy what you are doing, the moment you start to get pissed off , just walk away!    So far I`ve really enjoyed it. The body is 90% done.  

The right rear wheel arch was a mess. I had repaired it previously with one of vengs finest panels and I knew that the only way to fix that was to try and get a genuine body cut. I eventually managed to get some cuts from the states but it took a long time. I was out of action for months on the rear corner so I did some other metal repairs on other sections of the car. I will post up those bits later.   Now when I got the box full of vw tin, I was happy and a bit disappointed too as the vendor failed to understand that I wanted all the flanges complete. Drilling spot welds did not happen, instead they were cut using an air chisel. Now the only bonus of that is that there is no lost metal as it wasn't cut using a grinder.

Rusty shit  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1A365A23-E0B1-4C6E-95C6-92A4FB23BF80.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1A365A23-E0B1-4C6E-95C6-92A4FB23BF80.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/669BF947-8A81-4444-9A9D-5F75FEAF26F8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/669BF947-8A81-4444-9A9D-5F75FEAF26F8.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6F72CE05-1EDA-49C3-9212-AC8BF03EAA51.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6F72CE05-1EDA-49C3-9212-AC8BF03EAA51.jpg.html)

I was gutted to see that the flange had been cut on the boot floor  :-[

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4B511D5B-8DDD-414C-B5B5-92EAC6453A47.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4B511D5B-8DDD-414C-B5B5-92EAC6453A47.jpg.html)

Both the flanges were still attached to the rear arch though.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/50957362-DE2E-4B50-9B3E-B760F85E0E14.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/50957362-DE2E-4B50-9B3E-B760F85E0E14.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/14274AC7-7570-41E6-949A-72044DF10D6F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/14274AC7-7570-41E6-949A-72044DF10D6F.jpg.html)

It would have been rude not to use the an original flange  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2DCB27DA-9E0F-4350-8ED1-AA5C762E4CA4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2DCB27DA-9E0F-4350-8ED1-AA5C762E4CA4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BE3A5891-FF82-49EA-AC07-02A203547BB9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BE3A5891-FF82-49EA-AC07-02A203547BB9.jpg.html)

Welded, smoothed and modified to look like the other side

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D0503FDD-D177-42D6-BE3F-8BB256D70232.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D0503FDD-D177-42D6-BE3F-8BB256D70232.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B19A498D-BF45-4712-8702-3A53CEAFEB29.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B19A498D-BF45-4712-8702-3A53CEAFEB29.jpg.html)

Fortunately the bottom flange was intact

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7B3A5E59-4FA6-4B49-B7E9-D051D7F74550.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7B3A5E59-4FA6-4B49-B7E9-D051D7F74550.jpg.html)

I decided to remove the whole section.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CFC70A5D-A8D6-4387-B6CE-08282544B52C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CFC70A5D-A8D6-4387-B6CE-08282544B52C.jpg.html)

Nice!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E693FEA0-D617-4133-8573-25D796CEB6B9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E693FEA0-D617-4133-8573-25D796CEB6B9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/550B8CCA-8364-4A4B-83DC-BDFF22F86193.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/550B8CCA-8364-4A4B-83DC-BDFF22F86193.jpg.html)

If in doubt!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/56845973-4134-43F3-B4E5-E61991C9BCA2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/56845973-4134-43F3-B4E5-E61991C9BCA2.jpg.html)

I blasted it and protected it before tacking it in.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A6CFD4D7-3024-4CFB-B3FF-DCD9FB3259F5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A6CFD4D7-3024-4CFB-B3FF-DCD9FB3259F5.jpg.html)

Fit was nice

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BC3B1BF5-7682-4EA3-A248-0D6100BFFD31.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BC3B1BF5-7682-4EA3-A248-0D6100BFFD31.jpg.html)

Made a new overlap

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/13B996FF-5BB3-43E1-816C-FC7BFE7A1362.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/13B996FF-5BB3-43E1-816C-FC7BFE7A1362.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FE5EFEFF-5DA8-415E-BC48-F4A63216C349.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FE5EFEFF-5DA8-415E-BC48-F4A63216C349.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/090B31AB-04E1-4307-AE8D-E551DB885519.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/090B31AB-04E1-4307-AE8D-E551DB885519.jpg.html)

Next was to cut a huge hole out.  :shock:  Updates soon.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B24AADB1-7123-41D1-BB57-CAE37AFE123C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B24AADB1-7123-41D1-BB57-CAE37AFE123C.jpg.html)

Very nice work to say the least....You're a dedicated hard working VW guy for sure! Keep going! 8)

So next I had to think about the best way of welding the flange back on to the boot floor. I ended up lining up the two panels and tacking them together to get the fitment right and then drill the spot welds out to separate them.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4C9D2B33-3F3A-476A-BF8A-6A9767D60B2B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4C9D2B33-3F3A-476A-BF8A-6A9767D60B2B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4D73E944-56B1-469D-B1C0-F19081498A51.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4D73E944-56B1-469D-B1C0-F19081498A51.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/69763FE1-EE8B-4AFA-A04F-A7230AB196F2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/69763FE1-EE8B-4AFA-A04F-A7230AB196F2.jpg.html)

Separated, Why this wasn't done in the first place I will never know!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2516E09D-B1B4-400F-80D0-11C5F186A87A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2516E09D-B1B4-400F-80D0-11C5F186A87A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/55A543DF-56BC-45CF-8364-F948A761645F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/55A543DF-56BC-45CF-8364-F948A761645F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/154410F3-5A63-44BA-A7C5-3F0D8D11EE48.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/154410F3-5A63-44BA-A7C5-3F0D8D11EE48.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CB68F3FD-6971-40DE-8603-EEDE00B293AC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CB68F3FD-6971-40DE-8603-EEDE00B293AC.jpg.html)

Blasted and the dents knocked out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/886BF8EC-7E83-4E95-BA6F-FFB88044D275.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/886BF8EC-7E83-4E95-BA6F-FFB88044D275.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1ED78D47-1066-4E8C-9B65-623790D5FC9E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1ED78D47-1066-4E8C-9B65-623790D5FC9E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4E9F6B17-EFF6-467F-9E26-BBAEA19890A6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4E9F6B17-EFF6-467F-9E26-BBAEA19890A6.jpg.html)

The back of the boot floor had a tiny bit of rust under the seam sealer and as you know any rust is no good.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0B885F89-74F1-48A4-84EB-B52CBA561E70.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0B885F89-74F1-48A4-84EB-B52CBA561E70.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BA00E5A7-EC20-4436-A70D-7A3F22B2B6D6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BA00E5A7-EC20-4436-A70D-7A3F22B2B6D6.jpg.html)

Offered up. Fitted nice.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CEAEE1E2-0B3F-44DC-8319-D15878214585.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CEAEE1E2-0B3F-44DC-8319-D15878214585.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7A543DCC-9BA5-4D58-BB1E-0D3C874AC100.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7A543DCC-9BA5-4D58-BB1E-0D3C874AC100.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EEA5B958-6083-4ACD-96C4-EA6CBABC925C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EEA5B958-6083-4ACD-96C4-EA6CBABC925C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0996A225-E1E9-4175-876E-CCBBD3676D3E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0996A225-E1E9-4175-876E-CCBBD3676D3E.jpg.html)

Welding up the flange from the back

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/927D7F02-B5AD-4A65-BEFD-5D761F256C62.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/927D7F02-B5AD-4A65-BEFD-5D761F256C62.jpg.html)

If you get decent penetration its sometimes easier to smooth the weld this way, but its thin metal and mistakes can be made. This takes hours.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B060F557-D6FF-4887-B59E-337A2CA3F83D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B060F557-D6FF-4887-B59E-337A2CA3F83D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D43D6757-2295-4291-8AFD-80DE6C876D70.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D43D6757-2295-4291-8AFD-80DE6C876D70.jpg.html)

Almost done

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8CD23675-D943-45C5-9072-7C0AB63C9889.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8CD23675-D943-45C5-9072-7C0AB63C9889.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/854F5D09-4955-4601-B700-5C30AF5E31A7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/854F5D09-4955-4601-B700-5C30AF5E31A7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8B4B8398-76B7-4071-9E95-A609C48284FF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8B4B8398-76B7-4071-9E95-A609C48284FF.jpg.html)

Trial fitting again.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/46D529E2-E6EF-4D24-8FD2-0650B0B7C31A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/46D529E2-E6EF-4D24-8FD2-0650B0B7C31A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/10DDFB6C-206F-4661-9515-9E1BBCB26DAB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/10DDFB6C-206F-4661-9515-9E1BBCB26DAB.jpg.html)

Tacked in place but there was a problem

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/10DDFB6C-206F-4661-9515-9E1BBCB26DAB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/10DDFB6C-206F-4661-9515-9E1BBCB26DAB.jpg.html)

Lack of a gap as the welds had pulled it in.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/47731635-876C-4F34-9EE4-2DF72AD00870.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/47731635-876C-4F34-9EE4-2DF72AD00870.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E0A62EDA-C8E8-40F5-8F4B-37D356F90E7A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E0A62EDA-C8E8-40F5-8F4B-37D356F90E7A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5604E0CD-FF7F-4A43-9588-B6622BDDC6A4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5604E0CD-FF7F-4A43-9588-B6622BDDC6A4.jpg.html)

I had to run a 1mm cutting disc through the line to create a gap.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/68D4D437-1EE5-4ACF-8FCA-AB882F86512F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/68D4D437-1EE5-4ACF-8FCA-AB882F86512F.jpg.html)

No filler or bog

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4E970700-1B46-425E-9DD3-690E29C94A61.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4E970700-1B46-425E-9DD3-690E29C94A61.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6737F860-86F7-40D1-8FD5-FC2CE9DF9FE4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6737F860-86F7-40D1-8FD5-FC2CE9DF9FE4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CD841E28-BC4E-4418-9FA4-213F1A304559.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CD841E28-BC4E-4418-9FA4-213F1A304559.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B02C7C25-960B-456D-BFAA-6AF032CF2E0A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B02C7C25-960B-456D-BFAA-6AF032CF2E0A.jpg.html)

Layer of weld through primer to protect the metal for now

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/87A23B35-99A9-438B-B27B-19B2DC871B79.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/87A23B35-99A9-438B-B27B-19B2DC871B79.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5DED1FF1-6929-4E84-9F6A-F7AEA4F67A9E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5DED1FF1-6929-4E84-9F6A-F7AEA4F67A9E.jpg.html)

Underneath was fun

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6993B5D0-B1E6-49F7-B47D-4D2A72F8BEFB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6993B5D0-B1E6-49F7-B47D-4D2A72F8BEFB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/15BDAEF2-7F1C-486D-B454-97EC541FAC3F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/15BDAEF2-7F1C-486D-B454-97EC541FAC3F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D606A1B8-E334-469C-8FB3-2E05E6E534D2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D606A1B8-E334-469C-8FB3-2E05E6E534D2.jpg.html)

Slowly getting there

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/802C05B9-9C4B-4FE0-92B3-94308D2348A3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/802C05B9-9C4B-4FE0-92B3-94308D2348A3.jpg.html)

Next will be the rear arch. Happy days.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/ABE7024F-D5E6-42E2-BDC7-2DFDAA387091.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/ABE7024F-D5E6-42E2-BDC7-2DFDAA387091.jpg.html)

Body went back on the pan so I could weld in the rear cross member.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/19D39889-494B-4336-A151-7184EFFBBF17.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/19D39889-494B-4336-A151-7184EFFBBF17.jpg.html)

Plugged in

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EA173AF4-7E3E-41A6-A56B-FCBBA54A515A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EA173AF4-7E3E-41A6-A56B-FCBBA54A515A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/056377F6-0FDA-47A4-9418-FDC7677C955E_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/056377F6-0FDA-47A4-9418-FDC7677C955E_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/49440C12-5475-41AD-918A-5C9105BB527A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/49440C12-5475-41AD-918A-5C9105BB527A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2A5FBB91-A02A-4D4E-8F68-16DBA7866565.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2A5FBB91-A02A-4D4E-8F68-16DBA7866565.jpg.html)

Smoothed the plugs underneath

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EA1EF30D-AC74-408E-ACE0-B9C4E6F403EE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EA1EF30D-AC74-408E-ACE0-B9C4E6F403EE.jpg.html)



The rear arch arrived with a section missing so I had to fab up a replacement. I guessed how big the piece had to be for now as I wouldn't be able to get an accurate length until I tacked the whole arch in place first. Drilled out the spot too

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/30641285-D8FC-42EB-8265-FC901824ED77.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/30641285-D8FC-42EB-8265-FC901824ED77.jpg.html)

The wing nutserts were wrong too

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E5E7D4CD-5DE2-477E-93CE-22A60342E552.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E5E7D4CD-5DE2-477E-93CE-22A60342E552.jpg.html)

Fabricated a new section.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7D606E00-1452-4B8A-AA06-35FD6F7C0EE2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7D606E00-1452-4B8A-AA06-35FD6F7C0EE2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9A5DD84A-D426-458D-8FC7-4EA4FFD1AAE5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9A5DD84A-D426-458D-8FC7-4EA4FFD1AAE5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FC3E4C30-5C49-423C-B183-828ED6701E31.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FC3E4C30-5C49-423C-B183-828ED6701E31.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B8F2B51A-6316-4A0D-A133-B1D1E554EFAC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B8F2B51A-6316-4A0D-A133-B1D1E554EFAC.jpg.html)


First trial fitting and it didn't look good. The bitch wasn't playing ball!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0FCD1CFB-BE68-4A5B-B2DE-A9DFAF7BB0D9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0FCD1CFB-BE68-4A5B-B2DE-A9DFAF7BB0D9.jpg.html)

It took ages to fettle it into position.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6D7C218E-119B-4032-9451-FFDEC72AA6EE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6D7C218E-119B-4032-9451-FFDEC72AA6EE.jpg.html)

Notice the rear and the gap even though it was hard up against the boot floor in sections

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/26172993-1884-4CB1-BE9B-ED1471CDD807.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/26172993-1884-4CB1-BE9B-ED1471CDD807.jpg.html)

Getting there. Notice assortment of wing captive nutserts! This I would have to fix before welding the arch in.

[IMG]http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7AAAF113- (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7AAAF113-F01B-4C9F-ACE7-40D44EB99603.jpg.html)

To get the recess for the nutsert I made a press tool. I had sections of a front quarter to experiment with to get the size and shape right. First attempt the corners were too sharp so after I adjusted the tool it worked fine.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/75232B33-2949-4FE7-A244-EBC294BC3C6B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/75232B33-2949-4FE7-A244-EBC294BC3C6B.jpg.html)

First attempt was wrong

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/464DC670-DC25-40DB-8C5A-2BB553185ED5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/464DC670-DC25-40DB-8C5A-2BB553185ED5.jpg.html)

Second try

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/67B892D9-F8CC-4EDD-8349-5A551152F9EE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/67B892D9-F8CC-4EDD-8349-5A551152F9EE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6042AE6A-CAE4-4F64-BC88-34BB5FE4D42B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6042AE6A-CAE4-4F64-BC88-34BB5FE4D42B.jpg.html)

I was worried about panel distortion but that turned out to be minimal.
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FF2A1B7A-1E77-4F83-962B-CE7E70442082.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FF2A1B7A-1E77-4F83-962B-CE7E70442082.jpg.html)

Inside

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/79841B44-A9AC-425F-8006-37ECF2F14C9E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/79841B44-A9AC-425F-8006-37ECF2F14C9E.jpg.html)

This is a front quarter nutsert. I would silver solder the genuine nutserts in place. Silver solder has a low melting point and flows lovely so the weld would be invisible.  Now , I only had available enough genuine nuts to do the whole front of the car. The N/S front quarter needed the lot changing so for the rear I made my own.

You can just about see the weld between the nut and the surrounding metal

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/40A1FCA4-E53A-449E-8E5D-85979364E909.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/40A1FCA4-E53A-449E-8E5D-85979364E909.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/37096035-B6BE-4DFC-A8CC-398B83152959.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/37096035-B6BE-4DFC-A8CC-398B83152959.jpg.html)

So for the rear it wasn't important what the nutsert looked like from the back as they are all hidden. I bought some square weld nuts and modified them on the lathe.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6B71E019-89F4-4188-AA37-3445EF2BC8EF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6B71E019-89F4-4188-AA37-3445EF2BC8EF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9E105463-DD91-461A-B815-317301CB5109.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9E105463-DD91-461A-B815-317301CB5109.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2CA81551-742D-4A6D-94EC-17FF391BA0D0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2CA81551-742D-4A6D-94EC-17FF391BA0D0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A1A1238B-8994-4123-B103-E693619CE7ED.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A1A1238B-8994-4123-B103-E693619CE7ED.jpg.html)

Experimented a few times but they turned out ok

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/118174CB-8B58-44BE-B5DB-C4F19BD78C56.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/118174CB-8B58-44BE-B5DB-C4F19BD78C56.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/295131B8-C811-4F8E-8DD2-0B7B4D1278EF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/295131B8-C811-4F8E-8DD2-0B7B4D1278EF.jpg.html)

Welded one in, took ages as I didn't want to damage the rear quarter with heat

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CF87FB5E-4CDB-4A6F-873D-B14C10802D91.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CF87FB5E-4CDB-4A6F-873D-B14C10802D91.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2866BDB9-0C3C-4F71-ACBF-5B7BD01C640E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2866BDB9-0C3C-4F71-ACBF-5B7BD01C640E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/005312B2-D900-4B85-81DA-3C8740ECCCAB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/005312B2-D900-4B85-81DA-3C8740ECCCAB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B051C71F-F172-4FF9-9A7A-75DDB5B66314.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B051C71F-F172-4FF9-9A7A-75DDB5B66314.jpg.html)

Next I could finish the lower section of the arch now I could gauge the length of the panel. An overlap was left to form a lip after.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/47E6229C-208F-498D-BBB7-E0AF0D9BE668.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/47E6229C-208F-498D-BBB7-E0AF0D9BE668.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9BD68ABC-7496-43A0-9709-B118472CEEE8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9BD68ABC-7496-43A0-9709-B118472CEEE8.jpg.html)

I smoothed this weld up for an invisible repair

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F612E495-324F-4FAC-BEDC-1E937F84437A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F612E495-324F-4FAC-BEDC-1E937F84437A.jpg.html)

Every hole was welded up and smoothed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EC264C51-47BA-4913-B03B-F49364D52671.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EC264C51-47BA-4913-B03B-F49364D52671.jpg.html)

Fitted up

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0037AB64-1B09-4220-9BEE-4E874137647D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0037AB64-1B09-4220-9BEE-4E874137647D.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/586F5B43-C2D6-489F-8D32-80305660CB28.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/586F5B43-C2D6-489F-8D32-80305660CB28.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/038E7FCD-B34A-4D0A-A50B-D4CA16EC50DF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/038E7FCD-B34A-4D0A-A50B-D4CA16EC50DF.jpg.html)

Tacked in

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/038E7FCD-B34A-4D0A-A50B-D4CA16EC50DF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/038E7FCD-B34A-4D0A-A50B-D4CA16EC50DF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CF331855-C131-4EA3-945F-2396CA6DB9A2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CF331855-C131-4EA3-945F-2396CA6DB9A2.jpg.html)

Checking levels

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3B05B165-54B4-42B4-8435-040EFCEAD5E7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3B05B165-54B4-42B4-8435-040EFCEAD5E7.jpg.html)

fat fingers

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DB68F5B8-FFD2-4EC2-9FE5-D78FC9133E94.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DB68F5B8-FFD2-4EC2-9FE5-D78FC9133E94.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3869F2EC-93B6-4767-A60E-6CBC965720E4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3869F2EC-93B6-4767-A60E-6CBC965720E4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/74579196-47A6-4529-A67A-613329C781BF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/74579196-47A6-4529-A67A-613329C781BF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6D054B25-3CD3-483A-9115-2DFFBC8261B2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6D054B25-3CD3-483A-9115-2DFFBC8261B2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2630685D-E613-496A-9C4F-111E847BEA9F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2630685D-E613-496A-9C4F-111E847BEA9F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/70F50686-F8C3-4FFB-A6CE-8D78CF4C37A8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/70F50686-F8C3-4FFB-A6CE-8D78CF4C37A8.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/18F90014-A167-4000-BD48-629C6AD5EF3B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/18F90014-A167-4000-BD48-629C6AD5EF3B.jpg.html)

Once I had tacked the arch in, I made a new inner lip.


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/96E58A77-A286-4830-B667-B6F437927692.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/96E58A77-A286-4830-B667-B6F437927692.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3A797FE5-7F6F-456F-B467-D57F9766954B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3A797FE5-7F6F-456F-B467-D57F9766954B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/64D82873-1B47-47C0-8443-0F007CD84DD7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/64D82873-1B47-47C0-8443-0F007CD84DD7.jpg.html)




 I needed to check fitment with the pan and for that I needed the outer support panel in place. As that had been cut too, I needed to replace the lower part so I used the left over veng section as a donor panel.
  See the size difference from genuine to pattern. It was quite a bit different. Not much of it lined up.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B1BB4DE3-2D3D-481D-9017-0235EDFBCA18.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B1BB4DE3-2D3D-481D-9017-0235EDFBCA18.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/61B8FC4D-3717-42DA-9C8E-3FA8ED20A60E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/61B8FC4D-3717-42DA-9C8E-3FA8ED20A60E.jpg.html)

Getting into shape

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/164AD9C0-2F17-46EC-8B57-DD153848D06F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/164AD9C0-2F17-46EC-8B57-DD153848D06F.jpg.html)

After a load of work I had this

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AFECAC62-B834-48B1-8216-A1577C593681.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AFECAC62-B834-48B1-8216-A1577C593681.jpg.html)

Created a new lip from scratch

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FC0C277E-2790-433E-82F5-AE3409AE6643.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FC0C277E-2790-433E-82F5-AE3409AE6643.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/53749AB7-3C57-412E-8A30-9E6D8301B5F4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/53749AB7-3C57-412E-8A30-9E6D8301B5F4.jpg.html)

Fitting up

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EBC27330-51A0-4974-8E9D-522F02A732A1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EBC27330-51A0-4974-8E9D-522F02A732A1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/89BD5723-C9FD-4F6D-909B-F43B6780CA67.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/89BD5723-C9FD-4F6D-909B-F43B6780CA67.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1BA094F9-C35D-48C8-829D-53CEE002AB23.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1BA094F9-C35D-48C8-829D-53CEE002AB23.jpg.html)

On the pan  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C75F5DE7-4ED4-4DDA-8348-DB3BAC13EC91.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C75F5DE7-4ED4-4DDA-8348-DB3BAC13EC91.jpg.html)

Starting to weld the arch in

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/95B36EE9-5C10-4FBF-B53B-EA6817E95577.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/95B36EE9-5C10-4FBF-B53B-EA6817E95577.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4AF0BEB5-3E72-4E99-9DCC-8AFAD8F79E1A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4AF0BEB5-3E72-4E99-9DCC-8AFAD8F79E1A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DE42BF81-F878-4A1C-8CEC-9FFD4AFA8351.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DE42BF81-F878-4A1C-8CEC-9FFD4AFA8351.jpg.html)

Hours and hours into this bitch!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CB570C37-EEDE-4B58-AFA3-6578EA814704.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CB570C37-EEDE-4B58-AFA3-6578EA814704.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/16995F02-DAD3-45B0-A697-8FE4C83EB90E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/16995F02-DAD3-45B0-A697-8FE4C83EB90E.jpg.html)

Getting a nice finish on both sides takes all the time.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CAB4897C-7E6E-4D1B-B6F4-5B30FF4CEC4F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CAB4897C-7E6E-4D1B-B6F4-5B30FF4CEC4F.jpg.html)

No filler

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BF1CDE5C-593B-4936-BA93-29B0D5CA60BD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BF1CDE5C-593B-4936-BA93-29B0D5CA60BD.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/17198170-E710-4B0B-856C-C2C7031C8D8E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/17198170-E710-4B0B-856C-C2C7031C8D8E.jpg.html)

Getting there
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F6993484-5A63-4A80-822F-C5DEF949AA2E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F6993484-5A63-4A80-822F-C5DEF949AA2E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BF26696C-1E01-43B2-8B21-C462CB4F0436.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BF26696C-1E01-43B2-8B21-C462CB4F0436.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E1F48363-AB62-4259-8A2B-B136A1C92856.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E1F48363-AB62-4259-8A2B-B136A1C92856.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/268A2612-56E6-4274-9F53-B9E768748E54.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/268A2612-56E6-4274-9F53-B9E768748E54.jpg.html)

Finishing off in a few areas. Made a new closing piece, which isn't exactly the same as factory but I like it anyway as it flows better.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D69B0DF8-0A43-4880-B4F2-FF2D18CBA07E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D69B0DF8-0A43-4880-B4F2-FF2D18CBA07E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/92D9E9DB-F41B-467C-A265-4CABE5E72452.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/92D9E9DB-F41B-467C-A265-4CABE5E72452.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/562F2E0D-5DD6-43E4-B986-09AA2E17EB28.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/562F2E0D-5DD6-43E4-B986-09AA2E17EB28.jpg.html)

Load of plug welding and finishing needed.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B14E774E-83F2-4364-B6E2-8AF62EE9055A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B14E774E-83F2-4364-B6E2-8AF62EE9055A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/100868C9-EF6A-412A-9F1D-E8DBD8693227.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/100868C9-EF6A-412A-9F1D-E8DBD8693227.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D3809EB0-9805-4625-AADD-FF6DAA1B9A38.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D3809EB0-9805-4625-AADD-FF6DAA1B9A38.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CF19DF18-5F6E-4D0E-A7AD-D5805EA3988A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CF19DF18-5F6E-4D0E-A7AD-D5805EA3988A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F5891687-5F4F-48CC-BE09-300BAE0DAA8D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F5891687-5F4F-48CC-BE09-300BAE0DAA8D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/219182CC-4631-42A5-B289-45FADB0FA1CC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/219182CC-4631-42A5-B289-45FADB0FA1CC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1210ECEA-94D6-4441-AFFD-E6CC9EC9A961.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1210ECEA-94D6-4441-AFFD-E6CC9EC9A961.jpg.html)

Before and after  :D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B39F2C30-3BB3-40D7-9AA7-BBEC146D4315.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B39F2C30-3BB3-40D7-9AA7-BBEC146D4315.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5A830230-00F5-464D-9DF5-673F8CDBB9F8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5A830230-00F5-464D-9DF5-673F8CDBB9F8.jpg.html)

Money shot

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6581604F-F201-488B-BA37-66649514F4AB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6581604F-F201-488B-BA37-66649514F4AB.jpg.html)

amazing stuff dude!   

Nice work! Be a shame to cover it in carpet... ;) seriously tho, it shows how far standards have risen in the last 10 years or so. Beetles arent the cheap disposable cars they were. I hope the aftermarket realises that and produces some better repair panels. We've got Hooky and Autocraft, Wolf and Gerson for the early stuff, but I'd like to see companies like Veng and Klokkerholm just looking after their tools to produce decent quality panels in reasonable thickness steel. Anyway,  rant over! Please continue with putting my repairs to shame! ;D

I totally agree mate. I've found since starting the rebuild that there is a lack of decent repair panels for sixties bugs. There seems to be more available for earlier cars, even splits. I suppose it's a demand thing, maybe now as people are repairing sixties bugs to a nice standard the panel companies may take note and start offering correct pressings that not only fit but look right too. Easier said than done I suppose. I'm glad companies like hookys and virtanen , wolf and autocraft are about. I've tried to tell Steve Hook to look into cross members and boot floor edges as these are common rust areas.
PS, no carpet is covering my repairs , not even the front. ;)

Back to finishing the arch. Welded the support panel back on. Plenty of weld through between.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1DE86C75-3B48-4F28-BDCC-575B4C3690EF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1DE86C75-3B48-4F28-BDCC-575B4C3690EF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/93D50C51-229D-4C22-B7B2-916BDFF0C2FA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/93D50C51-229D-4C22-B7B2-916BDFF0C2FA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C712D170-D519-4FED-AA2F-7D235E4847DC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C712D170-D519-4FED-AA2F-7D235E4847DC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B868F30B-1BB7-423D-986E-B6BDB4ADDB7B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B868F30B-1BB7-423D-986E-B6BDB4ADDB7B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CD72DC72-B1A7-48B9-989F-763F495361C9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CD72DC72-B1A7-48B9-989F-763F495361C9.jpg.html)

The next section to get attention was the rear scuttle. I knew it was crusty from the last time so the only way forward was to cut it out and start over. Its a really tricky area to restore as access is limited to smooth the welds. Anyway here goes.

All is not well

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/83B13555-5BCF-49F5-956C-8E912401366E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/83B13555-5BCF-49F5-956C-8E912401366E.jpg.html)

Highlighting the spot welds for drilling

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DE87ADA2-38EA-4E44-B9F7-6030C425E6DA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DE87ADA2-38EA-4E44-B9F7-6030C425E6DA.jpg.html)

The inside wasn't pretty

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/78641817-3E35-44C8-B633-46CBF8507779.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/78641817-3E35-44C8-B633-46CBF8507779.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/ABFC6307-46AB-4326-A949-562E3822F585.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/ABFC6307-46AB-4326-A949-562E3822F585.jpg.html)

Prob loads of show cars out there with rust here

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C40CA3D6-971D-4098-BE0D-28CFF8120881.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C40CA3D6-971D-4098-BE0D-28CFF8120881.jpg.html)

I tried to clean the lip but it was very thin

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/89B97C5D-1EF1-46F9-9E06-65CC91AEDE50.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/89B97C5D-1EF1-46F9-9E06-65CC91AEDE50.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C8951D0D-25F9-429B-9CC1-B014622EDCE2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C8951D0D-25F9-429B-9CC1-B014622EDCE2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AAFCF5E2-440A-4488-A55F-F744D305D456.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AAFCF5E2-440A-4488-A55F-F744D305D456.jpg.html)

Nasty

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B00BE37C-95CB-4047-92D1-E9F8107736CF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B00BE37C-95CB-4047-92D1-E9F8107736CF.jpg.html)

Cut out the old and made a new one.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CBA5DF47-B9C5-4AEA-A25A-30746FC0D362.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CBA5DF47-B9C5-4AEA-A25A-30746FC0D362.jpg.html)

Blasted the edges

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E0C066E-EBC7-4B61-AC83-6ED807162BBC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E0C066E-EBC7-4B61-AC83-6ED807162BBC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8A068DD2-443F-427B-A5EB-935C3303B0C0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8A068DD2-443F-427B-A5EB-935C3303B0C0.jpg.html)

Kept the dimples

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5BCB91F1-682C-4EB8-8432-718CAAB43661.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5BCB91F1-682C-4EB8-8432-718CAAB43661.jpg.html)

Trimming it down

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/306662DE-5343-4434-84BA-A948AD62E731.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/306662DE-5343-4434-84BA-A948AD62E731.jpg.html)

Done

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/84DBA01A-67DE-4709-A930-7CF0406D2DB1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/84DBA01A-67DE-4709-A930-7CF0406D2DB1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/04812D43-9128-48BC-99CA-7DC3FFDD5B64.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/04812D43-9128-48BC-99CA-7DC3FFDD5B64.jpg.html)

Finding a donor section wasn't too hard as there was one on egay.  There will always be a part of the Smooth Ass Lowrider in my bug.  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/95D78829-070F-40A2-BCCD-665B3FC3520E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/95D78829-070F-40A2-BCCD-665B3FC3520E.jpg.html)

Chopped it up

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B8505C4E-E0B4-4C28-ADB8-2E2792DEB694.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B8505C4E-E0B4-4C28-ADB8-2E2792DEB694.jpg.html)

I blasted it and straightened it.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1F4C86AA-86A3-4B78-BE9F-D3B5B347ECBB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1F4C86AA-86A3-4B78-BE9F-D3B5B347ECBB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/76FF4DF0-73C2-4796-8630-7F2A043187AD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/76FF4DF0-73C2-4796-8630-7F2A043187AD.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0C2F5B1D-1F24-4F5E-9F98-8B978FCD8463.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0C2F5B1D-1F24-4F5E-9F98-8B978FCD8463.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/87BED8F0-0744-4212-B8A4-5D05831430E1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/87BED8F0-0744-4212-B8A4-5D05831430E1.jpg.html)

Trial fitted

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A66EB37C-4DAA-4B2F-8D09-7BCC0A4C0F14.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A66EB37C-4DAA-4B2F-8D09-7BCC0A4C0F14.jpg.html)

After a lot of fettling it fitted nice

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6570CE31-D1F8-4EC4-A872-D96CEABE5D01.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6570CE31-D1F8-4EC4-A872-D96CEABE5D01.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3233F40B-583E-4EED-AEB9-D312745B8824.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3233F40B-583E-4EED-AEB9-D312745B8824.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/214974F0-661A-433B-BB14-44B893F464D8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/214974F0-661A-433B-BB14-44B893F464D8.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AC4C8DF3-97F3-4A47-8D78-41806CE4ACF5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AC4C8DF3-97F3-4A47-8D78-41806CE4ACF5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E306056C-8FF7-47D5-A2FA-FF9BC14F1722.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E306056C-8FF7-47D5-A2FA-FF9BC14F1722.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D3BCE260-DAA0-4742-8F7F-B34D6D22C93D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D3BCE260-DAA0-4742-8F7F-B34D6D22C93D.jpg.html)

So while the scuttle was off I tackled this area. I converted it to standard style.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3ECBFBEA-985D-41D3-8A9F-4CB7348BC305.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3ECBFBEA-985D-41D3-8A9F-4CB7348BC305.jpg.html)

Smoother and neater

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/23839C09-5A2C-4FFC-A8A3-4F9DCC7B5D79.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/23839C09-5A2C-4FFC-A8A3-4F9DCC7B5D79.jpg.html)

Other side. These areas were really tricky to clean the weld, really awkward job and getting my pinky stuck in the sander didn't help. Nice 45 degree chamfer though. Bit of insulation tape and carry on  :D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3A10DCE4-A3E6-4066-8F06-942048637508.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3A10DCE4-A3E6-4066-8F06-942048637508.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/DCC886D1-1EFF-4AC8-9789-F7DDB997B0AB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/DCC886D1-1EFF-4AC8-9789-F7DDB997B0AB.jpg.html)

Back onto the scuttle, before tacking it in I fitted the hinge mount panel just to make sure that it was in the right place.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9A15E005-06A9-48FC-B3AD-3AA432CDEFFD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9A15E005-06A9-48FC-B3AD-3AA432CDEFFD.jpg.html)

Deck lid fitted ok.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/27A6605B-FFF1-4700-AECE-E333CE58C5D7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/27A6605B-FFF1-4700-AECE-E333CE58C5D7.jpg.html)

Gap still needs adjusting

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/994409D4-4FF5-4075-A969-8FFC2FE57D82.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/994409D4-4FF5-4075-A969-8FFC2FE57D82.jpg.html)

As the deck lid mount panel is still going to be a bolt on affair, I wanted it to look clean from the inside so instead of welding m6 nuts on the inside like last time I got some Henk nuts and pressed them on with my hydraulic press.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/06B21447-748D-43FC-A0EC-86C5DDD51392.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/06B21447-748D-43FC-A0EC-86C5DDD51392.jpg.html)

Neater

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/58C74B88-5B22-48ED-94FF-7CBFC208D87C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/58C74B88-5B22-48ED-94FF-7CBFC208D87C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F60C502A-A8BA-4EE0-BDC6-13196F2C6091.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F60C502A-A8BA-4EE0-BDC6-13196F2C6091.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5023415E-4EA7-4F66-AD6A-90534EFE6C39_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5023415E-4EA7-4F66-AD6A-90534EFE6C39_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B23668D1-28E4-4C90-BC5D-A62899370BC8_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B23668D1-28E4-4C90-BC5D-A62899370BC8_1.jpg.html)

Tack time

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0050CEAD-00B6-4226-9DC2-226306788098_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0050CEAD-00B6-4226-9DC2-226306788098_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B4F08562-8937-4DE4-B74C-40ACD4077A17.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B4F08562-8937-4DE4-B74C-40ACD4077A17.jpg.html)

Getting to the inside to smooth the weld was a bitch.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F3899DA6-E372-4737-B478-5D38043B3404.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F3899DA6-E372-4737-B478-5D38043B3404.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/15943BFD-8727-474D-9667-713C72D47CBB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/15943BFD-8727-474D-9667-713C72D47CBB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FD8CF21F-535F-43E9-8F96-35F2FB6D1AE3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FD8CF21F-535F-43E9-8F96-35F2FB6D1AE3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5A2DBF17-BF4C-4075-9161-B5547C00DF12.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5A2DBF17-BF4C-4075-9161-B5547C00DF12.jpg.html)

Edge needed building up.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7EAA06C8-A555-49BF-B8F3-CCB74ACB5F7D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7EAA06C8-A555-49BF-B8F3-CCB74ACB5F7D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/67BD548C-4FEB-4EFA-853A-F3B95657A37D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/67BD548C-4FEB-4EFA-853A-F3B95657A37D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E5E9158F-DE49-4C1E-B108-BF2492BABDFD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E5E9158F-DE49-4C1E-B108-BF2492BABDFD.jpg.html)

While I was there I tidied this bit

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/113B3882-D40E-4742-9940-1770B8656236.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/113B3882-D40E-4742-9940-1770B8656236.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FB0C9D93-DA23-4FB4-BC18-B9CFEBB86DE9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FB0C9D93-DA23-4FB4-BC18-B9CFEBB86DE9.jpg.html)

Other side

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BBCFCE02-E835-4AB0-9270-EFF25E0B548D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BBCFCE02-E835-4AB0-9270-EFF25E0B548D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DF8A04E4-F004-4263-A210-61D0ACC47725.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DF8A04E4-F004-4263-A210-61D0ACC47725.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/18C8BE25-FD60-48A4-BC64-796D6ACB4E00.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/18C8BE25-FD60-48A4-BC64-796D6ACB4E00.jpg.html)

Welded and tidied up the seam too

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EA2BE0B5-E5FD-49C0-B20A-8155395CD804.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EA2BE0B5-E5FD-49C0-B20A-8155395CD804.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F9341653-D36F-4424-BCD6-06A8B2532E3B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F9341653-D36F-4424-BCD6-06A8B2532E3B.jpg.html)

Hinge mount tidied up.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/151EB04F-DAA8-4056-B8AB-18891961B0D8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/151EB04F-DAA8-4056-B8AB-18891961B0D8.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/42E9C64E-6EC1-47DB-BF23-997BD167513F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/42E9C64E-6EC1-47DB-BF23-997BD167513F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/257AFFD3-9B28-4EB9-B92B-CE5140BFEDDF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/257AFFD3-9B28-4EB9-B92B-CE5140BFEDDF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C872172F-FC9B-490A-85AB-4078549F6A62.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C872172F-FC9B-490A-85AB-4078549F6A62.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8EE8700C-DDC7-4DEF-846E-A48D4D45D67C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8EE8700C-DDC7-4DEF-846E-A48D4D45D67C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/158A5FCF-7DF9-4B27-9489-2316A1F90C80.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/158A5FCF-7DF9-4B27-9489-2316A1F90C80.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9F8A093A-CB78-41BD-A51C-D4A722C8DF43.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9F8A093A-CB78-41BD-A51C-D4A722C8DF43.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2716591F-053C-4A47-8AEC-01478EFDADC6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2716591F-053C-4A47-8AEC-01478EFDADC6.jpg.html)

Done

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/43E49E71-DBA2-4E43-91C8-CFE1A7A94804.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/43E49E71-DBA2-4E43-91C8-CFE1A7A94804.jpg.html)

so you are trying to impress us, huh? you know what - it works! ;D
i did most of these areas a couple of times and it didnt remotley look as clean - stellar work, bud

This thread is off the hook. :o Kudos.

Thanks for the comments.

Remember the crusty egay rear valence?   Well I thought about using it instead of my NOS one as I still want to convert it into a quick release panel and the thought of cutting up a genuine new one fills me with dread. I`m going down a different route with this and I`m going to try and make it release in two sections.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0CE1871C-1A38-4553-87B3-534338E6D679.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0CE1871C-1A38-4553-87B3-534338E6D679.jpg.html)


I blasted it first to see how bad it was . It was bent and twisted but not too badly pitted.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/61D44DF0-E01B-4FD4-8B0E-FA9D24434A06.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/61D44DF0-E01B-4FD4-8B0E-FA9D24434A06.jpg.html)

Edge had disappeared

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E7F9A23C-0EDB-46C1-9818-B176B27C343C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E7F9A23C-0EDB-46C1-9818-B176B27C343C.jpg.html)

Made a new one

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E5A63246-074D-4840-8E80-646765A46F5F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E5A63246-074D-4840-8E80-646765A46F5F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/625C6D36-F5C5-4289-9376-C26E491C85B6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/625C6D36-F5C5-4289-9376-C26E491C85B6.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FFC04A1C-BEBF-411F-A157-709DA35D5F3F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FFC04A1C-BEBF-411F-A157-709DA35D5F3F.jpg.html)

old new and new old  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2C90DECF-3254-4209-B8E0-E16E4331856D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2C90DECF-3254-4209-B8E0-E16E4331856D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DF9DB231-4923-4109-8383-E5ED38F83301.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DF9DB231-4923-4109-8383-E5ED38F83301.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C6DABF8C-35E2-4CE3-A960-EF9CE6E77189.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C6DABF8C-35E2-4CE3-A960-EF9CE6E77189.jpg.html)

The inner panel was removed and modified with a few choice dimple holes. I had to rebuild the corners too.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/61188D01-3D90-43DE-A9A2-B675DB75D5F2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/61188D01-3D90-43DE-A9A2-B675DB75D5F2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/76821A8B-EB5B-4242-A321-501B9917AD72.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/76821A8B-EB5B-4242-A321-501B9917AD72.jpg.html)

I`ve still got to finish and figure out how I`m going to do this but I will make some quick release mounts so that the inner panel can be removed separately as not to scratch paint or have the fixings showing from the outside.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/63525C28-F2A7-4162-A833-8EDDA2025D6D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/63525C28-F2A7-4162-A833-8EDDA2025D6D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/558D8121-90A2-420D-8287-CAC329128D18.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/558D8121-90A2-420D-8287-CAC329128D18.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C9CF7071-554E-43C1-898D-722F3F25BB46.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C9CF7071-554E-43C1-898D-722F3F25BB46.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B399427F-FA31-4C20-8880-16C798D4A2DC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B399427F-FA31-4C20-8880-16C798D4A2DC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DEBF1128-4951-49DF-B400-222B97E9B7AF.jpg)[/URL (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DEBF1128-4951-49DF-B400-222B97E9B7AF.jpg.html)

One of the previous owners had fitted aluminium panels so I had to get rid of the nutserts and weld up the holes.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6AD85E4F-42C4-41B4-9039-69C0E4A179E9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6AD85E4F-42C4-41B4-9039-69C0E4A179E9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3D7D480D-83DE-4A49-85CD-FCF9C7BB8629.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3D7D480D-83DE-4A49-85CD-FCF9C7BB8629.jpg.html)

Going back to the N/S rear wheel arch , where I had replaced the rear quarter panel previously , the original square nutserts had gone so I had to replicate them. Again this took hours and hours as I didn't want to warp the quarter panel with heat.
 Before

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3FA6FA86-DF29-4C88-9A00-453BD77F48C0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3FA6FA86-DF29-4C88-9A00-453BD77F48C0.jpg.html)

Made a new section.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8A9713CD-3732-4EF0-842D-B9853A7DA4A0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8A9713CD-3732-4EF0-842D-B9853A7DA4A0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D7D16169-9828-47D0-A853-4269AC6B5608.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D7D16169-9828-47D0-A853-4269AC6B5608.jpg.html)

Patented super tool

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6FECABFC-D794-42D9-B333-816EEEB928EA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6FECABFC-D794-42D9-B333-816EEEB928EA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9DA47AAB-9E26-498A-9C40-A0F466066C26.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9DA47AAB-9E26-498A-9C40-A0F466066C26.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E7E4E4AF-B919-4F53-ABCF-2B9B27BD0437.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E7E4E4AF-B919-4F53-ABCF-2B9B27BD0437.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/77672DC9-E605-45F0-8908-C9FD4251BCE0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/77672DC9-E605-45F0-8908-C9FD4251BCE0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/99F28DE9-70C5-4DF1-8BFE-76B5BE04F673.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/99F28DE9-70C5-4DF1-8BFE-76B5BE04F673.jpg.html)

Another one

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8C53086B-C7F3-43A4-92F5-CAA3216D6E17.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8C53086B-C7F3-43A4-92F5-CAA3216D6E17.jpg.html)

And another

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E9F856FA-DABD-439B-9C2F-01CAC9202D10.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E9F856FA-DABD-439B-9C2F-01CAC9202D10.jpg.html)

No filler required

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2843F600-CF01-47B4-8E4C-3953F7CF801B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2843F600-CF01-47B4-8E4C-3953F7CF801B.jpg.html)

Next I had to tackle the channels. As I had replaced them all those years ago I knew they were rot free but the wrong shape so I had to convert them to the early smooth style. Some of you may question why I did this and not just put in a pair of gerson ones but I had fitted these old ones correctly, the doors fitted nice so to me it was easier to modify these plus I'm getting rid of the heater vents at the front too so I would have had to modify the gerson ones too. I also had to get rid of the harness mounts I had welded to them too.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5D693731-0BA9-440A-BBB4-D68AA1E23C10.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5D693731-0BA9-440A-BBB4-D68AA1E23C10.jpg.html)

I had to cut a section out and replace it as I had indented this area for the harness mount.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/73818675-1983-412A-BC81-AE1C2749937F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/73818675-1983-412A-BC81-AE1C2749937F.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3323BB01-5E74-42D9-AD63-D541710818AC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3323BB01-5E74-42D9-AD63-D541710818AC.jpg.html)

Big section to cut out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9FEE117A-5F49-4ED2-B0C5-88E7AF379D91.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9FEE117A-5F49-4ED2-B0C5-88E7AF379D91.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E6C7E58C-4804-4E19-AB64-4C319BED5426.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E6C7E58C-4804-4E19-AB64-4C319BED5426.jpg.html)

Cut out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9E079C24-2E20-4594-92B3-A5C0490F1F28.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9E079C24-2E20-4594-92B3-A5C0490F1F28.jpg.html)

I first had to make an infill panel to make up for the indent left from the pressing used for the later heater outlet.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/68E4A813-4466-4075-8524-7D8F5925B1CF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/68E4A813-4466-4075-8524-7D8F5925B1CF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/146083CB-2F1E-4A99-B854-EA124E40E2C5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/146083CB-2F1E-4A99-B854-EA124E40E2C5.jpg.html)

Onto the roller with some fresh steel. I used the old section to get the correct curve.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FAB28BF0-F45E-4EC3-B3DC-847FD7272B4E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FAB28BF0-F45E-4EC3-B3DC-847FD7272B4E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E0EC1F8B-F68A-4545-9163-158815354E22.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E0EC1F8B-F68A-4545-9163-158815354E22.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A1A355E9-A8FA-4FDC-9CEF-5350E94BB66F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A1A355E9-A8FA-4FDC-9CEF-5350E94BB66F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4090A476-3A70-4771-9DAD-F9A2D30BF084.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4090A476-3A70-4771-9DAD-F9A2D30BF084.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BFEADA0A-8171-451D-9E1C-5573C6B60641.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BFEADA0A-8171-451D-9E1C-5573C6B60641.jpg.html)



(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2F2F6F63-B54E-4704-835A-C744C65DD0D5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2F2F6F63-B54E-4704-835A-C744C65DD0D5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/993349C5-0E56-4C03-8567-F0EDFC11FE95.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/993349C5-0E56-4C03-8567-F0EDFC11FE95.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/72EACC91-3F29-4485-89C8-F731E0019759.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/72EACC91-3F29-4485-89C8-F731E0019759.jpg.html)

Next to go was the cheap heater vent pressing. I did toy with the idea of replacing this with a genuine section of vents but went for the smooth look anyway.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/62009752-DF91-47D9-856A-CA7EA952D2D5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/62009752-DF91-47D9-856A-CA7EA952D2D5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/55A9EFAE-F212-4712-B041-32D2B7E92087.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/55A9EFAE-F212-4712-B041-32D2B7E92087.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/793B44BF-8CE6-4160-8F07-4F82F79C0240.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/793B44BF-8CE6-4160-8F07-4F82F79C0240.jpg.html)

Traced a line to cut the extra wide lip down too

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/793B44BF-8CE6-4160-8F07-4F82F79C0240.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/793B44BF-8CE6-4160-8F07-4F82F79C0240.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B51031BF-467D-4960-9F2C-6E1C5E8F5148.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B51031BF-467D-4960-9F2C-6E1C5E8F5148.jpg.html)

better

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DB67CA5C-39D5-447D-9133-97DB0AE2B0F4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DB67CA5C-39D5-447D-9133-97DB0AE2B0F4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3CBE7C93-5CC3-4D78-814E-ABB88A0FFC53.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3CBE7C93-5CC3-4D78-814E-ABB88A0FFC53.jpg.html)

Other side smoothed and trimmed too

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B1FE536C-8292-4F55-8EDC-6F8D0AC99275.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B1FE536C-8292-4F55-8EDC-6F8D0AC99275.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D60F8BEC-AD45-419C-AB8D-B1D29336F267.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D60F8BEC-AD45-419C-AB8D-B1D29336F267.jpg.html)

Modified for the correct smooth style

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D11C6BB6-A09B-4B0E-9ACA-38FE4B4D16C1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D11C6BB6-A09B-4B0E-9ACA-38FE4B4D16C1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/74ACE6ED-1748-4BFE-A1DD-BA115384BD4A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/74ACE6ED-1748-4BFE-A1DD-BA115384BD4A.jpg.html)

Now the next section to get attention was the door pillar. Now I could have just used a chunk of filler to smooth over the seam and job done as it was not rusty or welded in the wrong place but that wasn't going to cut it and I needed access to the wing nutserts on the front quarter panel. I thought about what options I had , door pillar repair panels are not high enough to get decent access so I managed to get a nos dash and pillar panel so I could cut that up instead.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/58FE2278-4332-4282-956F-B48B20A69348.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/58FE2278-4332-4282-956F-B48B20A69348.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9AC5B4E8-0245-4B9D-8D5F-C7E97073DDE6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9AC5B4E8-0245-4B9D-8D5F-C7E97073DDE6.jpg.html)

Nos door pillar

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/47D886E3-B261-46F2-BD51-955F37B9E779.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/47D886E3-B261-46F2-BD51-955F37B9E779.jpg.html)

Goes to show what lies beneath. This seam was only about seven years old as the front quarter had been replaced in the crash. Lack of weld through primer.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8380FC8D-41D2-4CA4-AF69-A70A79000363.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8380FC8D-41D2-4CA4-AF69-A70A79000363.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7FE547D0-6530-4B6D-B92C-F4457B3E5DCC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7FE547D0-6530-4B6D-B92C-F4457B3E5DCC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/13168EE6-0C44-4D39-BF56-3B2E845FA63E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/13168EE6-0C44-4D39-BF56-3B2E845FA63E.jpg.html)

As you can see, the nutserts were wrong. Access was still a pain in the arse and also I had to replicate the original look as they are visible from inside the bonnet. Trusty press tool was used again.

Grinding off the incorrect nutsert took a while as not to damage the panel.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/214D5874-D9DD-4A8A-95A5-A877C0E67775.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/214D5874-D9DD-4A8A-95A5-A877C0E67775.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1DCDEC23-BD86-43AE-B81F-081AB3E85C2F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1DCDEC23-BD86-43AE-B81F-081AB3E85C2F.jpg.html)

They were well stuck on!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AC2AEA4F-0FB1-47DE-A8E8-9607F3CC008D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AC2AEA4F-0FB1-47DE-A8E8-9607F3CC008D.jpg.html)

Indent making

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C1F01619-64CC-48D8-8FBB-4A3EA49496F1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C1F01619-64CC-48D8-8FBB-4A3EA49496F1.jpg.html)

Outside

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CBBABE83-CFDB-4C5D-84BE-40F96F771820.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CBBABE83-CFDB-4C5D-84BE-40F96F771820.jpg.html)

A square hole was made to accept the genuine nutsert

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3D5024A0-484F-430E-B990-AE39FAE848F1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3D5024A0-484F-430E-B990-AE39FAE848F1.jpg.html)

Inside

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/81E8C94A-97C8-4098-89C2-F8CAC9E7332C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/81E8C94A-97C8-4098-89C2-F8CAC9E7332C.jpg.html)

Both

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B0CA84AE-56A0-406A-9C85-C5906933B6C5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B0CA84AE-56A0-406A-9C85-C5906933B6C5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/13311978-D654-4A18-8EE0-946ECCA2B0BD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/13311978-D654-4A18-8EE0-946ECCA2B0BD.jpg.html)

Each nut was blasted and the inside of the quarter was too.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/281AE9A2-A1FD-4920-8D23-44FD59FB30CF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/281AE9A2-A1FD-4920-8D23-44FD59FB30CF.jpg.html)

Now , silver soldering the nut in place was tricky, limited access and heat damage.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D9A347E2-95BF-447D-8EE7-162A71627C06.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D9A347E2-95BF-447D-8EE7-162A71627C06.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/135DF188-24FA-4209-9B6F-4B1479AE72F2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/135DF188-24FA-4209-9B6F-4B1479AE72F2.jpg.html)

Nearly done

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C28DA11B-8F3D-46AA-9FF9-35194C29E7DB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C28DA11B-8F3D-46AA-9FF9-35194C29E7DB.jpg.html)

Just the inside of the pillar was used. I wanted the seam to be flawless.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D6360D07-3399-4D4B-B859-45CE204F8A42.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D6360D07-3399-4D4B-B859-45CE204F8A42.jpg.html)

The wiring hole was in the wrong place too.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/904728F2-1F03-44F9-90A8-1700DC638A7C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/904728F2-1F03-44F9-90A8-1700DC638A7C.jpg.html)

Used a dimple die to give it a little custom touch  :D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F4ED09AC-3424-4D1B-9AEB-DC2720FFCD5F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F4ED09AC-3424-4D1B-9AEB-DC2720FFCD5F.jpg.html)

Filler piece and welded up the old wiring hole

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A5351EA3-1D91-48F7-87B8-CB8AD1C95646.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A5351EA3-1D91-48F7-87B8-CB8AD1C95646.jpg.html)

New was made closer to the pillar.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/613C8A37-C7C7-4A4A-ACE7-2BA29370E447.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/613C8A37-C7C7-4A4A-ACE7-2BA29370E447.jpg.html)

I added a second tab so to keep the main loom tidier.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E172F04-940D-483C-A3EE-B432FC96FE17.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E172F04-940D-483C-A3EE-B432FC96FE17.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E47CC8AC-D440-4E48-A968-365E7242E9D8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E47CC8AC-D440-4E48-A968-365E7242E9D8.jpg.html)

Now before welding in the panel, I epoxy primed the lower front quarter on the inside so that it is protected and the correct colour. I have premixed colour matched  (near as dammit) epoxy. There is now way to get this coverage after the panel is welded back on.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3913B51D-BAF3-4C12-BAE0-6B8B3F4D79AF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3913B51D-BAF3-4C12-BAE0-6B8B3F4D79AF.jpg.html)

I had blasted this area before paint.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/65FD91E3-060B-41F2-A4D6-09B5D21818F9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/65FD91E3-060B-41F2-A4D6-09B5D21818F9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7C71A90E-F4A7-4D65-BE1B-912AD89CE700.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7C71A90E-F4A7-4D65-BE1B-912AD89CE700.jpg.html)

what kind of weld-through primer do you use?

upol Wed#2 Good stuff

Half way through welding it in

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A44DB31E-ABC4-403D-A7AA-E836B617975E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A44DB31E-ABC4-403D-A7AA-E836B617975E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/867740DC-BF98-4DB5-9F36-D2A567010E38.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/867740DC-BF98-4DB5-9F36-D2A567010E38.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/30A36956-846F-46B8-A83C-081A0E916935.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/30A36956-846F-46B8-A83C-081A0E916935.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/75C0DF04-27EF-447B-A27D-5BD424D2E350.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/75C0DF04-27EF-447B-A27D-5BD424D2E350.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D970EB9F-1D8E-4A51-9231-C663A4CB6386.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D970EB9F-1D8E-4A51-9231-C663A4CB6386.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4CEA82AB-C77E-492A-BD55-260F05EA5607.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4CEA82AB-C77E-492A-BD55-260F05EA5607.jpg.html)

nicer than before

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5421322A-C264-420A-AF20-72AD87803439.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5421322A-C264-420A-AF20-72AD87803439.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E64368B4-1601-43BB-8126-6D8A76E62365.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E64368B4-1601-43BB-8126-6D8A76E62365.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2F5EEA18-D600-435A-AFEA-D75BE5D7FE4B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2F5EEA18-D600-435A-AFEA-D75BE5D7FE4B.jpg.html)

Volvo also have a really good one:

(http://i122.photobucket.com/albums/o273/volvo_raggare/Volvo%20945%2096mod/IMG_6347_1024x683_zps2e49e2c2.jpg)

Best rgs
BB

Yeah but that's only for Volvos  ;D

Really loving your resto!

Keep the updates commin'!  8)

i tried to get the upol primer, but no one in the uk will ship it to Austria :(

I`m sure there are other products on the market  :)

Next on the list was to do something about the poor quality pressing on the front of the channel. It had not been formed properly so I had to do something about it.
 The black line was where I had to cut the lower quarter as it sloped downwards and I wanted it straight.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/41048AE8-C969-4932-9F90-713B028C25BD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/41048AE8-C969-4932-9F90-713B028C25BD.jpg.html)

Trimmed straight first

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DEB299A5-BA2D-4C22-8E7D-DA27AAA01CAF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DEB299A5-BA2D-4C22-8E7D-DA27AAA01CAF.jpg.html)

These are the two sections I had to cut out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D8F93D40-4BBA-4CE6-8032-B0B617612341.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D8F93D40-4BBA-4CE6-8032-B0B617612341.jpg.html)

Done

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9F68D2A2-5D7A-4C5E-9AED-48F4EEE81437.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9F68D2A2-5D7A-4C5E-9AED-48F4EEE81437.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2565F84F-F72A-4216-800D-C50ABDA37A97.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2565F84F-F72A-4216-800D-C50ABDA37A97.jpg.html)

Up to this point the shell looked like this . More and more silver areas were added  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1B63E637-F8A7-466D-B548-2C09ACC569BD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1B63E637-F8A7-466D-B548-2C09ACC569BD.jpg.html)

I knew the other side would be a problem, I had tried to get a nos front quarter but failed so I was left with the job of rebuilding the original.  So much of it had been changed, Its had two front clips since I`ve known the car, so trying to put it back to how it should look like was going to be a lot of graft .  I started with the door pillar.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/739FE4A5-7852-4105-933C-8CB966DAC5AF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/739FE4A5-7852-4105-933C-8CB966DAC5AF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/968368A3-0E69-42FD-AE56-219DD63BCF12.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/968368A3-0E69-42FD-AE56-219DD63BCF12.jpg.html)

Cut out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4E243792-1F08-41B4-9044-3C37D48E7AF6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4E243792-1F08-41B4-9044-3C37D48E7AF6.jpg.html)

Even though I had blasted the shell, there are still areas where you cannot get too..   Rusty shit.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A2CCEF2D-6448-477A-BD37-F168CC04E595.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A2CCEF2D-6448-477A-BD37-F168CC04E595.jpg.html)

The door pillar is made up of two skins and I`ve wondered about how many cars  are out there with just the outer skin welded and not the inner strengthener panel touched . I used a Hookys panel for this which I straight away drilled out the spot welds to separate them.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1645E06D-1783-4A62-806F-D8291A60909D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1645E06D-1783-4A62-806F-D8291A60909D.jpg.html)

Tool

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EF58AA2C-7075-412A-A35F-7330619ECCCF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EF58AA2C-7075-412A-A35F-7330619ECCCF.jpg.html)

Hidden rust

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F5892D73-75B4-4EF7-A8DE-4BFB1132914A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F5892D73-75B4-4EF7-A8DE-4BFB1132914A.jpg.html)

Welded and smoothed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6F889B2C-281E-4CC1-9F1E-FB615E08947C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6F889B2C-281E-4CC1-9F1E-FB615E08947C.jpg.html)

I blasted the whole area

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2FAC90A4-C5E3-464D-9568-9E4A86490950.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2FAC90A4-C5E3-464D-9568-9E4A86490950.jpg.html)

Blasted all this

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AE834240-72BE-4718-A00C-EC35883138C4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AE834240-72BE-4718-A00C-EC35883138C4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4A22F71B-0D1D-4161-A57F-1F2ED54CF128.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4A22F71B-0D1D-4161-A57F-1F2ED54CF128.jpg.html)

Trial fitting the outer. Notice that the seam does not line up as the panel was too long.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5143940E-E219-4335-83A1-E95B73DC9AA7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5143940E-E219-4335-83A1-E95B73DC9AA7.jpg.html)

Rest of it fitted nice

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/300B7CF4-3942-47ED-9F69-AF9B24A89FE1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/300B7CF4-3942-47ED-9F69-AF9B24A89FE1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EEF0C8C3-46D2-45EA-A877-F70F2618A8C5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EEF0C8C3-46D2-45EA-A877-F70F2618A8C5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/30BF579E-E103-4EE7-9B15-E25997BB88CC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/30BF579E-E103-4EE7-9B15-E25997BB88CC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4E10711C-EFC6-43AA-97F4-5E3E62C8403C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4E10711C-EFC6-43AA-97F4-5E3E62C8403C.jpg.html)

First tack

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A312823B-ECE3-4DA9-BB6D-3E81C350D7F1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A312823B-ECE3-4DA9-BB6D-3E81C350D7F1.jpg.html)

Door on to check gaps

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/730F023F-E5A3-4D88-85C9-3B2CE494FB8B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/730F023F-E5A3-4D88-85C9-3B2CE494FB8B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4CDCA1B2-94B3-45CF-B347-AC7B3059380B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4CDCA1B2-94B3-45CF-B347-AC7B3059380B.jpg.html)

I had to cut and adjust the seam so it lined up correctly

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5891A6FF-F977-4287-A2C2-59861FAE8E90.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5891A6FF-F977-4287-A2C2-59861FAE8E90.jpg.html)

Nearly there, tonnes of time spent here.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4BDA8481-E4B5-4786-A93F-42EE29134F3C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4BDA8481-E4B5-4786-A93F-42EE29134F3C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A43F00AE-A2E9-4FC0-A43B-72419DBC287B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A43F00AE-A2E9-4FC0-A43B-72419DBC287B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9E0DE168-7972-4179-9AD7-583331EFAACB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9E0DE168-7972-4179-9AD7-583331EFAACB.jpg.html)

I drilled and spot welded the inner to the outer like it should be done.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EDF4A92F-3DCF-43BF-8B5C-2E519DC38F63.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EDF4A92F-3DCF-43BF-8B5C-2E519DC38F63.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1D037419-58BF-47C6-8C7D-F931D4409760.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1D037419-58BF-47C6-8C7D-F931D4409760.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C3416637-6EAE-4D6C-A9A0-F92005922005.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C3416637-6EAE-4D6C-A9A0-F92005922005.jpg.html)

No filler reqd  ;D
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B99BBDF9-34CD-469D-B5E0-76D933259C42.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B99BBDF9-34CD-469D-B5E0-76D933259C42.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7AE08BF4-4DB1-4102-A313-C3D81F32D2D0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7AE08BF4-4DB1-4102-A313-C3D81F32D2D0.jpg.html)

I cant believe I`m skipping through all this so quick, its taken a lot of hours to get to just this point and there is a lot more to come. Hope I`m entertaining you and not boring you with my shit. I just wanted to show what has been done so that when its finished its not just the same car tidied up.  Many many hours have been put into all the other detail stuff too. I think I should slow this thread down a bit.  :D

Please keep the updates coming. You are setting new standards and it is really interesting to see all the work you have done and your detailed pictures.

Best rgs
BB

Yep and the sh... part is it looks so easy...  :-\ :-[

but I tried it sometimes I am not skilled yet..  :-[

Ta muchly  ;D

Next was the front cross member or napoleons hat or what ever you call it. I decided to tackle this section next rather than the lower front O/S quarter because its best way round as you will see.

This bit

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7B220410-3448-4A96-B71F-3486F11835EE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7B220410-3448-4A96-B71F-3486F11835EE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/55EEB2A6-2D32-44FE-85CE-6CB857026005.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/55EEB2A6-2D32-44FE-85CE-6CB857026005.jpg.html)

I had previously worked on this area and it was far from show worthy. In amongst the box of body cuts I got from the states I had a replacement cross member inc the front firewall which was still spot welded on..

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A9BF0AE1-4C4A-415D-9A86-044DEEC1E385.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A9BF0AE1-4C4A-415D-9A86-044DEEC1E385.jpg.html)

Where it had been cut off he had caught a few of the seams which pleased me no end  >:(


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F4BDF131-ABB6-46EF-A061-B457C294D770.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F4BDF131-ABB6-46EF-A061-B457C294D770.jpg.html)

This seam was missing completely  >:(

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EDCBFA0E-C9BD-419F-8AD4-20CE0EB57597.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EDCBFA0E-C9BD-419F-8AD4-20CE0EB57597.jpg.html)

Nicely butchered

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4AF3B374-5C0F-42CD-8D74-109F4F00D9B8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4AF3B374-5C0F-42CD-8D74-109F4F00D9B8.jpg.html)

The missing seam was found still stuck on the quarter panel lower which I had bought too ( and never used as it was shit, really shit!)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2B18F4F7-D778-4860-AC8C-DCF71E6EF5E6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2B18F4F7-D778-4860-AC8C-DCF71E6EF5E6.jpg.html)

I drilled the seam off and it would have been rude not to use it..

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F48FEA01-CE14-4EF0-9669-2236B419E26A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F48FEA01-CE14-4EF0-9669-2236B419E26A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2BBCD29B-DA25-4798-A019-EC269B66E8A7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2BBCD29B-DA25-4798-A019-EC269B66E8A7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AA765985-8CEA-451A-841F-00A305B4871F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AA765985-8CEA-451A-841F-00A305B4871F.jpg.html)

Tacked back on

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CCDF98E0-2F90-4BF5-8DAA-155F33894643.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CCDF98E0-2F90-4BF5-8DAA-155F33894643.jpg.html)

Separated the two, at this point I had just blasted the outside.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7CD80E98-72FB-4B0B-8B8C-7FBA9245039C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7CD80E98-72FB-4B0B-8B8C-7FBA9245039C.jpg.html)

Little bit of rot but nothing serious

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/61815A14-7750-459D-B1C0-59E970102645.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/61815A14-7750-459D-B1C0-59E970102645.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E78887B4-DDDE-4FF8-A78E-CC0CB1A2C72A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E78887B4-DDDE-4FF8-A78E-CC0CB1A2C72A.jpg.html)

Now, being that my car is RHD , I didn't see the point in keeping the ugly LHD dip switch recess as this area will not be carpeted because carpet hides nasties.  So I made this...

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F9E0D8E6-8B24-4061-860B-3C1D4C597BB4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F9E0D8E6-8B24-4061-860B-3C1D4C597BB4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/80EC14C3-382A-482A-9FB7-D96C19197437.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/80EC14C3-382A-482A-9FB7-D96C19197437.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EFC974C6-9606-4D85-B56F-5D826052D7A8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EFC974C6-9606-4D85-B56F-5D826052D7A8.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7FCA6C54-3830-4250-945D-412F4430AA0E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7FCA6C54-3830-4250-945D-412F4430AA0E.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8E485ABE-EFFD-4BFF-A670-A93DE76B939F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8E485ABE-EFFD-4BFF-A670-A93DE76B939F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FD201FBD-9D68-4C82-864F-48F3FD6A867F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FD201FBD-9D68-4C82-864F-48F3FD6A867F.jpg.html)

Also filled in the slots for the foot plates

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C6E343D6-7A90-4B96-AB42-4475143E0B9C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C6E343D6-7A90-4B96-AB42-4475143E0B9C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CD69C470-E68F-4C81-A74F-1493E12D424A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CD69C470-E68F-4C81-A74F-1493E12D424A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F1557C78-1766-4E46-959A-BCBAA949D0C6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F1557C78-1766-4E46-959A-BCBAA949D0C6.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EE1BD643-5CAC-433C-BF6A-56638CE8A3B9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EE1BD643-5CAC-433C-BF6A-56638CE8A3B9.jpg.html)

Nice and flat

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0AF0FD18-4EF6-4550-8957-CA980618D2EA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0AF0FD18-4EF6-4550-8957-CA980618D2EA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/985C8B42-1825-423D-A3E5-C44B060B48EC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/985C8B42-1825-423D-A3E5-C44B060B48EC.jpg.html)








 

Before I cut the cross member out , I cut out the horrible repair I did years ago on the front quarter. It was nasty..

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/67943C64-403C-4AD9-86A5-2EDB923D3818.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/67943C64-403C-4AD9-86A5-2EDB923D3818.jpg.html)

The 'needed' writing was there so there was no confusion as to what sections i needed when emailing people with photos with exactly what i wanted!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/334ED4FF-5010-4274-A9DF-3FB2EA29E142.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/334ED4FF-5010-4274-A9DF-3FB2EA29E142.jpg.html)

This is what it was hiding!  :shock:

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2AA56102-7267-4321-A5AB-37576CCFAEAA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2AA56102-7267-4321-A5AB-37576CCFAEAA.jpg.html)

Told you it was nasty!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DF28045B-3FFD-4B0A-87D6-84CA638C817E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DF28045B-3FFD-4B0A-87D6-84CA638C817E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/08575F2A-362F-4D4D-945A-3CB5BED678CF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/08575F2A-362F-4D4D-945A-3CB5BED678CF.jpg.html)

I was dreading this area to be honest, i knew it would be difficult to get it to look factory fresh.

Cut out the old one, which was a bastard of a job

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/31194043-B38F-4DF5-A551-8D8DC4452E78.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/31194043-B38F-4DF5-A551-8D8DC4452E78.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3AC77AAB-B22B-40E7-94E3-5E67161861F5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3AC77AAB-B22B-40E7-94E3-5E67161861F5.jpg.html)

Job done.....

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2D54A779-262D-43DC-8D1E-ACECE412AD6F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2D54A779-262D-43DC-8D1E-ACECE412AD6F.jpg.html)



Only joking  :D

going to smooth the boss where the steering column passes through the bulkhead on LHD cars?

You got me !  ;D  I did think about it and I still might delete it but being that its a flat panel and thin sheet (0.6mm)  it would be really difficult to get it right and also I might use that raised area for something else.  ;)

Started by cutting out the bad and cleaning up the channel. The end plate was shit , so I cut that off too.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BC15325A-905E-4BC5-863D-5B819DB515AE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BC15325A-905E-4BC5-863D-5B819DB515AE.jpg.html)

I had this genuine end plate which was a little bit crusty but useable

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9CF15A41-CA1F-48A9-9AD5-7CE634FB9470.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9CF15A41-CA1F-48A9-9AD5-7CE634FB9470.jpg.html)

Now the firewall. This is an area that's got to look right and unfortunately its made of thin steel. Why vw chose to use such thin steel I will never know. Even the replacement section I got from the states was thin and that was in good condition.  Welding thick to thin sheet is a no no , it will cause you all sorts of grief, not only clamping it in position , but welding it and finally flatting and dressing it after.

Good genuine vw replacement, original thickness of 0.6mm

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/04DC78C4-9870-4974-8EFE-DCE169CC7B8F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/04DC78C4-9870-4974-8EFE-DCE169CC7B8F.jpg.html)

Original on my car

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F73D1955-AF73-4C5D-98AE-10B5AAC87385.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F73D1955-AF73-4C5D-98AE-10B5AAC87385.jpg.html)

Fortunately I had some correct thickness sheet to make my own section . Now you are prob wondering why I didn't use the one from the states? It had been butchered so I couldn't use it.  >:(

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/37BDC9B8-C24A-4BFE-9389-C003B34A63DB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/37BDC9B8-C24A-4BFE-9389-C003B34A63DB.jpg.html)

Used a straight edge and clamped my sheet to it after putting a 90 degree bend in it

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2C85E496-B10C-4AB0-8086-7756CBC99CD9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2C85E496-B10C-4AB0-8086-7756CBC99CD9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/612502F8-838D-439D-A45F-272F306310C6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/612502F8-838D-439D-A45F-272F306310C6.jpg.html)

Missing the dimple and we all know its all about the dimple!  As it happens, the dimple is not a straight forward shape to replicate as it has a flat surface where it sits on the inner bulkhead ,so making a press tool to get the shape 100% correct would be difficult.

See what I mean?

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6A254932-686F-48A1-B5C3-91E0C66AEE56.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6A254932-686F-48A1-B5C3-91E0C66AEE56.jpg.html)

So I cut out the genuine dimple

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DE10F01F-B624-40A8-9A37-017BFF0B89B3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DE10F01F-B624-40A8-9A37-017BFF0B89B3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/940AA518-1F68-497F-9C6A-FFE044B85552.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/940AA518-1F68-497F-9C6A-FFE044B85552.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/56CDD18D-9C6A-4BF1-A5F1-53B2039AD7FB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/56CDD18D-9C6A-4BF1-A5F1-53B2039AD7FB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8483F6FE-0FE6-4959-8E02-0D69FB089C85.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8483F6FE-0FE6-4959-8E02-0D69FB089C85.jpg.html)

Yet to sort out the end plate.


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B57D30DC-785D-4BC2-A39A-5C68829DF37F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B57D30DC-785D-4BC2-A39A-5C68829DF37F.jpg.html)

Also the seam does not flow straight, it has a ridge at the bottom to account for the channel end plate. I formed mine like the genuine one.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/77C6B41B-92FA-4B09-ACD4-28355C8574DD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/77C6B41B-92FA-4B09-ACD4-28355C8574DD.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/97049195-9FBA-4986-B701-3BE53B4DD0E3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/97049195-9FBA-4986-B701-3BE53B4DD0E3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/336B5935-13FC-4FB9-9B65-220CFF527FC9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/336B5935-13FC-4FB9-9B65-220CFF527FC9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C91D0BE3-9AAF-4AEB-834A-A0A7C649AF55.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C91D0BE3-9AAF-4AEB-834A-A0A7C649AF55.jpg.html)

You can see here what its for

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/50FA538E-C581-4DC5-90AC-91CD2B1891FF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/50FA538E-C581-4DC5-90AC-91CD2B1891FF.jpg.html)

Still needed blasting at this point

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/78A44B42-B55F-4754-A1FD-9FC89FA4963D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/78A44B42-B55F-4754-A1FD-9FC89FA4963D.jpg.html)

Cleaned up and blasted.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F7D62D4D-AA72-4BDF-95DC-4EDE576FFF8A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F7D62D4D-AA72-4BDF-95DC-4EDE576FFF8A.jpg.html)

This side was really bad

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9A99F027-E8B6-4B11-B3F7-15FA1F710497.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9A99F027-E8B6-4B11-B3F7-15FA1F710497.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BA8ECA71-CAC7-42C7-B753-1B374E9191AE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BA8ECA71-CAC7-42C7-B753-1B374E9191AE.jpg.html)

Starting to look better

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D64BC74A-FE8B-45DA-977A-925B7F98B172.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D64BC74A-FE8B-45DA-977A-925B7F98B172.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/11FB4D01-327F-4676-89FC-922AD985EB65.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/11FB4D01-327F-4676-89FC-922AD985EB65.jpg.html)

End plate needed a bit of work

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C2E5C656-DFAF-42EE-BF77-4DCE6DF69EAD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C2E5C656-DFAF-42EE-BF77-4DCE6DF69EAD.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3C960CCD-67CC-4B8E-9689-7809D126CB7C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3C960CCD-67CC-4B8E-9689-7809D126CB7C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5FAC320E-7F42-4679-BA75-6BBE67193FD4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5FAC320E-7F42-4679-BA75-6BBE67193FD4.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AA21EC25-A1B5-46FF-99C2-8B24EE1CF6FC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AA21EC25-A1B5-46FF-99C2-8B24EE1CF6FC.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AF887699-2213-4DFF-8E49-B7C3C7BA2C36.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AF887699-2213-4DFF-8E49-B7C3C7BA2C36.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DDC972BB-BC12-463F-BBD4-10D6E81477D0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DDC972BB-BC12-463F-BBD4-10D6E81477D0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/023A713A-1F48-4ED6-8269-65EFB9E9F7BE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/023A713A-1F48-4ED6-8269-65EFB9E9F7BE.jpg.html)

Getting the repair panel into place. This takes ages to get right as I wanted a nice uniform weld gap as welding this thin sheet is difficult

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A6FBAA51-59FB-4211-B2A3-0784B40023F5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A6FBAA51-59FB-4211-B2A3-0784B40023F5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2B17BE3E-AF38-4A78-B251-8AC2CF1372A3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2B17BE3E-AF38-4A78-B251-8AC2CF1372A3.jpg.html)

Tacked

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/436A6B9B-8348-406D-A260-0E117C1CF197.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/436A6B9B-8348-406D-A260-0E117C1CF197.jpg.html)

Nearly done
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C139152D-F9B9-4D9E-B1D0-2AD2055D4E6B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C139152D-F9B9-4D9E-B1D0-2AD2055D4E6B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0371E6BD-FB06-4621-AA58-C0D8935CAA58.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0371E6BD-FB06-4621-AA58-C0D8935CAA58.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C778E3D6-0AA7-494E-8105-44C9E8EF084F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C778E3D6-0AA7-494E-8105-44C9E8EF084F.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BFFC0097-1889-4599-A197-71464B4FAB38.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BFFC0097-1889-4599-A197-71464B4FAB38.jpg.html)

No filler  :D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1051A14D-0BB7-4989-A619-883387B11377.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1051A14D-0BB7-4989-A619-883387B11377.jpg.html)

One of the biggest pain in the arse was seeing what you are doing , no kidding , being able to see what you are grinding without steaming goggles etc is half the battle!! I`ve found that a full face shield is the way to go, full protection and no steaming up , I combine this with a 3m mask. Makes all the difference.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9772D424-82DC-41DA-9D30-30C4BE2316C1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9772D424-82DC-41DA-9D30-30C4BE2316C1.jpg.html)

This is an awesome thread your work is amazing.

It reminds me of the 50's cabriolet on restowagen all those years ago.

Thought same thing. This is great work.

Keep 'em coming. This thread shows some amazing work. You're a true master at what you do. Unbelievable. I spend an hour just looking at your pics. How many hours do you have in time so far? I can only imagine!! :o

Awesome work and great pictures! Very instructive! Thanks for sharing and to spend times taken pics and explain what you do. ;)

Thanks for the kind comments, I just love what I do and I`m doing it for myself and for no one else. 

This lot got blasted next

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D05F608F-DA94-4D5E-AA49-2F80D00327CA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D05F608F-DA94-4D5E-AA49-2F80D00327CA.jpg.html)

This side was going to be a lot of work as it was a mess and I had to replace a section of the smile  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B4071A47-B7BB-42BC-B858-B05B72A5E97A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B4071A47-B7BB-42BC-B858-B05B72A5E97A.jpg.html)

If you ignore the straight edge measuring that was going on, you can see the difference in the pressing. The panel I had got hold of was from a slightly earlier car and the smile was longer so that ruled out using the whole panel  :( >:(   So I had to cut through the smile at a point and join it half way down which was very tricky as not only was it thin but I had a dip in the pressing to contend with...

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/652250EC-D3DA-4D4C-9EB7-C0F62A38B8AD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/652250EC-D3DA-4D4C-9EB7-C0F62A38B8AD.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/038B1FAE-FF20-42B4-A109-D6F11E72AC9B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/038B1FAE-FF20-42B4-A109-D6F11E72AC9B.jpg.html)

Again , I cut off the end plate

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BD6D381E-E634-4EF9-8D6D-8EC3AFD69B7D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BD6D381E-E634-4EF9-8D6D-8EC3AFD69B7D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/47EBA004-5DCB-47F4-937F-EF8AF5CAAD06_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/47EBA004-5DCB-47F4-937F-EF8AF5CAAD06_1.jpg.html)

I had a genuine end plate to use again

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/30C5A0B1-A309-430C-A38E-4D9B60686C20.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/30C5A0B1-A309-430C-A38E-4D9B60686C20.jpg.html)

You can see that I bent the lower quarter to get better access to this area.  Blasted the surface rust away.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4E9C92DA-EEF1-49C8-A23A-0964FE652A96.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4E9C92DA-EEF1-49C8-A23A-0964FE652A96.jpg.html)

Part way through welding it on after careful measuring

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FD8EE649-EC03-4043-A9FD-9A9A44205558.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FD8EE649-EC03-4043-A9FD-9A9A44205558.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/72B8622C-E4FC-425C-A8C3-C5FFF12BE189.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/72B8622C-E4FC-425C-A8C3-C5FFF12BE189.jpg.html)

I had already repaired the lower on the replacement panel as it was a little bit crusty

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A66D6F73-6E72-4516-B0E5-A8BCD9964D6C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A66D6F73-6E72-4516-B0E5-A8BCD9964D6C.jpg.html)

Nice fit which is half the battle

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E10F03B8-E1A8-4D46-ABC9-82ECA74A59F0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E10F03B8-E1A8-4D46-ABC9-82ECA74A59F0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A3005AD8-658D-46E4-B704-4505C4F35BBF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A3005AD8-658D-46E4-B704-4505C4F35BBF.jpg.html)

Final panel prep before tacking in

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D7694B3A-5A09-4C98-8585-2DA44603A088.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D7694B3A-5A09-4C98-8585-2DA44603A088.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/944CB19C-30D6-49D7-97FE-ED933C34EC22.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/944CB19C-30D6-49D7-97FE-ED933C34EC22.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/36B6851C-F740-4582-84DC-03FF9605863D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/36B6851C-F740-4582-84DC-03FF9605863D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/83351613-99CD-479D-B664-F33607A908C5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/83351613-99CD-479D-B664-F33607A908C5.jpg.html)

Finished the smile first as this bit was the most difficult

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9CBD8BCD-FF31-4C40-8A63-F69EA11E0091.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9CBD8BCD-FF31-4C40-8A63-F69EA11E0091.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A909D913-DC81-45E2-8B88-9757C3188390.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A909D913-DC81-45E2-8B88-9757C3188390.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F9050E65-42B3-4433-A4A6-760FBFF10255.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F9050E65-42B3-4433-A4A6-760FBFF10255.jpg.html)

Nearly there

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AEC2869B-1912-479C-8137-76ED591F3A5D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AEC2869B-1912-479C-8137-76ED591F3A5D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/293CE3A3-51CD-465B-AFBE-79364DF9536A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/293CE3A3-51CD-465B-AFBE-79364DF9536A.jpg.html)

Bent the quarter back into shape and yet to weld the seam in place

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/08CD14B8-3476-4251-AFBE-CFF79432E162.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/08CD14B8-3476-4251-AFBE-CFF79432E162.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1CB5F4E4-E8F2-4B8E-93BF-FDA29E03FA63.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1CB5F4E4-E8F2-4B8E-93BF-FDA29E03FA63.jpg.html)

In amongst the body cuts I had there was a section of the front cross member that showed me how it was welded from the factory. It was a bit untidy to be honest.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D0982795-C75D-44E0-B7F8-CB2A87CDE955.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D0982795-C75D-44E0-B7F8-CB2A87CDE955.jpg.html)

Made my own seam, it is a complex curve and took a bit of time to get right.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/737DC0FF-644D-471D-9702-653883E96FD9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/737DC0FF-644D-471D-9702-653883E96FD9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/482AFDE6-9012-40BD-BF45-66F9373EFC91.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/482AFDE6-9012-40BD-BF45-66F9373EFC91.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B90F8B93-9236-4368-95D8-6E8B542D5599.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B90F8B93-9236-4368-95D8-6E8B542D5599.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E3733CE3-C207-4E6B-B312-B87FE253BF25.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E3733CE3-C207-4E6B-B312-B87FE253BF25.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A0ACC406-D35F-47B4-B73A-D8EBDD9F23E7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A0ACC406-D35F-47B4-B73A-D8EBDD9F23E7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/302B8734-F73A-4966-80BB-C98A8A1816CF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/302B8734-F73A-4966-80BB-C98A8A1816CF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B4E3C99B-5574-4582-80D8-0A1C1174DA1F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B4E3C99B-5574-4582-80D8-0A1C1174DA1F.jpg.html)

Other side

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B3172E95-5600-4BD6-A97E-54FA323D1B03.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B3172E95-5600-4BD6-A97E-54FA323D1B03.jpg.html)

Slowly getting there

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E6BA3DA-B618-414B-B390-5B14D58D89C5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E6BA3DA-B618-414B-B390-5B14D58D89C5.jpg.html)

I also trimmed the late front quarter to the correct sixties style

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1A2780FA-16CB-4471-9F82-3E88BE983BE7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1A2780FA-16CB-4471-9F82-3E88BE983BE7.jpg.html)

So then it was a case of welding up all the holes made when I had drilled out the spot welds on the cross member, and generally prepping the panel for its new home.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7D2BF8C9-689F-489B-A30D-C94FB653F9C9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7D2BF8C9-689F-489B-A30D-C94FB653F9C9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/23C928A1-A8F3-46C5-A7B3-374F42539F6F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/23C928A1-A8F3-46C5-A7B3-374F42539F6F.jpg.html)

Drilling holes in my newly repaired firewall wasn't nice

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8B278AD3-EA7F-4B4B-B36C-01BAFB5635F0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8B278AD3-EA7F-4B4B-B36C-01BAFB5635F0.jpg.html)

I also made a new dimple in the modified section to even things out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/37A177FC-EE30-44F2-8FD0-2E2577628614.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/37A177FC-EE30-44F2-8FD0-2E2577628614.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8666DDBE-DC9D-452D-8543-36121CB8B467.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8666DDBE-DC9D-452D-8543-36121CB8B467.jpg.html)

Left my mark before welding it on.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B0CBBF1B-4535-419F-AC50-8BC893BE7F7C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B0CBBF1B-4535-419F-AC50-8BC893BE7F7C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8E055534-4ADD-4749-A75D-EB1A92FC48D2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8E055534-4ADD-4749-A75D-EB1A92FC48D2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DA112A7B-B07B-430C-B3C2-B35F78ECF46A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DA112A7B-B07B-430C-B3C2-B35F78ECF46A.jpg.html)

Even weld through primer sometimes needs to be scratch off for the best results

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BAB215E9-39F2-4E8D-AB45-1E8CAE55D4AC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BAB215E9-39F2-4E8D-AB45-1E8CAE55D4AC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/840B418C-C8CD-4922-8CC3-E91C07441D04.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/840B418C-C8CD-4922-8CC3-E91C07441D04.jpg.html)

Seam welded on to

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4E00250D-4681-4BAE-ADA9-28C38366AB04.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4E00250D-4681-4BAE-ADA9-28C38366AB04.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F01A3C59-A0C2-469C-8061-6460D366CE9E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F01A3C59-A0C2-469C-8061-6460D366CE9E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8D8972EB-BFD5-4DF9-95EC-391BDD011693.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8D8972EB-BFD5-4DF9-95EC-391BDD011693.jpg.html)

Seam tidied up

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/32A0B7E8-E4D7-4A96-93B1-1B418E08B3A0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/32A0B7E8-E4D7-4A96-93B1-1B418E08B3A0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/67785D15-4713-4B61-A3EB-2E5C9F930A95.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/67785D15-4713-4B61-A3EB-2E5C9F930A95.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D79C67EE-19FF-40C5-B474-8F3E43BA4CD2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D79C67EE-19FF-40C5-B474-8F3E43BA4CD2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E2BE6E59-1634-41C2-8451-6B33F8A635DD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E2BE6E59-1634-41C2-8451-6B33F8A635DD.jpg.html)

two questions:

1 - what weld through primer are you using

2 - how are you finishing the welds?  What type of sander is it etc

Upol weld 2

I linish the weld with a 1" belt sander and then use a random orb sander.  All of my tools are Makita.  I know them inside and out.

So next on the list was to sort the crumpled pressing on the right channel, so I cut out the section and welded in a new one.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2726BB47-742A-4911-BAA8-4CBF20D3A6E6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2726BB47-742A-4911-BAA8-4CBF20D3A6E6.jpg.html)

Sorted

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A3EDA597-BE61-4C18-B64E-9CE99400CB1B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A3EDA597-BE61-4C18-B64E-9CE99400CB1B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/815DF22D-213C-4FB0-A959-41CC75C89ED3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/815DF22D-213C-4FB0-A959-41CC75C89ED3.jpg.html)

Onwards to the lower front quarter. Now the Virtanen panel I bought is a good pressing but there was a few differences as it was for an oval , so I modified it to the later sixties spec.  I cut the end off completely and grafted on a genuine section I had, so that it lined up perfectly

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/962CD528-0BCB-4769-B1C6-178D6901DA4D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/962CD528-0BCB-4769-B1C6-178D6901DA4D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/08C8D5A8-A3CC-407F-ACCF-9C340A85B805.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/08C8D5A8-A3CC-407F-ACCF-9C340A85B805.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/245B6A1A-F9FC-4EF1-976B-B2DD6FAFA874.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/245B6A1A-F9FC-4EF1-976B-B2DD6FAFA874.jpg.html)

I had to be very careful to get the measurement and cut right

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6FC740EC-BE20-47AE-8542-336079C69619.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6FC740EC-BE20-47AE-8542-336079C69619.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/30D43E25-345A-442D-9769-67670C9B14CF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/30D43E25-345A-442D-9769-67670C9B14CF.jpg.html)

Right shape and thickness

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FB64F6E7-4188-472F-AEBE-41D69C30E54D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FB64F6E7-4188-472F-AEBE-41D69C30E54D.jpg.html)

Nutsert started like this, wrong for my car.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3E6D29B5-42B8-468C-92BE-066C4B75F80E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3E6D29B5-42B8-468C-92BE-066C4B75F80E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2930113B-8696-4E11-B27C-6C8CCABEBF06.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2930113B-8696-4E11-B27C-6C8CCABEBF06.jpg.html)

Super Tool  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/43852A9C-0BB7-4743-BEDE-1EB363161F70.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/43852A9C-0BB7-4743-BEDE-1EB363161F70.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8076EC59-30F3-4F32-8399-82C710596691.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8076EC59-30F3-4F32-8399-82C710596691.jpg.html)

Genuine nutsert

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/32326297-110A-4F75-B07B-2A4DA548F10A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/32326297-110A-4F75-B07B-2A4DA548F10A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/55070DBC-D2E5-47AB-9D60-0D691022ECF2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/55070DBC-D2E5-47AB-9D60-0D691022ECF2.jpg.html)

Silver soldered in

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/40A1FCA4-E53A-449E-8E5D-85979364E909.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/40A1FCA4-E53A-449E-8E5D-85979364E909.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8D0F34A0-E04E-4510-87EF-447A3FECCE17.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8D0F34A0-E04E-4510-87EF-447A3FECCE17.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/37096035-B6BE-4DFC-A8CC-398B83152959.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/37096035-B6BE-4DFC-A8CC-398B83152959.jpg.html)

The bottom didn't flow properly either so I added some metal

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/95AA88EA-8588-4DAB-A448-28407D66BF08.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/95AA88EA-8588-4DAB-A448-28407D66BF08.jpg.html)

Matched from the other side

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C1139323-B3B1-43EC-AFBD-BEEEF8C83A5D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C1139323-B3B1-43EC-AFBD-BEEEF8C83A5D.jpg.html)

I needed to trim it down after this shot

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DED34380-B71A-44E2-A33B-E0B37CC8854D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DED34380-B71A-44E2-A33B-E0B37CC8854D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1027CF93-9104-45F3-B047-97E9C3B90709.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1027CF93-9104-45F3-B047-97E9C3B90709.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9AC35FF4-657B-458B-BFFF-6B15F3F12DA9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9AC35FF4-657B-458B-BFFF-6B15F3F12DA9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FDF6A7C5-7AB0-410E-A2C1-95C0A890934B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FDF6A7C5-7AB0-410E-A2C1-95C0A890934B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EEA8B557-E415-4CCB-84AC-37E81962FB81.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EEA8B557-E415-4CCB-84AC-37E81962FB81.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6398BCF8-5362-4724-A011-1590F3E0C09C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6398BCF8-5362-4724-A011-1590F3E0C09C.jpg.html)

As I wanted a nice invisible repair both inside and out I knew there would be an issue with metal thickness and I was right. Over the years of abuse, rust, blasting, scraping etc the inner quarter had gone thin, it starter from the factory as around 1mm sheet and mine was on average .7mm

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DC217407-61FC-46C0-8D05-978CA8D4D608.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DC217407-61FC-46C0-8D05-978CA8D4D608.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C6E92B4A-C2BE-4B35-9204-67838E568BAA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C6E92B4A-C2BE-4B35-9204-67838E568BAA.jpg.html)

Again welding thick to thin does not work especially if you want a nice finish on the inside too. The new repair panel was 1mm

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DE455E9C-29E9-458C-B210-3129C733628A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DE455E9C-29E9-458C-B210-3129C733628A.jpg.html)

I thought about this problem for a while, what could I do.....?
The only way around it and I know this sounds crazy but I had to make my new panel thinner, so I put it on the linisher ( basically an upside down 4"belt sander) . You can see where I sanded the whole side down.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8D7B8A5D-99DB-491E-A1DC-DE1ED71B5124.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8D7B8A5D-99DB-491E-A1DC-DE1ED71B5124.jpg.html)

Got it down to a nice even .73mm

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/29BD8D06-F416-4878-9233-E6DE7FD90509.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/29BD8D06-F416-4878-9233-E6DE7FD90509.jpg.html)

I epoxy primed the inner door pillar first like the other side

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8BBEF67E-C76B-46D4-8B61-545F6D559B89.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8BBEF67E-C76B-46D4-8B61-545F6D559B89.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CD3D12F3-68D5-48EB-A1A4-F37490826624.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CD3D12F3-68D5-48EB-A1A4-F37490826624.jpg.html)

Spent a long time panel prepping

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/302FD35D-A73D-4E6B-A193-0F785963BF8D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/302FD35D-A73D-4E6B-A193-0F785963BF8D.jpg.html)

Then started the welding

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/34FCBF54-B390-4ECC-84F4-33E4A81DC50C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/34FCBF54-B390-4ECC-84F4-33E4A81DC50C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6139B238-ABCF-4D3F-BF48-B1B1162334D5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6139B238-ABCF-4D3F-BF48-B1B1162334D5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2467B5DB-4EA0-4121-8372-F2A51F8C04CD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2467B5DB-4EA0-4121-8372-F2A51F8C04CD.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7E644304-2527-46CF-96A3-65B8D78FA52E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7E644304-2527-46CF-96A3-65B8D78FA52E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1834B9B9-AEEF-4B02-AC8F-4EAB13BC3551.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1834B9B9-AEEF-4B02-AC8F-4EAB13BC3551.jpg.html)

All the spot welds are just temp plugged for now but the main join is getting there. This took an age.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/885F8B18-18FD-4A42-8E29-BB8B7B114E9F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/885F8B18-18FD-4A42-8E29-BB8B7B114E9F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3F73525D-607A-4FA8-8956-2E988C8B9C0A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3F73525D-607A-4FA8-8956-2E988C8B9C0A.jpg.html)

Inside nearly done

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CAFB7B38-9D17-4F33-9C03-CEBE21EE3FEB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CAFB7B38-9D17-4F33-9C03-CEBE21EE3FEB.jpg.html)

Bare metal

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E39D6B6-B589-48FB-BB8B-D2E0E2D303A5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E39D6B6-B589-48FB-BB8B-D2E0E2D303A5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F2B36428-D9BD-4863-A57E-B260B6C29364.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F2B36428-D9BD-4863-A57E-B260B6C29364.jpg.html)

Much nicer than before

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A0C68A6F-4002-40DD-823D-7ECA7C38D86B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A0C68A6F-4002-40DD-823D-7ECA7C38D86B.jpg.html)

No filler

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FCFB6EDE-72B4-4647-8969-0AA96C668990.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FCFB6EDE-72B4-4647-8969-0AA96C668990.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/42A12E6F-542E-4E1B-9698-DEBFE5E5557E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/42A12E6F-542E-4E1B-9698-DEBFE5E5557E.jpg.html)

Getting to the inside here was hard

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/92EC0D15-F0A0-4E66-971F-4BDCF7AE1C47.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/92EC0D15-F0A0-4E66-971F-4BDCF7AE1C47.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C2CA9413-D491-4B07-8782-34551B160BC4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C2CA9413-D491-4B07-8782-34551B160BC4.jpg.html)

Happy days  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2AAE27E6-9BA2-4AD5-94FF-38CCDAF795B6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2AAE27E6-9BA2-4AD5-94FF-38CCDAF795B6.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A91BCB4C-B364-456D-9496-055E596B50A7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A91BCB4C-B364-456D-9496-055E596B50A7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/13B7D5DE-9096-4C70-AF4A-F5260C3D63FE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/13B7D5DE-9096-4C70-AF4A-F5260C3D63FE.jpg.html)

Wouw insane metalwork, love it

Those virtanen panels look nice - i remember when the Veng panels had that full closing piece in for the bottom of the quarter panel - now it's just a slot! Great work as always.

Ha, veng stuff is so shit, none of it fits right!

To get away from the welding etc here is some of the other stuff I`ve been doing . All the bolt on panels have had their own various issues, the wings that were on the car when I bought it back were Day moulding ones. They are great quality and I was going to reuse them and had thoughts about getting the insides gel coated too but for a show car fiberglass doesn't cut it.  Finding a nice set of original wings is getting harder, especially the fronts.  I got a pair off a well known person in the vw scene, they are slightly earlier ones so the indicator holes are wrong for my year but I am going to fill those in anyway and run us spec headlamps. They needed quite a bit of straightening, some of the dents were very difficult to get out but after a lot of beating they are good now.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5EDFB689-BA25-411A-AC79-DEF898834AD3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5EDFB689-BA25-411A-AC79-DEF898834AD3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9EEF3D68-F00A-4D8D-A8BB-BF3141BD9EBB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9EEF3D68-F00A-4D8D-A8BB-BF3141BD9EBB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C0EBFE00-7949-45D6-93F6-8F3EE49325F2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C0EBFE00-7949-45D6-93F6-8F3EE49325F2.jpg.html)

I had to heat this area up to get it straight

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F71D5F27-32BD-4A4D-82BC-60B586931DF3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F71D5F27-32BD-4A4D-82BC-60B586931DF3.jpg.html)

It split

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/290AAE6D-3180-4DDA-B440-B4CD2C89B129.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/290AAE6D-3180-4DDA-B440-B4CD2C89B129.jpg.html)

After welding etc

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5FB732AF-EA5D-417A-BBD3-AFB31886D7B8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5FB732AF-EA5D-417A-BBD3-AFB31886D7B8.jpg.html)

I was not 100% sure if the bonnet on the car was original vw , it fitted ok but I had a nagging doubt that it wasn't so I did a deal with the same well known vw person for my old day wings and bonnet for the two fronts and a genuine bonnet.  We arranged to meet one weekend to exchange the panels but when he turned up with the bonnet I was a bit cheesed. He actually turned up with two , one was peppered with stone chips . had some splits here and there , some dents too and there was this one  ::)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AD171145-C169-4D3B-A4DA-6F12DFC82E3D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AD171145-C169-4D3B-A4DA-6F12DFC82E3D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BAD2B324-B394-41E8-ACA9-09951B69219A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BAD2B324-B394-41E8-ACA9-09951B69219A.jpg.html)

So I bought both  ;D     This rusty one had been previously blasted and for some reason just left with no primer or protection whatsoever. Running my hand over it there is no dents and no splits or cracks, just rust.  I was confident I could get it back so to start I ran a DA sander over it first , just to get the worst off.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D9A22FE8-5160-4852-BCAD-38C3B51069A1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D9A22FE8-5160-4852-BCAD-38C3B51069A1.jpg.html)

The trim holes had been welded and leaded. I will put the holes back in.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/08C70B58-07FD-4562-990D-7EF3BF64FA88.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/08C70B58-07FD-4562-990D-7EF3BF64FA88.jpg.html)

Outside for a bit of rust removal  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DE874698-EB80-4AD6-A2F4-B18D4B9169B2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DE874698-EB80-4AD6-A2F4-B18D4B9169B2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DA35D1C6-2DFC-43DD-9EB8-0ED059015C08.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DA35D1C6-2DFC-43DD-9EB8-0ED059015C08.jpg.html)

Other bonnet which maybe for sale soon !

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0B83B25E-4CB2-4921-8832-0F6FEEC92346.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0B83B25E-4CB2-4921-8832-0F6FEEC92346.jpg.html)

No substitute for blasting

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B92F05ED-6532-4E08-89E6-38F5CFCA772D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B92F05ED-6532-4E08-89E6-38F5CFCA772D.jpg.html)

This is the ex rusty one

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CA2B1E4D-934D-4F31-B94D-EF777D2439C5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CA2B1E4D-934D-4F31-B94D-EF777D2439C5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/79789FEF-2604-44D4-AC3A-755E0892EAE4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/79789FEF-2604-44D4-AC3A-755E0892EAE4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/691E66D4-70AA-4B2C-9ED3-BD72521422AE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/691E66D4-70AA-4B2C-9ED3-BD72521422AE.jpg.html)

Other one came up good too

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A91440DE-6E63-4B86-AAB8-113EBFE9E0A2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A91440DE-6E63-4B86-AAB8-113EBFE9E0A2.jpg.html)

Underseal took an age to scrape off

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6E7936E0-12C5-4D45-BD37-A583CCE79822.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6E7936E0-12C5-4D45-BD37-A583CCE79822.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/81A5470B-644D-4355-A01B-022D82033BD4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/81A5470B-644D-4355-A01B-022D82033BD4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/62BCCA77-0CAB-4239-91E7-DE030D584414.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/62BCCA77-0CAB-4239-91E7-DE030D584414.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/77C8263F-9F1F-43A1-81DC-EB2E3DBBA891.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/77C8263F-9F1F-43A1-81DC-EB2E3DBBA891.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8D0B41FD-7F88-4CC3-B7FB-8B0E6A8E53F7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8D0B41FD-7F88-4CC3-B7FB-8B0E6A8E53F7.jpg.html)

Came up nice

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3DD271E7-6702-4DDD-86AA-7EF53008DAB6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3DD271E7-6702-4DDD-86AA-7EF53008DAB6.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/96EEDED1-8A9A-4300-83CC-C673FD0586E8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/96EEDED1-8A9A-4300-83CC-C673FD0586E8.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/854A21AA-5B44-45BF-8B67-C6028C10F5DF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/854A21AA-5B44-45BF-8B67-C6028C10F5DF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0DFED20C-4D63-4766-8B32-D1437E22F37E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0DFED20C-4D63-4766-8B32-D1437E22F37E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9B216E23-0BAE-43AC-AE46-4B8D83E8F784.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9B216E23-0BAE-43AC-AE46-4B8D83E8F784.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3A474923-822A-4013-8D53-09DAD6F6BD5C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3A474923-822A-4013-8D53-09DAD6F6BD5C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1D32BB8B-9FB9-4430-A3FA-F28F21495EB3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1D32BB8B-9FB9-4430-A3FA-F28F21495EB3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/312B154C-211D-4F37-B276-7A47FFC4F14A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/312B154C-211D-4F37-B276-7A47FFC4F14A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/15069726-33F5-4B58-A9E5-547DA12FB5D6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/15069726-33F5-4B58-A9E5-547DA12FB5D6.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CEA0DD5C-D4F0-4F3D-B579-8746F4EED281.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CEA0DD5C-D4F0-4F3D-B579-8746F4EED281.jpg.html)

The wings like I said had numerous issues, dents and bent etc. Took a week off to massage them out

Doesn't look bad here but it was out of shape

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5EA474B2-AC38-4A4F-B84E-55AA8E5F7030.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5EA474B2-AC38-4A4F-B84E-55AA8E5F7030.jpg.html)

Large area misshapen

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/75294DD6-1AC0-4B20-AD51-CAA526A0FB7A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/75294DD6-1AC0-4B20-AD51-CAA526A0FB7A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/028A8441-78AB-4304-86E7-578722CDA929.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/028A8441-78AB-4304-86E7-578722CDA929.jpg.html)

Came out nice

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6C69357A-6461-4673-8AB9-39F130664A97.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6C69357A-6461-4673-8AB9-39F130664A97.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9057F9A4-DEA7-4E5C-A99F-AF1AA0475800.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9057F9A4-DEA7-4E5C-A99F-AF1AA0475800.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8FEAB0CF-C920-41E9-96D0-14AE108D1FCA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8FEAB0CF-C920-41E9-96D0-14AE108D1FCA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/27A2A7F1-D3B3-4CBD-8DA1-5E96514E47B8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/27A2A7F1-D3B3-4CBD-8DA1-5E96514E47B8.jpg.html)

Showing the high and low spots on the same wing

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D275867F-AC91-47B9-9B8C-F2355072200F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D275867F-AC91-47B9-9B8C-F2355072200F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1ACF6BB2-29A0-495B-85E0-A3AD5885E712.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1ACF6BB2-29A0-495B-85E0-A3AD5885E712.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D5624CC7-9FA8-4F2C-B055-3949473C3437.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D5624CC7-9FA8-4F2C-B055-3949473C3437.jpg.html)

Almost there

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/46F016D5-1958-438E-8F1E-5C5211D98206.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/46F016D5-1958-438E-8F1E-5C5211D98206.jpg.html)

Other side had more issues

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/05A806FE-28EB-4BCE-813B-4D3351F3DA43.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/05A806FE-28EB-4BCE-813B-4D3351F3DA43.jpg.html)

You cant see it but the whole lip wing edge had been pushed in and was out of shape

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C55C163D-45FC-486B-B6A4-BDF36A16B4CA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C55C163D-45FC-486B-B6A4-BDF36A16B4CA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/003FB7B3-8C4A-43E6-A876-B426EB808E7B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/003FB7B3-8C4A-43E6-A876-B426EB808E7B.jpg.html)

Difficult to get straight

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AA0C7665-BB58-4EED-8A78-ED15189CEACB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AA0C7665-BB58-4EED-8A78-ED15189CEACB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/66C86B11-08A3-4FF5-84C3-185A13B4D87B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/66C86B11-08A3-4FF5-84C3-185A13B4D87B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/47694C70-3ABB-49F7-9597-F739C93A4F6F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/47694C70-3ABB-49F7-9597-F739C93A4F6F.jpg.html)

Top had a crease

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D228CF15-C56C-4C4E-B859-CD509E799F43.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D228CF15-C56C-4C4E-B859-CD509E799F43.jpg.html)

It had stretched too so I had to shrink it with heat

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/74E634BE-A224-4500-BEFE-6D32FE04D94F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/74E634BE-A224-4500-BEFE-6D32FE04D94F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DCA7CB0B-F3AB-4924-8A3A-936A6F16F9B0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DCA7CB0B-F3AB-4924-8A3A-936A6F16F9B0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A95D0507-CB6B-458F-A564-D86415428096.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A95D0507-CB6B-458F-A564-D86415428096.jpg.html)

After shrinking and a quick layer of primer to check

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1A1E2F74-5B11-40A8-878F-648B4762F35C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1A1E2F74-5B11-40A8-878F-648B4762F35C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4DB42D0D-C544-4FE5-8CD7-3B38C794859C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4DB42D0D-C544-4FE5-8CD7-3B38C794859C.jpg.html)

Getting rid of some of the factory pressing marks. Suppose I could have used a bit of filler here but that aint my style

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/24318600-3740-4AC7-A4C9-D403431FF40E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/24318600-3740-4AC7-A4C9-D403431FF40E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/345D9DC5-14F8-430D-BA44-2E4F9B472C05.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/345D9DC5-14F8-430D-BA44-2E4F9B472C05.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BF5AF492-FDE3-4599-A443-4B740AD9B5D6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BF5AF492-FDE3-4599-A443-4B740AD9B5D6.jpg.html)

Still work to do on this wing, the mounting flange needs welding etc

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E06C6E47-F91A-4507-BA4B-F3171FAA7CA1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E06C6E47-F91A-4507-BA4B-F3171FAA7CA1.jpg.html)

The passenger door that was on the car turned into a bit of an issue. After blasting it looked ok to start of but at closer inspection the skin had stretched and was out of shape and I knew that without many many hours of work it still wouldn't be ok to use. I had worked on the door previously, it was a rust free cali door but was bent when I got it and I remember I had to cut the window frame to straighten it. Maybe the whole door was under tension or something and the blasting process compounded the fault causing metal the stress relieve maybe.  

Looked Straight

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A7239C98-6B32-4013-9F73-A5C1D52BDA66.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A7239C98-6B32-4013-9F73-A5C1D52BDA66.jpg.html)

Being that its a 65 model, these doors are pretty rare in that they only made them for two years so finding another one was going to be a prob.   Luckily FBI had one advertised on evilbay so I bought it now !  It looked on the advert to be a really nice one until it arrived.........

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2C941165-29F7-48AC-9CC3-4208E1BDAAE9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2C941165-29F7-48AC-9CC3-4208E1BDAAE9.jpg.html)

It looked like it had been driven over with a forklift truck or something.  >:( :( :( :(

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9472C762-09B7-477A-8425-430FC21D25C5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9472C762-09B7-477A-8425-430FC21D25C5.jpg.html)

I was gutted

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8C0EEF38-F8D1-43E6-915C-6E7CD4EF54CC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8C0EEF38-F8D1-43E6-915C-6E7CD4EF54CC.jpg.html)

I knew I would get nowhere with the courier company but fbi sorted me out with a discount fairplay, fantastic service.   I knew the corner had had a big sqeeze and there was no way of straightening the inner panel so the only way to fix it was to cut it out.

I had another scrap door for the section I needed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8F6B1C24-7611-4F5D-8D27-910843952D13.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8F6B1C24-7611-4F5D-8D27-910843952D13.jpg.html)

Drilled out the spot welds

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6BAF8A42-0ACA-4684-B035-30DFCC447B3E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6BAF8A42-0ACA-4684-B035-30DFCC447B3E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2D90CF30-827E-412D-8A98-2DF97AE6A11A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2D90CF30-827E-412D-8A98-2DF97AE6A11A.jpg.html)

The reason why most doors rot from the corner is this lump of sealant that they used. Its just a water trap.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BDA8DE04-0B42-4D29-97A9-5B315E5B8A8D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BDA8DE04-0B42-4D29-97A9-5B315E5B8A8D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AB61262E-0AC7-41F7-A766-AD9863939F0E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AB61262E-0AC7-41F7-A766-AD9863939F0E.jpg.html)

Blasted

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C1C0E121-C774-4620-9AF3-E05C54D141D4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C1C0E121-C774-4620-9AF3-E05C54D141D4.jpg.html)

Fortunately the skin was undamaged and when I removed the damaged inner section , the outer pretty much sprung back into shape

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/25D2B7E0-E22C-483F-AFE3-A9E571CEB1DB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/25D2B7E0-E22C-483F-AFE3-A9E571CEB1DB.jpg.html)

Tacked

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3ABD088C-16F6-43ED-AEC5-D53625133294.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3ABD088C-16F6-43ED-AEC5-D53625133294.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/96FDC910-A4B2-479E-B15C-2760442FA524.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/96FDC910-A4B2-479E-B15C-2760442FA524.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/65A3009A-8375-432A-9913-B40BA0B5D277.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/65A3009A-8375-432A-9913-B40BA0B5D277.jpg.html)

Lined up correctly

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CD2DD92F-1CE5-4B55-91AD-605EEE24E2E0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CD2DD92F-1CE5-4B55-91AD-605EEE24E2E0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4B87BA58-934D-49E6-AF92-D9F45F14DD81.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4B87BA58-934D-49E6-AF92-D9F45F14DD81.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2BBDBF2D-2F23-46AD-BC9C-2BAC18F1487D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2BBDBF2D-2F23-46AD-BC9C-2BAC18F1487D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C91B2924-4306-46F5-8C82-2E679FF4A08F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C91B2924-4306-46F5-8C82-2E679FF4A08F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/70ECE4DF-2D92-4806-8792-17E45357701C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/70ECE4DF-2D92-4806-8792-17E45357701C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/386CB12C-8DD5-483C-9D41-B2C0DE50AC72.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/386CB12C-8DD5-483C-9D41-B2C0DE50AC72.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/33FDE51D-9B41-4552-8345-FB526BAAC351.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/33FDE51D-9B41-4552-8345-FB526BAAC351.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9F0D6234-7973-45D0-89A4-BBBC88D02CD1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9F0D6234-7973-45D0-89A4-BBBC88D02CD1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4E477F9C-FDD6-433F-A0FC-A92AD797F781.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4E477F9C-FDD6-433F-A0FC-A92AD797F781.jpg.html)

I was extra careful blasting this one!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D4DA2CA7-6694-458C-9572-AECF3B5A87A7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D4DA2CA7-6694-458C-9572-AECF3B5A87A7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F48398E6-C3B6-4C47-8B90-3EEE0D5D04DA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F48398E6-C3B6-4C47-8B90-3EEE0D5D04DA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CA2208B2-8C66-4C39-88E9-94004A6791E2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CA2208B2-8C66-4C39-88E9-94004A6791E2.jpg.html)

I love this thread. Where did you get those mini adjustable jaws

Thanks lids

Here
http://pages.ebay.com/link/?nav=item.view&alt=web&id=121486566962&globalID=EBAY-GB

thank you, just ordered some :)

Awesome Work!! Love It :)

Great work on that door. Will you work on other people's cars? ;D

Been thinking about doing other work when this is finished, but would have to travel to North Wales, suppose it's not the end of the world! I Would have to call it Custom Creams too.  :)
Thanks for the compliments by the way.   

Onto the front and again it was a proper mix of wrong shape panels and modifications. I`m replacing the front beam for one that doesn't need body mods so I could get rid of my previous cycle chain guards !  :D

It seemed a good idea at the time to modify the bodywork instead of the suspension  :-[

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1164874E-0350-49E3-B982-CDE61EB1C417.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1164874E-0350-49E3-B982-CDE61EB1C417.jpg.html)

Finding the correct replacement front clip sides would prove to be a bit of a problem. I placed various wanted ads on some sites and had a few replies. Some folk on the Samba wanted to charge me up to $1000 to ship the two side panels to the UK  ::) but fortunately I came up trumps with a near side one on VZI and then a while later Alex Taylor from Defcon3 sorted me out with both front panels off a UK car.   All three panels needed work so I chose the best and took it from there.

Super cycle fenders

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1DDFAD0D-1B0D-4EB4-AA61-5C22E74775BB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1DDFAD0D-1B0D-4EB4-AA61-5C22E74775BB.jpg.html)

Lovely spot of welding

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/36D2DA94-3873-4B31-B753-07FCCD174D1C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/36D2DA94-3873-4B31-B753-07FCCD174D1C.jpg.html)

Drilling out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/39BD6D7F-F494-462A-ABE8-4CB119A8D758.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/39BD6D7F-F494-462A-ABE8-4CB119A8D758.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F03011A5-27D1-465D-BEEE-1CA9BA27F070.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F03011A5-27D1-465D-BEEE-1CA9BA27F070.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D0337CBF-9C1B-4599-9E58-9B0FE9EB21D3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D0337CBF-9C1B-4599-9E58-9B0FE9EB21D3.jpg.html)

I blasted the panels and drilled out the tank support and bumper mounts etc as I knew there would be rust behind them. I was right, bet there are plenty of show cars out there with rust behind here  :D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DBD468DF-7749-42C6-99AB-F371FBC9ECA6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DBD468DF-7749-42C6-99AB-F371FBC9ECA6.jpg.html)

It was pretty straight but thin in places. This is the UK one

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/160B4635-9028-4228-82A7-51EFDDB12DC0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/160B4635-9028-4228-82A7-51EFDDB12DC0.jpg.html)

Nice on the outside....

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/23139001-31C5-4B16-AFBC-3884EEFE8D36.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/23139001-31C5-4B16-AFBC-3884EEFE8D36.jpg.html)

Shit on the inside

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/57E2F8BE-722A-4294-AA3E-C92DFE5DFA65.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/57E2F8BE-722A-4294-AA3E-C92DFE5DFA65.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C460003B-1F57-4309-A38F-52E8DC4F093D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C460003B-1F57-4309-A38F-52E8DC4F093D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F34BC637-354A-40CE-8D50-E66EAFE5206E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F34BC637-354A-40CE-8D50-E66EAFE5206E.jpg.html)

More

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9EF7A33C-93D4-46F4-AB4C-C1F2E5D9348B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9EF7A33C-93D4-46F4-AB4C-C1F2E5D9348B.jpg.html)

Its strange but there are two captive nuts that are different than the rest. Its more square for some reason. I had a couple spare.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5E3DE2A1-6AA4-4F34-A4A9-19435434C2E3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5E3DE2A1-6AA4-4F34-A4A9-19435434C2E3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9FD81871-9BB4-42C3-8427-B38B4F364D7C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9FD81871-9BB4-42C3-8427-B38B4F364D7C.jpg.html)

Silver soldering it back on

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D9A347E2-95BF-447D-8EE7-162A71627C06.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D9A347E2-95BF-447D-8EE7-162A71627C06.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/68942BF2-FD1F-4BB1-94CF-72F81B4775A2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/68942BF2-FD1F-4BB1-94CF-72F81B4775A2.jpg.html)

Lower one

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C6A6BEF9-D3A3-4765-833C-D4F3177019C3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C6A6BEF9-D3A3-4765-833C-D4F3177019C3.jpg.html)

Had your horn mount off recently?  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4C4569D7-4254-40B0-959C-E460887474DC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4C4569D7-4254-40B0-959C-E460887474DC.jpg.html)

This is the near side Californian panel. It was in good shape

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/85F37CDA-F861-407D-9EBD-1D3E07A389E0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/85F37CDA-F861-407D-9EBD-1D3E07A389E0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C31AA8AF-349D-401D-B79D-2AA395483C20.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C31AA8AF-349D-401D-B79D-2AA395483C20.jpg.html)

I cut the front off and quickly offered up the replacement

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A60C84E6-A395-40E7-8BD1-57D173090A60.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A60C84E6-A395-40E7-8BD1-57D173090A60.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D76C6DEF-753A-42A8-852F-177C89E875C0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D76C6DEF-753A-42A8-852F-177C89E875C0.jpg.html)

It lined up nice

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B9308444-F1C6-4B52-9896-CC9E4C9B3F09.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B9308444-F1C6-4B52-9896-CC9E4C9B3F09.jpg.html)

Wing on to check

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/37A73EA8-D170-46E5-A100-6DC8B551C070.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/37A73EA8-D170-46E5-A100-6DC8B551C070.jpg.html)

Everything was good

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C45E7D2E-1C15-4772-A81F-A06823464396.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C45E7D2E-1C15-4772-A81F-A06823464396.jpg.html)

What was left of the original tank support was removed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/829D9085-5E43-40C9-BD94-490D8862A369.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/829D9085-5E43-40C9-BD94-490D8862A369.jpg.html)

Plenty of rust

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/41875A2D-ED5B-478B-8ACA-0296AEE54370.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/41875A2D-ED5B-478B-8ACA-0296AEE54370.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/27E3F2B8-CF04-45B7-8F68-99D790CFCF29.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/27E3F2B8-CF04-45B7-8F68-99D790CFCF29.jpg.html)

Blasted clean

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/95D916ED-501F-497A-BAFE-4A94DB35F472.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/95D916ED-501F-497A-BAFE-4A94DB35F472.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9C954091-CBB9-4D93-8557-710F32CFF3FC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9C954091-CBB9-4D93-8557-710F32CFF3FC.jpg.html)

The UK panel was holed and thin so I had to replace various sections. I cut the repo panel up and used that as donor panels.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2482AA40-658A-4D8D-B42D-B34795497DE5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2482AA40-658A-4D8D-B42D-B34795497DE5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4BB4BABF-7EEA-4031-9B71-FB30534ACD51.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4BB4BABF-7EEA-4031-9B71-FB30534ACD51.jpg.html)

Super tool

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C9CEEE96-EA42-46E2-88B2-F4CC1295D3C5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C9CEEE96-EA42-46E2-88B2-F4CC1295D3C5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2FD6F184-B1C3-456C-999C-20F9CCF235F4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2FD6F184-B1C3-456C-999C-20F9CCF235F4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/49BAB491-0B3D-44AE-8EE2-7EEDF732435F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/49BAB491-0B3D-44AE-8EE2-7EEDF732435F.jpg.html)

Matching up to the cali side

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EC24E9B2-B192-4E43-9F79-21B89521871E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EC24E9B2-B192-4E43-9F79-21B89521871E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/704D852E-2201-4686-83EA-B75443F116A1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/704D852E-2201-4686-83EA-B75443F116A1.jpg.html)

Welded on

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9189CE6A-C386-4DE7-A4E1-DFC20233EE81.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9189CE6A-C386-4DE7-A4E1-DFC20233EE81.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1FCD83B4-3D3E-4B66-90D8-8C093E74008E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1FCD83B4-3D3E-4B66-90D8-8C093E74008E.jpg.html)W

I offered up the new tank support which I modified a bit by adding some dimpled holes for that custom touch.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/09FF336D-8441-432C-815E-D4129E488BDE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/09FF336D-8441-432C-815E-D4129E488BDE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C0593BAA-D5A9-4FFC-89D8-D82F107D5E95.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C0593BAA-D5A9-4FFC-89D8-D82F107D5E95.jpg.html)

This was encouraging, the spot weld holes all lined up

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/429C4347-AE26-4303-A7AA-DF6243EFCCDA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/429C4347-AE26-4303-A7AA-DF6243EFCCDA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/205E59B1-85BD-4598-8A53-FECB1BDC7A54.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/205E59B1-85BD-4598-8A53-FECB1BDC7A54.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4B8BEA97-D12A-463F-8E86-B0B2FC6A5174.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4B8BEA97-D12A-463F-8E86-B0B2FC6A5174.jpg.html)

The UK panel needed more work

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0321048F-8C15-43FB-B35A-D39374164282.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0321048F-8C15-43FB-B35A-D39374164282.jpg.html)

I used the old panel as a donor

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E4EBBAA0-9E5D-4D0D-B9E7-ECF858C01777.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E4EBBAA0-9E5D-4D0D-B9E7-ECF858C01777.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/18B911D2-4B3B-48F1-992C-E76E433F46BA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/18B911D2-4B3B-48F1-992C-E76E433F46BA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5B383682-E904-421A-AE6E-3414E99CA990.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5B383682-E904-421A-AE6E-3414E99CA990.jpg.html)

Neater than factory. This area is always crumpled from the factory

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/99242776-76FC-431B-8AAD-75D6E8454398.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/99242776-76FC-431B-8AAD-75D6E8454398.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8CAA7C9D-0E10-4678-8608-610E9FC1835F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8CAA7C9D-0E10-4678-8608-610E9FC1835F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0AF22402-A34F-4B8B-918E-B468903370C0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0AF22402-A34F-4B8B-918E-B468903370C0.jpg.html)

There was also a section which was thin so I cut that out too . I had to make a buck to form the panel in one piece.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9A89CB9D-55D4-424A-92F7-198ED0341B2F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9A89CB9D-55D4-424A-92F7-198ED0341B2F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9E2FE71B-11B2-47B3-AEEB-FB46B35617AB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9E2FE71B-11B2-47B3-AEEB-FB46B35617AB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/ED47D141-7C93-4C54-A34A-E6E4EA76C97F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/ED47D141-7C93-4C54-A34A-E6E4EA76C97F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AB4EBD67-D571-43CE-B75C-09D2FDCA533B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AB4EBD67-D571-43CE-B75C-09D2FDCA533B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5A664226-C8D4-4937-93A1-D0BDAB5057AC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5A664226-C8D4-4937-93A1-D0BDAB5057AC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E21F705-4807-426A-AF50-526825E8F428.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E21F705-4807-426A-AF50-526825E8F428.jpg.html)

Cleaned up the inside more.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/10E3C96C-0B2C-4AFA-A010-07B868232762.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/10E3C96C-0B2C-4AFA-A010-07B868232762.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B73D5574-FA22-4664-A630-BDD87702B9D3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B73D5574-FA22-4664-A630-BDD87702B9D3.jpg.html)

Almost ready to start attaching the front on for good

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/297D30C1-2AB7-4096-9D47-0ABD3C2417F1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/297D30C1-2AB7-4096-9D47-0ABD3C2417F1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E5095C36-59A5-4377-8040-3295703E37D5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E5095C36-59A5-4377-8040-3295703E37D5.jpg.html)

Tacked

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3020CC60-1216-4837-9AEE-6548DC9779C2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3020CC60-1216-4837-9AEE-6548DC9779C2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DDD7DB7D-D76B-4D9C-94CB-58C1FDE8D788.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DDD7DB7D-D76B-4D9C-94CB-58C1FDE8D788.jpg.html)

Kept a check on this

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0CC2A32B-DF1A-4168-96DD-5CCAD8DA5612.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0CC2A32B-DF1A-4168-96DD-5CCAD8DA5612.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0FCD39BB-0961-45D5-B933-DADC11D8A8D9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0FCD39BB-0961-45D5-B933-DADC11D8A8D9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DDBF1E7F-36D2-45FF-9152-AB5C54F72A9B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DDBF1E7F-36D2-45FF-9152-AB5C54F72A9B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7958920B-CF1D-48C8-890C-04F05829A4BC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7958920B-CF1D-48C8-890C-04F05829A4BC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/45C578F0-418D-4F08-8350-E10982E45C51.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/45C578F0-418D-4F08-8350-E10982E45C51.jpg.html)

So much time welding this on and being extra careful with dressing the welds after

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1C53B7E6-E15F-4DF9-95E4-4A60CF1C71BB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1C53B7E6-E15F-4DF9-95E4-4A60CF1C71BB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9DC0EACD-3929-46BD-82E8-20BA4C64C9F3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9DC0EACD-3929-46BD-82E8-20BA4C64C9F3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/11987389-BAE3-4B82-8CC2-964D0BF75574.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/11987389-BAE3-4B82-8CC2-964D0BF75574.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9CBFFABA-C4A7-4911-A216-5B1D53D313A0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9CBFFABA-C4A7-4911-A216-5B1D53D313A0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B902614C-9D12-4490-BB73-DB606A1729DC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B902614C-9D12-4490-BB73-DB606A1729DC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DC24BB86-9A72-4975-BC51-CEA9BD9F2BD5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DC24BB86-9A72-4975-BC51-CEA9BD9F2BD5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/09C0F603-2B1F-4DC0-B9AD-23874E6320F4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/09C0F603-2B1F-4DC0-B9AD-23874E6320F4.jpg.html)

No filler

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/141437BE-C334-4A02-91A8-24ADC36C9D97.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/141437BE-C334-4A02-91A8-24ADC36C9D97.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6314FCF4-08C9-4A15-8B56-5638B51058D6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6314FCF4-08C9-4A15-8B56-5638B51058D6.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F2BFE508-B926-4A72-86F6-B253D6DC8AE9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F2BFE508-B926-4A72-86F6-B253D6DC8AE9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4F5C98FD-8053-418B-89BA-E7F140A9E6CE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4F5C98FD-8053-418B-89BA-E7F140A9E6CE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E9880554-7EC1-4F84-825D-20EEDF177598.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E9880554-7EC1-4F84-825D-20EEDF177598.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/52064058-D6EC-41A6-964F-C8210595B4DA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/52064058-D6EC-41A6-964F-C8210595B4DA.jpg.html)

After welding the tank support on I trimmed the lip so that it flowed straight

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/487A01BB-AEFC-456E-8D9A-04A272BE365F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/487A01BB-AEFC-456E-8D9A-04A272BE365F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6513F6F9-B4E4-44BB-85D8-77C916360CF7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6513F6F9-B4E4-44BB-85D8-77C916360CF7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E75B2984-2F28-45D8-A932-F4E7BD37BEF1_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E75B2984-2F28-45D8-A932-F4E7BD37BEF1_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6E6F25E0-F8F2-43BA-BF00-688915FDD323.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6E6F25E0-F8F2-43BA-BF00-688915FDD323.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8D8BDFFA-2BC2-4A68-B07E-35155FA4BAB1_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8D8BDFFA-2BC2-4A68-B07E-35155FA4BAB1_1.jpg.html)

Cheeky pic through the glove box

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A10A080B-C200-4806-85E8-5E7C1A3C7424.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A10A080B-C200-4806-85E8-5E7C1A3C7424.jpg.html)

Onto the other side and I knew this was going to be more of a challenge as mixing a new style quarter with an old front would be difficult to get to look right. There was numerous differences.

In the pic you can see I had to add a piece to the new front as it had been previously cut short.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DD72A511-51C5-4FA9-B43F-99AF24567AFC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DD72A511-51C5-4FA9-B43F-99AF24567AFC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/77D6CA27-9CB5-4A11-B906-4FC48CA42D5B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/77D6CA27-9CB5-4A11-B906-4FC48CA42D5B.jpg.html)

Notice too the scorch mark, this is where I had to heat up the metal to get rid of the bulge pressing for the twin brake master cylinder feed pipes to pass between the tank and the quarter. This took quite a while to get right as the metal wasn't playing ball to start off with.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/77D6CA27-9CB5-4A11-B906-4FC48CA42D5B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/77D6CA27-9CB5-4A11-B906-4FC48CA42D5B.jpg.html)

Like I thought , this side was proving to be a pain  :D
 
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D1E6EDAE-3523-4021-A888-4F80179A507C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D1E6EDAE-3523-4021-A888-4F80179A507C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/23AEB63A-1993-4CA3-9160-16C62D076109.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/23AEB63A-1993-4CA3-9160-16C62D076109.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/383A1739-8A29-46CF-B363-627CA834B5FE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/383A1739-8A29-46CF-B363-627CA834B5FE.jpg.html)

See if you can spot the other problem

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4713626F-CFEB-4D32-BD45-886B8F443E4F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4713626F-CFEB-4D32-BD45-886B8F443E4F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5A0709D3-EFA8-4074-9326-8AF9C78403CC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5A0709D3-EFA8-4074-9326-8AF9C78403CC.jpg.html)

top profile of the panel is different?

  Correct  ;D

I would sort that problem later but for now I had some other stuff to do.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/50BFFAB9-D122-46F1-853B-BF472C601CAE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/50BFFAB9-D122-46F1-853B-BF472C601CAE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5C843C53-9165-4AFB-9843-7EB5CB505CF7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5C843C53-9165-4AFB-9843-7EB5CB505CF7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0503FBDF-9C50-4D57-B7EA-4FFC18AC5D41.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0503FBDF-9C50-4D57-B7EA-4FFC18AC5D41.jpg.html)

The speedo cable clip was wrong for my car so I modified it to the correct sixties spec

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4662C118-15D8-445F-BE82-E5227DF4AE1F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4662C118-15D8-445F-BE82-E5227DF4AE1F.jpg.html)

I did think about cutting it out and welding this genuine section in but I came up with another idea

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E440B35-AC75-484E-A2B5-B5429BBA0ECE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E440B35-AC75-484E-A2B5-B5429BBA0ECE.jpg.html)

I lined up the old section and sprayed some primer through it to get an outline

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7999EF37-0DBC-4EF4-8E36-AE8A143E2463.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7999EF37-0DBC-4EF4-8E36-AE8A143E2463.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F2B696B7-A15A-4F94-9C95-FAA3DB70378D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F2B696B7-A15A-4F94-9C95-FAA3DB70378D.jpg.html)

Cut two slots

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C33B8C15-9FE1-4670-980B-5C772E056EBB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C33B8C15-9FE1-4670-980B-5C772E056EBB.jpg.html)

I then made a form to replicate the bridge

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3E459902-7CCD-4966-A6BF-804E7F638688.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3E459902-7CCD-4966-A6BF-804E7F638688.jpg.html)

Tacked the former onto the quarter

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/363ED502-B826-4BCE-9A1A-E5484D43D6FC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/363ED502-B826-4BCE-9A1A-E5484D43D6FC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0622D372-A39E-4468-86E3-F626F155B010.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0622D372-A39E-4468-86E3-F626F155B010.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AC99F0CE-44C3-47A0-BEC7-477A031F62CE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AC99F0CE-44C3-47A0-BEC7-477A031F62CE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B0B3EAF7-23A7-4270-B0D0-DFF4A92DBAD2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B0B3EAF7-23A7-4270-B0D0-DFF4A92DBAD2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4E8F28C6-5889-45F9-AAAA-BB326C3A69D7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4E8F28C6-5889-45F9-AAAA-BB326C3A69D7.jpg.html)

Next I had to do something about the crappy factory pressing

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F44961DB-AE98-4427-86B9-B6D0C39F2528.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F44961DB-AE98-4427-86B9-B6D0C39F2528.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7365368F-7504-49D2-A963-9BEE15FAAAF9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7365368F-7504-49D2-A963-9BEE15FAAAF9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4AF481C9-DC56-497B-8991-CF13E6852A43.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4AF481C9-DC56-497B-8991-CF13E6852A43.jpg.html)

Matched to the other side

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F2797131-A2BD-4E69-ADCD-68F4CFB38711.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F2797131-A2BD-4E69-ADCD-68F4CFB38711.jpg.html)

Tacked on

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/309C8569-B695-41BD-A9E6-0C61BAABB89C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/309C8569-B695-41BD-A9E6-0C61BAABB89C.jpg.html)

Wing on to check

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/50363577-CF09-45F7-9B6F-0410C5DEB010.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/50363577-CF09-45F7-9B6F-0410C5DEB010.jpg.html)

Seems to fit ok

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0013C1E5-46BB-4203-9AB5-CA08F31DD65F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0013C1E5-46BB-4203-9AB5-CA08F31DD65F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9CA50342-4E46-4AFE-A0ED-168A6AF305E3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9CA50342-4E46-4AFE-A0ED-168A6AF305E3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4662683D-37ED-40A1-98B3-3D41D50ECFA4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4662683D-37ED-40A1-98B3-3D41D50ECFA4.jpg.html)

Problem I would have to sort later

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B2FAA189-BE31-48BE-BA08-F97C359A1F13.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B2FAA189-BE31-48BE-BA08-F97C359A1F13.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E7E9AA6-85BA-4F8C-9A88-ED7A825510CE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E7E9AA6-85BA-4F8C-9A88-ED7A825510CE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/15DFF0E9-87F7-463A-BA48-FFDA4253462F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/15DFF0E9-87F7-463A-BA48-FFDA4253462F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/93471081-35CB-4FBA-81D2-4BF1523B8B68.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/93471081-35CB-4FBA-81D2-4BF1523B8B68.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/94369162-71B9-45FD-905F-1503E4A08E81.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/94369162-71B9-45FD-905F-1503E4A08E81.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C1393AFB-EA18-4595-8F83-8A74F6156887.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C1393AFB-EA18-4595-8F83-8A74F6156887.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/086E3834-C6BD-413C-920C-187300FC8BC9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/086E3834-C6BD-413C-920C-187300FC8BC9.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/256F68BC-2ABB-4A65-8981-E193926040E7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/256F68BC-2ABB-4A65-8981-E193926040E7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4ABBCEF2-001E-4001-9679-34CDFB2E33CA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4ABBCEF2-001E-4001-9679-34CDFB2E33CA.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EF6C4A26-D130-4FFC-AC20-A17D5AAB1D45.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EF6C4A26-D130-4FFC-AC20-A17D5AAB1D45.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9544FC0E-3CA1-4E68-AA50-8369BB62C72A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9544FC0E-3CA1-4E68-AA50-8369BB62C72A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7E9FA51F-1D82-4438-9B7F-4EE98AA1DDD3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7E9FA51F-1D82-4438-9B7F-4EE98AA1DDD3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7DD2F926-CDFC-4129-A3AE-DCCE3DFEED75.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7DD2F926-CDFC-4129-A3AE-DCCE3DFEED75.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/49800682-B14B-49B6-806A-E27D5402D73E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/49800682-B14B-49B6-806A-E27D5402D73E.jpg.html)

Nearly done

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4DDAA438-FCCC-4215-B1B1-4166B69A3EA2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4DDAA438-FCCC-4215-B1B1-4166B69A3EA2.jpg.html)

The black line is where I made a cut

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8104485F-BA4C-49A2-90D4-6C9713D74A10.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8104485F-BA4C-49A2-90D4-6C9713D74A10.jpg.html)

You can see the problem here

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AE1AABFD-D6FE-4B69-A84A-01284D5CA6B3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AE1AABFD-D6FE-4B69-A84A-01284D5CA6B3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/08D4762D-E249-4C0B-940C-4FDDFC62DD8A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/08D4762D-E249-4C0B-940C-4FDDFC62DD8A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C4131B39-02E8-49F3-A5F8-05059CE307A2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C4131B39-02E8-49F3-A5F8-05059CE307A2.jpg.html)

Sorted

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/39A530CF-92DE-466E-9120-185490D9E433.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/39A530CF-92DE-466E-9120-185490D9E433.jpg.html)

Tank support welded back on

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F616517A-723E-4B9B-A32A-F9EBF2362C67.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F616517A-723E-4B9B-A32A-F9EBF2362C67.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/16BE9A10-819C-4966-81E1-39DE39955505.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/16BE9A10-819C-4966-81E1-39DE39955505.jpg.html)

Factory spot welds still there

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B84E8E1E-9360-4A25-9476-82AAFAA5824F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B84E8E1E-9360-4A25-9476-82AAFAA5824F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7FCA2542-B1E1-43CA-8F4C-CE1D06E6EEBF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7FCA2542-B1E1-43CA-8F4C-CE1D06E6EEBF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/54F93EF4-A6ED-45E5-BBB0-6E5B78C62D15.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/54F93EF4-A6ED-45E5-BBB0-6E5B78C62D15.jpg.html)

Time to do something about the crappy factory bumper mounts

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7E2CC1D3-B9F4-4B0F-B72D-4D58339E59E1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7E2CC1D3-B9F4-4B0F-B72D-4D58339E59E1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1C1A54CD-FB0B-433D-9B03-32BBE9B6C980.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1C1A54CD-FB0B-433D-9B03-32BBE9B6C980.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B37A1FEF-606E-49FC-8A92-8CAA379484B0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B37A1FEF-606E-49FC-8A92-8CAA379484B0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4A0F399A-CE7B-404A-AAB4-DE593AC87B58.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4A0F399A-CE7B-404A-AAB4-DE593AC87B58.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/96257BB3-B9B4-48C2-BBE6-2FFEA66DBCEB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/96257BB3-B9B4-48C2-BBE6-2FFEA66DBCEB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/83151FD7-0CB4-494E-A28F-A9645C9B485D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/83151FD7-0CB4-494E-A28F-A9645C9B485D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A46F6720-A906-4921-BE72-0F0C39065E32.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A46F6720-A906-4921-BE72-0F0C39065E32.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C2C686AB-B11E-4449-9551-99D9EB578A5F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C2C686AB-B11E-4449-9551-99D9EB578A5F.jpg.html)

Next problem  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8CBE5870-8C48-442D-A69C-921FC3DF2DB4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8CBE5870-8C48-442D-A69C-921FC3DF2DB4.jpg.html)

Looking at this there seems to be a common issue, I could have easily welded it all together and hammered it into place but it would have looked crap so I spent a lot of time making it good

The only way was to make a pie cut and add a section in

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D16ABE32-12E5-48F6-A584-3B85511CF241.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D16ABE32-12E5-48F6-A584-3B85511CF241.jpg.html)

I was so careful to get this right, the bonnet and wings were constantly on and off

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4E128287-3F71-47D8-B9F5-953EF54E88A5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4E128287-3F71-47D8-B9F5-953EF54E88A5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0C09E0A6-16B0-4128-88D1-26D6B4CB7EBE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0C09E0A6-16B0-4128-88D1-26D6B4CB7EBE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/82200EB6-2418-425D-87EE-10B7107587FB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/82200EB6-2418-425D-87EE-10B7107587FB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/86C12AB6-6E0D-41B3-B7D6-54B892A84B8A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/86C12AB6-6E0D-41B3-B7D6-54B892A84B8A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3685D629-C0E3-4A57-A28E-528391F3DEEE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3685D629-C0E3-4A57-A28E-528391F3DEEE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C63EFF04-908C-42B3-8325-1CBFF745CDB2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C63EFF04-908C-42B3-8325-1CBFF745CDB2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B7D1A089-F20C-492C-9293-088219138B14.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B7D1A089-F20C-492C-9293-088219138B14.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DADC7E82-B24D-4D4F-B5C7-B8EA09AF3C1C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DADC7E82-B24D-4D4F-B5C7-B8EA09AF3C1C.jpg.html)

Autocraft front valence fits nice

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DADC7E82-B24D-4D4F-B5C7-B8EA09AF3C1C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DADC7E82-B24D-4D4F-B5C7-B8EA09AF3C1C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6E7996AB-4401-4891-9426-F29175D31734.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6E7996AB-4401-4891-9426-F29175D31734.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7FAD953D-E03A-4928-BA3D-5DB481571D37.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7FAD953D-E03A-4928-BA3D-5DB481571D37.jpg.html)

Obviously had to do the same on the other side

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0C5C2D1A-19FC-46F4-8ADC-A5B3F908CF16.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0C5C2D1A-19FC-46F4-8ADC-A5B3F908CF16.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A532557D-FBCF-4AC3-8049-A0E815C2A9A6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A532557D-FBCF-4AC3-8049-A0E815C2A9A6.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/80A9CED9-9FA6-4E3E-999F-A1E8E9333B95.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/80A9CED9-9FA6-4E3E-999F-A1E8E9333B95.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9B25C387-1BB0-408B-B946-2984ED2DA486.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9B25C387-1BB0-408B-B946-2984ED2DA486.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1783E3C0-9929-48A7-8EDC-435D3624B7AD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1783E3C0-9929-48A7-8EDC-435D3624B7AD.jpg.html)

Other bumper mount

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/834AE8D3-DAC3-4C53-88D3-EE6D216D2CD6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/834AE8D3-DAC3-4C53-88D3-EE6D216D2CD6.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/573CD53B-489E-4B03-9563-10932736505A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/573CD53B-489E-4B03-9563-10932736505A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FE4ECB7E-7579-4A07-BB02-B7E6099CA777.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FE4ECB7E-7579-4A07-BB02-B7E6099CA777.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6E0B27A7-DD20-4467-9529-B4A05B8BFC11.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6E0B27A7-DD20-4467-9529-B4A05B8BFC11.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E9FCD6E6-3CF3-4389-9209-0DE3DB29E2B2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E9FCD6E6-3CF3-4389-9209-0DE3DB29E2B2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3925EBC9-F18B-4B62-8EED-89841D381688.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3925EBC9-F18B-4B62-8EED-89841D381688.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CF1D6A24-065D-47C9-9669-6B3D9D84A77C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CF1D6A24-065D-47C9-9669-6B3D9D84A77C.jpg.html)

Well folks, this is it for now. Like I said I just wanted to show the amount of work that's gone into my bug so far. I`ve been doing many many more hours work on all the other details which I will keep to myself for now. I`ve done more bodywork and there is still lots to do but you get the picture?!  Its got to be ready for paint by spring next year and then its off for its new coat of sea blue by someone who knows what it takes to paint a show winner.  :D   Cheers for the compliments

Parting shot. Bye for now...

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9AD0802F-7EAB-4500-B668-90E28926B8B2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9AD0802F-7EAB-4500-B668-90E28926B8B2.jpg.html)

Well done. Amazing work. I loved it the first time round so can not imagine how good it will be this time.
Lee

Stunning work mate , it's coming along nicely   ;D

Dam nice work ! Great detail !!

I need to get my fix.. 


What's up? Any update?

 ;D
I`ve been doing lots to it, the body is back on the pan for mock up,  fitted the spare wheel tray and fitted the gearbox and motor. There has been a tonne of work with the engine mock up side of things, I`ve had to fab up a new traction bar as the old one didn't fit because of the exhaust, cut and remount the whole trapeze bar, build a stainless 304 muffler , create a three piece removable rear valence and then I had an issue with the deck lid gaps which I am now nearly finished in fixing that.  I`ve been doing lots of custom bits like steering column mods, mag switch location etc.    Final bodywork will start prob around November which will give me plenty of time to get it ready for paint next spring.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4B1C281E-68EE-4185-A047-88EFDF72DE70.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4B1C281E-68EE-4185-A047-88EFDF72DE70.jpg.html)

I modified the lip on the nos spare wheel tray so it flowed nicely, no gaps.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/66884F3E-F679-4E82-97D2-4C32055185E5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/66884F3E-F679-4E82-97D2-4C32055185E5.jpg.html)

Also doing lots of detail bits like this, so many small areas that need attention, its unreal

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DBD28E92-FF45-4FB6-AB57-C7001FDB0CF5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DBD28E92-FF45-4FB6-AB57-C7001FDB0CF5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/457F5817-4FE0-4DE8-A346-EB734F422220.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/457F5817-4FE0-4DE8-A346-EB734F422220.jpg.html)

Defrost delete, ugly dash part beautified  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D57E4AEF-102D-4EA9-A051-B9EAB4CCDEC6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D57E4AEF-102D-4EA9-A051-B9EAB4CCDEC6.jpg.html)



 Thank you so much for the kind comments, its appreciated. Cheers

Any more updates? I`m eager to see and to learn more from your fantastic work.

-BB-

Thanks
 For the past two or three months its been all about the engine mock up. I must have installed and removed the block about twenty bloody times. You know how it goes, to fit this, the carb has to be mounted, to clear that ,the fan housing has to be mounted ........
 
I`ve realised that I`ve wasted a lot of time polishing lots of parts that were previously fitted only to realise that I will not use them again. The tall manifolds have gone, I must have spent three days smoothing and polishing those only to find that that age old problem of the stack to foul the lid.  Also I`ve been having a few issues with the deck lid fit. The car was involved in a minor accident way before I bought it the first time in the nineties, the previous owner had reversed into a waterboard truck and pushed the offside corner of the deck lid inwards hitting the dynamo in the process. the damage caused was cosmetic but I had not reckoned with the fact that the offside engine bay side was pushed downwards in the event.   The gap between the lid and body on the nearside was perfect but the offside there was much larger.

Perfect

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9DE37839-C20F-4EB8-85FE-ED077B763047.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9DE37839-C20F-4EB8-85FE-ED077B763047.jpg.html)

Really bad

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8F2BBC82-8176-4FD2-9407-9D6E2804194C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8F2BBC82-8176-4FD2-9407-9D6E2804194C.jpg.html)

Now , I tried to fix this by panel beating the body upwards which worked to a degree but I wasn't happy with the fact that some filler would have had to have been used so I cut it out and replaced the corner with a new section from a later donor car.

Gap at the top was great

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/36CF5779-7533-4349-92DD-AC035164138A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/36CF5779-7533-4349-92DD-AC035164138A.jpg.html)

I tried using my dent puller

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C42D6778-B621-4934-BD9F-03556586DB73.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C42D6778-B621-4934-BD9F-03556586DB73.jpg.html)

No luck so I cut it out

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B38880CC-8520-4797-94E0-E2091FDA1C42.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B38880CC-8520-4797-94E0-E2091FDA1C42.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4614C93F-C358-4978-81CA-1129CE0856CB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4614C93F-C358-4978-81CA-1129CE0856CB.jpg.html)

It would have took a lot of filler to fix this  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7F958B78-8FB0-4B27-BBE2-EC338758EC45.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7F958B78-8FB0-4B27-BBE2-EC338758EC45.jpg.html)

Donor section from a late bug

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/22B91B28-6BC0-476E-AD86-0CFC6DE23958.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/22B91B28-6BC0-476E-AD86-0CFC6DE23958.jpg.html)

Quickly fitted, one hell of a difference

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8FDB0477-8C2D-4F5E-8A28-7A5A9219EC83.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8FDB0477-8C2D-4F5E-8A28-7A5A9219EC83.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0B387E69-27AC-4A4E-8E17-E2171A083D7F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0B387E69-27AC-4A4E-8E17-E2171A083D7F.jpg.html)

Surprise surprise the wing captive nut was wrong so out came the trusty super press tool

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1D300B87-D8CA-422D-9113-858C2E0E3B2E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1D300B87-D8CA-422D-9113-858C2E0E3B2E.jpg.html)

Genuine nut

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4EFF18BD-12C7-40CC-B944-9ED5E27F6AD8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4EFF18BD-12C7-40CC-B944-9ED5E27F6AD8.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0852DBF9-8B62-49E9-9385-8CF5170A8DDC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0852DBF9-8B62-49E9-9385-8CF5170A8DDC.jpg.html)

See the difference in the shape

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BA2EE1B7-A550-4314-AA76-8EFD87F52E48.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BA2EE1B7-A550-4314-AA76-8EFD87F52E48.jpg.html)

Part way in

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/880AA444-D97D-4612-A40E-36FBF1D5884E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/880AA444-D97D-4612-A40E-36FBF1D5884E.jpg.html)

Mucho bettterrer

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/015A6043-2A21-4D43-B38E-6592AC1F775D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/015A6043-2A21-4D43-B38E-6592AC1F775D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B77ABE70-BE3D-4B86-8A2E-DB3E8D9527D8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B77ABE70-BE3D-4B86-8A2E-DB3E8D9527D8.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5B7A220D-04D8-4CC6-91F6-B022E78565DB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5B7A220D-04D8-4CC6-91F6-B022E78565DB.jpg.html)

No filler

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8411B5AA-2E18-42B1-B720-3BED7D7F1B10.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8411B5AA-2E18-42B1-B720-3BED7D7F1B10.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/28AC6B23-7F7C-438E-8141-88B8AAA26E3A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/28AC6B23-7F7C-438E-8141-88B8AAA26E3A.jpg.html)

Other little but important jobs like this too. Trying to find the sealing clamping strip on the rear valence proved to be a challenge until Autocraft engineering sorted me out with a new strip. It was sort of bent to a shape but took a bit of careful massaging to fit. The old one was never going to look right.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DCFF1085-D06A-481A-BDBC-952F82600CA1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DCFF1085-D06A-481A-BDBC-952F82600CA1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AE61B20C-71E0-4147-9D6F-43A56CD13849.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AE61B20C-71E0-4147-9D6F-43A56CD13849.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/60227EAA-98D4-449E-862D-BE9124AE3CD8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/60227EAA-98D4-449E-862D-BE9124AE3CD8.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/639540E4-F238-4256-B880-8695791D7D9F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/639540E4-F238-4256-B880-8695791D7D9F.jpg.html)

Also been working on a cabrio deck lid which I will get ready for paint so I`ve got the choice of two lids. Exhaust is now finished, the oiling system is finished with a new cooler etc, all the fuel lines are done, the motor is stripped and ready to be taken for a full rebuild and a capacity hike and cam change , many parts are ready for the chrome.....
 
I`m finishing all the tiny jobs that need doing before I start to prime and body prep and panel fit. There are a few decisions about some other stuff to be made and I`m having trouble making my mind up what to do. These changes radically change the look of the car.... :o

Very inspiring work!

Stupid question from a beginner: What type is the yellow primer that you use after blasting?

He answered that earlier in the thread

The yellow is an ordinary etch primer, 1:1 mixed with activator

Cheers.

Oh, my, this is lovely to behold... I'm floored.
So much detail!

Care to share a bit more of your methods?

Am i to believe that you do all of your rough dressing of welds with the little electric Makita belt fella in the pic here?
(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F01A3C59-A0C2-469C-8061-6460D366CE9E.jpg)

No stone grinding wheels at all ???
I am baffled how you dress welds down inside right angles and tight crevices and such..! :o

Do you have a picture of your DA sander?
It's also electric?

What grits do you prefer for these?

-Also-
You are spot-blasting up high there, or forking the thing down every time?
I could see blasting up there making the mother of all messes..


Learning SO much here.. Pretty much spent most of today studying this.
Thanks for taking the time to document so thouroughly.

Built the frame at the end of last week. A year and a bit too late me thinks  :'(

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9DCA08EA-A4BF-4BE8-8B29-358C1E536E7C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9DCA08EA-A4BF-4BE8-8B29-358C1E536E7C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/97EC28EA-C770-4D6D-B91E-3F400A0EBFC7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/97EC28EA-C770-4D6D-B91E-3F400A0EBFC7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/39560006-7767-4444-B183-794FA0117ABE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/39560006-7767-4444-B183-794FA0117ABE.jpg.html)

Redoing work I did a year ago  :)  It really bugged me that this pressing I made was not the right shape so I repaired the rusty cut one from the states.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8D9F2CE1-E809-4205-83CE-8A01AB939041.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8D9F2CE1-E809-4205-83CE-8A01AB939041.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/ADA00C64-614F-4904-8EAA-D105FF0CA805.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/ADA00C64-614F-4904-8EAA-D105FF0CA805.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9F970E22-2D24-4960-819E-05DCD5C13544.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9F970E22-2D24-4960-819E-05DCD5C13544.jpg.html)

... and made my own weber windows

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/003833EA-24A5-4FBA-BF9F-6316C85D634E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/003833EA-24A5-4FBA-BF9F-6316C85D634E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0CE4A151-3AE7-48D8-8853-B73415AB9874.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0CE4A151-3AE7-48D8-8853-B73415AB9874.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E58954C8-983D-421C-85AC-6BEA505C998D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E58954C8-983D-421C-85AC-6BEA505C998D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D7EA448A-13B1-4957-86CD-194BA808099B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D7EA448A-13B1-4957-86CD-194BA808099B.jpg.html)

A few pics of the re repair of the boot floor edge. Not an easy place to get too to finish it properly.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/ADA00C64-614F-4904-8EAA-D105FF0CA805.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/ADA00C64-614F-4904-8EAA-D105FF0CA805.jpg.html)

I had to weld on a new seam as it was missing completely

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B18E91E1-6CE0-4FF8-8B79-37CF5FE139FC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B18E91E1-6CE0-4FF8-8B79-37CF5FE139FC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/40D80B97-2B9E-49C3-B0FA-F4098D9F123C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/40D80B97-2B9E-49C3-B0FA-F4098D9F123C.jpg.html)

Part way through

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/06A38380-B882-4DCE-BD49-4E96BD2AE10A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/06A38380-B882-4DCE-BD49-4E96BD2AE10A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9FF03542-BE54-44A0-8B3A-7CB43E8A2437.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9FF03542-BE54-44A0-8B3A-7CB43E8A2437.jpg.html)

Job made easier

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/315F75E4-30B5-4900-8FB6-3B0FC16C7041.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/315F75E4-30B5-4900-8FB6-3B0FC16C7041.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/291BFB4D-2486-40EC-9C54-2922B7882B47.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/291BFB4D-2486-40EC-9C54-2922B7882B47.jpg.html)

Next problem was that the seam didn't flow right. Had to do something about it

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/66A34D6D-0E45-4423-8559-46577BE95C3E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/66A34D6D-0E45-4423-8559-46577BE95C3E.jpg.html)

Added a fill in piece

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EBF5E295-7246-429D-B0F9-402F77896B1C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/EBF5E295-7246-429D-B0F9-402F77896B1C.jpg.html)

finished

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6C8E08EC-DD8E-4F37-86B5-C1B53F90C5E5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6C8E08EC-DD8E-4F37-86B5-C1B53F90C5E5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/18B4B9C2-2161-4A0F-A940-518A61B5071E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/18B4B9C2-2161-4A0F-A940-518A61B5071E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E014FF87-8F72-40D1-A8EB-D110B5FDCC59.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E014FF87-8F72-40D1-A8EB-D110B5FDCC59.jpg.html)

Modded the hinge mount. Ugly as standard.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3807BD18-6A21-409E-8F54-B0FDE394F036.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3807BD18-6A21-409E-8F54-B0FDE394F036.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4333088F-19A2-431B-B321-22EA638C2D8D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4333088F-19A2-431B-B321-22EA638C2D8D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8A8DAC3C-4AFF-4829-ACD6-F7561D38A6D6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8A8DAC3C-4AFF-4829-ACD6-F7561D38A6D6.jpg.html)

very impressive!

could you show how you did the mounting of the rear apron? i see some kind of fastener system to mount it.

thanks

as always - watching in awe! i have no fucking idea of how you get it that clean, i tried but i never even come close to your work....

Thanks, just takes time and lots of it.  As for the rear valence, I will show how I`ve done it a bit later. Took a bit of head scratching to get it right.  ;D

F*ckin Hell!! Your attention to detail is awesome, and you metal working skills are amazing!! Proper respect to you. :)

Dude  8)

Cheers Neil , if it turns out anywhere near as good as your looker then I will be happy.
While the bodywork has taken up all my time and it's still ongoing, all the other parts are being worked on in the background. The odd couple of hours here and there, lunch times etc are being used for all the other stuff that needs doing. A full engine strip and rebuild was reqd even though it ran with no problems or issues, I just wanted it freshening up and a hike in capacity and power will go down well. Cosmetically it needs a tonne of work, linkage and manifolds and a whole host of other parts are being changed too.
  The manifolds needed changing because the tall skat ones made the stacks foul the decklid and that just won't do. I bought a set of unbranded short ones and set about match porting them to my Jeff Denham heads. Shame really as I spent an age polishing the tall ones :(

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B9368009-AD98-4D53-A25F-908267A2E5C5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B9368009-AD98-4D53-A25F-908267A2E5C5.jpg.html)

Copying the port shape

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7EC606C0-2EB1-4B4D-9EBE-5CC0C9BAAE67.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7EC606C0-2EB1-4B4D-9EBE-5CC0C9BAAE67.jpg.html)

Bought the necessary tools

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FB634978-C4A1-403D-BD3E-FC638E07DEDA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FB634978-C4A1-403D-BD3E-FC638E07DEDA.jpg.html)

And got on with it

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D0D1BEB1-0D2B-4A81-B83D-36A15E30D5A2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D0D1BEB1-0D2B-4A81-B83D-36A15E30D5A2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9E7EEEA4-6FB4-4AAE-8234-1E53769DA17B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9E7EEEA4-6FB4-4AAE-8234-1E53769DA17B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6CB9B5A0-7B4B-4D81-9726-9D3301B2C254.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6CB9B5A0-7B4B-4D81-9726-9D3301B2C254.jpg.html)

They were rough castings

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A532C70F-5A60-4BAB-A267-0E555981D08A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A532C70F-5A60-4BAB-A267-0E555981D08A.jpg.html)

Very rough!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1E8EC57E-0992-4756-AC51-0F376739C6A7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1E8EC57E-0992-4756-AC51-0F376739C6A7.jpg.html)

Got there in the end

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/803B40CB-CD2B-40F7-9178-0FC8B2FDB784.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/803B40CB-CD2B-40F7-9178-0FC8B2FDB784.jpg.html)

The strip revealed a few issues, lifters, cam and lifter bores are pretty worn, crank and rods look ok and the case needs a little line bore. The Denham heads will be checked over. I'm going for a hike in cc, 2276 is the order of the day.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2CBE240A-E6BE-4D7D-A2D3-2B35BF5A510A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2CBE240A-E6BE-4D7D-A2D3-2B35BF5A510A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C6448915-02BD-4C52-9B62-9EFB6FE9F0D2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C6448915-02BD-4C52-9B62-9EFB6FE9F0D2.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B27C90EB-66AB-49F5-96F0-679042E4AAF0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B27C90EB-66AB-49F5-96F0-679042E4AAF0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F8525B8E-3363-40D2-8817-1918B277555E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F8525B8E-3363-40D2-8817-1918B277555E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A9A64F1F-0270-47FF-8B79-099089A07F5A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A9A64F1F-0270-47FF-8B79-099089A07F5A.jpg.html)

Ongoing story...

Nice work. What tool and tool bits are you using to do the manifolds?
Lee

Cheers. I used a bergen long burr set but to be honest a short set did the job. HPS supplied the sanding roll set. Not cheap stuff but very handy! Got a blue point die grinder to use with the long burrs so I could regulate the speed. Mainly used a Mikita electric die grinder for most of the job.

Great, have been looking for an electric die grinder for a while. What model is yours?
Lee

It's a really old one mate. 110v which I run off a transformer.

Ok, that's cool. I've google'd a few  ;D
£30 for the Scat Traks?
Lee

They are on my mantelpiece. :)

vwhelmot; what is the area at the tightest point in your new manifolds compared to the cylinder head intake channel and valve size? You should try to avoid thight areas throughout the intake channel since you do not want a second venturi.

Best rgs
BB

I've done about as much porting on these manifolds as I can without having to weld them. The tightest area I suppose is the curve on the inside. 

Dude, its already better. Honestly, the standard of metal work and attention to detail on this car is another level. :)

If I ever do another car this will be the standard I aim for. :)

Dude  8)

Lee

I've got a nice 110v one if you need to borrow it

Ta Ron

Thanks Ron  ;D

Fourteen months ago

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7F5AA362-C2C2-46EF-BC82-226AC7847E6A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7F5AA362-C2C2-46EF-BC82-226AC7847E6A.jpg.html)

It's been a blur! :)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7AB040B9-DAC7-424E-83C7-7643C88E63C5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7AB040B9-DAC7-424E-83C7-7643C88E63C5.jpg.html)

When it came to the channels , I knew that the closing plates were all wrong. Wrong shape and wrong pressing. I knew it would be a bit of a pain to drill out all the spot welds but it had to be done. 95 in each closing plate, my blair cutter did the trick.

Check out the horrible pressing, it wasn't even a one piece panel

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9DD3121B-E37E-481A-9D3B-35C3B0C5D9D4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9DD3121B-E37E-481A-9D3B-35C3B0C5D9D4.jpg.html)

The way the crossmember lip on the outside is wrong too

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/79753CB2-BEED-48B8-8111-894E38676799.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/79753CB2-BEED-48B8-8111-894E38676799.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A3B7F930-A8DC-4407-9C3C-A238A4430C3A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A3B7F930-A8DC-4407-9C3C-A238A4430C3A.jpg.html)

Steve Hook made me a pair of panels that are slightly different. The way the panel angles forward is different on the later channels , the early pressings had more of a curve so Steve made mine a bit wider at his point but I knew I would have to add more metal to this area to accommodate.

See here

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8D6CA0FC-B56D-478E-A8FE-650C3A382C65.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8D6CA0FC-B56D-478E-A8FE-650C3A382C65.jpg.html)

Blasted on the outside, rust on the inside

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2D8E96A5-7CA4-4EB4-9EFC-02A732D27023.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2D8E96A5-7CA4-4EB4-9EFC-02A732D27023.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B2D29719-4336-4B9D-8B25-10A56FACAA32.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B2D29719-4336-4B9D-8B25-10A56FACAA32.jpg.html)

From the factory, there are some dimples that are pressed into the lip like these

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4EE9AD56-5053-459B-9203-37B9D97E1DF4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4EE9AD56-5053-459B-9203-37B9D97E1DF4.jpg.html)

Mine didn't have any. So I made a simple tool and pressed some in

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/FA2D9791-6CF2-4D0E-9FDA-266DEC864E37.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/FA2D9791-6CF2-4D0E-9FDA-266DEC864E37.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5BEDF3B5-6065-4630-A84A-FE8CDDBBCA3B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5BEDF3B5-6065-4630-A84A-FE8CDDBBCA3B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4B5DE15A-665A-47A2-B5B0-264757064251.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4B5DE15A-665A-47A2-B5B0-264757064251.jpg.html)

I then made a quick blast cabinet, it had to be done and I was prepared for the mess afterwards

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/488276E5-D953-4CAD-AFAB-85D3F9595E7F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/488276E5-D953-4CAD-AFAB-85D3F9595E7F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A35C0E02-EFEF-4E40-9548-5C4413425749.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A35C0E02-EFEF-4E40-9548-5C4413425749.jpg.html)

Also blasted and etch primed the new panels too

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F1F87294-9B57-4835-8DD9-09C576F33AF4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F1F87294-9B57-4835-8DD9-09C576F33AF4.jpg.html)

Starting to line things up

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/AB9B58AA-93B2-41EF-9D7B-72CD49725BAC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/AB9B58AA-93B2-41EF-9D7B-72CD49725BAC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/612DC441-041F-40E2-893E-53CE9E913E9A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/612DC441-041F-40E2-893E-53CE9E913E9A.jpg.html)

More metal needed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DF328DA8-9AAF-473C-86DB-5A452B19D9ED.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DF328DA8-9AAF-473C-86DB-5A452B19D9ED.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D110F13D-07ED-425C-B498-9320C38AD892.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D110F13D-07ED-425C-B498-9320C38AD892.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D0511E7A-7C65-4E45-A99A-2A91EFCDFE11.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D0511E7A-7C65-4E45-A99A-2A91EFCDFE11.jpg.html)

Joy

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/692EDDD9-2847-4E53-BBE9-2C043CB3FF62.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/692EDDD9-2847-4E53-BBE9-2C043CB3FF62.jpg.html)

Crossmember was welded to the inner lip of the channel then the closing panel welded on top

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CC310E74-F0E9-4B89-B4A6-DBD5537656E2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CC310E74-F0E9-4B89-B4A6-DBD5537656E2.jpg.html)


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3E56A7DD-90F2-40D0-923B-46A2C2209A3C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3E56A7DD-90F2-40D0-923B-46A2C2209A3C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5761504F-7C72-4A2B-95B2-F7CCF99DF65A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5761504F-7C72-4A2B-95B2-F7CCF99DF65A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/09FB85D4-47AC-4869-B2C0-EC9E56B80E6E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/09FB85D4-47AC-4869-B2C0-EC9E56B80E6E.jpg.html)

Sorted

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BBEF44A4-6018-46EF-896C-8D0AC674B408.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BBEF44A4-6018-46EF-896C-8D0AC674B408.jpg.html)

I think I prefer the 1st picture :o :D   



Seriously stupid amount of work you have done, well done 8)

cheers Richie

So do I :) haha

Onto the other side it was much the same story, it also gave me the chance to remove the heater tubes too and the amount of glass dust that was trapped inside was an eye opener

Just from one side

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/889E551F-5661-4EF6-8F7D-783C7BB6C48D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/889E551F-5661-4EF6-8F7D-783C7BB6C48D.jpg.html)

More spot weld drilling

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/49B36299-DD3F-4C5A-8A33-C1BEEEF25BD8.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/49B36299-DD3F-4C5A-8A33-C1BEEEF25BD8.jpg.html)

Had one of those rare moments when I had drilled out all the spots in the right place. Stuck the chisel in and it just fell apart. Happy days

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/07EFDBC9-3F8E-45BC-BEFC-CCD288AA6242.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/07EFDBC9-3F8E-45BC-BEFC-CCD288AA6242.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4A174B30-A4CD-4E18-9EB7-9D503D099E6B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4A174B30-A4CD-4E18-9EB7-9D503D099E6B.jpg.html)

Goes to show where rust lurks

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A86E58DF-2777-4A20-9BE7-183FC013993C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A86E58DF-2777-4A20-9BE7-183FC013993C.jpg.html)

So, after filling up the whole are with crushed glass, it was onto cleaning up all the lips and getting the new panel ready for fitting. Welded the crossmember to the channel like this.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/92A55519-F1DF-48C1-B81A-E51D20F69099.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/92A55519-F1DF-48C1-B81A-E51D20F69099.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/97F584B6-AD47-4598-8C51-D2A0AF414AD3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/97F584B6-AD47-4598-8C51-D2A0AF414AD3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/25FBD9DB-DF28-4C7A-AB8A-FEA18987D8F3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/25FBD9DB-DF28-4C7A-AB8A-FEA18987D8F3.jpg.html)

Clamping up the rear. It's such a strong structure when finished. Great design

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D0B59FE9-28C2-454B-BDFF-AEB56816F7E3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D0B59FE9-28C2-454B-BDFF-AEB56816F7E3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/234E6044-7B77-4701-A560-2F46F90B7036.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/234E6044-7B77-4701-A560-2F46F90B7036.jpg.html)

Took a long time to make sure everything was straight. The body had been placed on the pan a few times to align up the bolt holes

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C94549A5-0968-4E78-949C-2B995681BA7C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C94549A5-0968-4E78-949C-2B995681BA7C.jpg.html)

Finished

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/627C7FB9-26F6-48C7-A5B6-AE119CCD2B26.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/627C7FB9-26F6-48C7-A5B6-AE119CCD2B26.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CBBCF842-4F6D-4D8A-A0D3-57388A75AB36.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CBBCF842-4F6D-4D8A-A0D3-57388A75AB36.jpg.html)

You have the patience of a saint. Well done.

I`m single  ;D

running out of superlatives here....

Cheers  :D
  Getting the front valence on was pretty straight forward, welding the seal clamping strip is a bit of a pain, its very hard to attach it neatly and to bend it right. I found the best way was to run a steel rod up through the strip and after that it was a lot easier to bend without kinking it. I welded it from behind too. The valence itself is an Autocraft engineering item. Its a nice pressing, fitted well but I did clean and straighten some of the edges a bit. It would be nice if they offered one with the seal strip already attached but I guess they know that's its a pain to do.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BF53362F-F1F8-42AF-A50C-2AFDB2AA063C_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BF53362F-F1F8-42AF-A50C-2AFDB2AA063C_1.jpg.html)

Wings on to check fitment

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/94E91A4F-5F04-457C-B6CD-CA4ECBFFD790.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/94E91A4F-5F04-457C-B6CD-CA4ECBFFD790.jpg.html)

Edge needed trimming straight, it was a bit off

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3F733951-909A-4CF9-B971-6FF5A2CDB8C1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3F733951-909A-4CF9-B971-6FF5A2CDB8C1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3244B320-C685-4288-AF2B-F9BB8AD09F87.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3244B320-C685-4288-AF2B-F9BB8AD09F87.jpg.html)

The factory used to braze the corner on like this so that what I had to do

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/120268DB-BCB2-411A-9D5E-5A68692D2DBF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/120268DB-BCB2-411A-9D5E-5A68692D2DBF.jpg.html)

One side done

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1BCA8B09-62B9-4657-B3EB-BAABBF11ACE3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1BCA8B09-62B9-4657-B3EB-BAABBF11ACE3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/A5BEA1CF-D89E-4C0B-8E74-0B6FD28B7DB4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/A5BEA1CF-D89E-4C0B-8E74-0B6FD28B7DB4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8119D6AB-8B2E-440C-9310-8C6FE4CA7DCA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8119D6AB-8B2E-440C-9310-8C6FE4CA7DCA.jpg.html)

Sorted

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D0108FA0-0912-480D-B05D-AC066CD21A83.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D0108FA0-0912-480D-B05D-AC066CD21A83.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D68C7868-4746-4AD4-9B98-4408F71A5700.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D68C7868-4746-4AD4-9B98-4408F71A5700.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/58693580-E384-4420-859B-142AD202896F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/58693580-E384-4420-859B-142AD202896F.jpg.html)

Even this small job took a whole day, roughly 8 hours to do and that was not including welding on the seal strip because I did that the night before. Its crazy where the time goes.
This is really it for a while, I have just the wings to work on and a small job on one of the doors and after that its getting it prepped for paint.  There is lots I haven't shown but I will update next year.

Happy Christmas to everyone!   ;D

Awesome workmanship dude! I have a question regarding the sealing strip on the rear valence, I'm about to do the same thing & was wondering how you managed to put the curve into it without any puckering on the inside edge? I got my strip from autocraft too but it came completely straight   ::)

I managed to find a length of steel rod that I could insert into the sealing strip so that when you form it and bend it etc it will not kink. I bent it as I welded it, little at a time. After I finished , the dowel rod could be just pulled out easy. The job still took time and with the rear valence make sure the strip is high enough not to foul the decklid. Mine took two attempts :)

What spot weld drill/ cutter do you use? I'm looking for a new one and could do with a recommendation.
Cheers Paul

These are the best I've come across, they work best when instead of using a centre pop , use a small drill to make a dimple first. This way the cutter won't wander at the start.

http://www.ebay.co.uk/ulk/itm/351041392853

Found some pics

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/DB7E9715-AD03-4B3D-9143-B8638A36F397.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/DB7E9715-AD03-4B3D-9143-B8638A36F397.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/B615B272-B70F-4FE1-ABF3-091DE6FB2C60.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/B615B272-B70F-4FE1-ABF3-091DE6FB2C60.jpg.html)

I've got to admit it , I hate working on bug wings. They are just a pain in the arse. You can't clamp them down while working on them easily, if you need to do detail work on them like grinding/ cleaning the mounting flange it's almost impossible to get light to see what you are doing. As soon as you cut them they move etc so all in all its been a chore.  From the start I vowed to get an original set of genuine wings. As you know getting a decent set is getting really difficult and when you do 99% of the time they need work. Even nos ones variably need some sore of dent repair or blasting due to storage rust etc.  The rears have been the most work, I've ended up restoring two sets of rears. I have bought six rear wings to find that I can only use two. I bought what I thought was a nos right side only for it to turn up and I straight away had doubts to whether it was genuine. The return lip just looked wrong etc. The second set turned out to be a IGP set , repo. To be honest these ones fitted great and needed minimal work and I spent quite some time making them perfect. The only problem was that I knew they were repo and they were slightly wrong for the year in that the mounting flanges were dimpled like on earlier cars. They would have stuck out like a sore thumb and I should not have wasted so much time.   The third set is the ones I'll use. Bought off here from Rob the Manx , they too needed work but they fitted and looked right and are genuine.

IGP repo wings. They fitted great

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CCEFABFA-718D-43CE-8B30-C2F51A868EAB_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CCEFABFA-718D-43CE-8B30-C2F51A868EAB_1.jpg.html)

Spent some time cutting out and making good all the untidy lips and returns.


(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1319A8F3-9DDF-48EA-AE62-67C7CE05A95A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1319A8F3-9DDF-48EA-AE62-67C7CE05A95A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D2CA1169-90CF-45AF-8163-E062382E9A37_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D2CA1169-90CF-45AF-8163-E062382E9A37_1.jpg.html)

Front was too long so I modded it

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/18223BE2-5124-4C56-9F01-67A8693639CD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/18223BE2-5124-4C56-9F01-67A8693639CD.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F0EAF055-6EDA-4B36-95A2-410FE5EA1444.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F0EAF055-6EDA-4B36-95A2-410FE5EA1444.jpg.html)

Blasted them

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/639A130D-789B-4B66-A982-D238BCEBE372.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/639A130D-789B-4B66-A982-D238BCEBE372.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6686179A-CFFF-4FBF-B332-B839757F9117.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6686179A-CFFF-4FBF-B332-B839757F9117.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6C912003-B094-4512-8AAE-A390E669206A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6C912003-B094-4512-8AAE-A390E669206A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/CF58A36F-245A-45C0-B750-E43131A4496F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/CF58A36F-245A-45C0-B750-E43131A4496F.jpg.html)

Then decided not to use them. :)

So onto the genuine ones. Spent a lot of time trimming down the return lips and basically doing the same work over again. I had already lost over a weeks worth of evenings on the repo set so I wasn't going to look forward doing it again but hey ho.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/F016D3AB-C7BB-48B2-8A84-778E04C87FC5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/F016D3AB-C7BB-48B2-8A84-778E04C87FC5.jpg.html)

Factory pressing isn't always nice. Mass produced after all.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/36722C37-3351-40DE-A2C7-BBD50DAD2227.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/36722C37-3351-40DE-A2C7-BBD50DAD2227.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/43F81E54-D7A3-41A5-BED0-C67B7746D768.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/43F81E54-D7A3-41A5-BED0-C67B7746D768.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7F7566B5-C781-40CE-8713-08C99069D66D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7F7566B5-C781-40CE-8713-08C99069D66D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/16142ACD-BEE5-4B15-8F13-9EB8B78A0C25.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/16142ACD-BEE5-4B15-8F13-9EB8B78A0C25.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9EE885D1-AADB-4714-8EA8-C55DF3F34796.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9EE885D1-AADB-4714-8EA8-C55DF3F34796.jpg.html)

Making sure that the lips match side to side.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/29413BFD-A688-4E94-B363-042D5CD37645.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/29413BFD-A688-4E94-B363-042D5CD37645.jpg.html)

Then filling in the US spec over rider holes

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/78977A2F-F1A0-40A5-9A12-866868038903.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/78977A2F-F1A0-40A5-9A12-866868038903.jpg.html)

Other side

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2406121F-134A-4A7D-AD34-D879C60F799D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2406121F-134A-4A7D-AD34-D879C60F799D.jpg.html)

Fronts still needed work. Like this.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/09E66E00-6951-4725-A4E3-75BC194BE109.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/09E66E00-6951-4725-A4E3-75BC194BE109.jpg.html)

New sections welded in.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9ADF5CE1-6CB7-4FD2-82ED-A8701C220BE7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9ADF5CE1-6CB7-4FD2-82ED-A8701C220BE7.jpg.html)

And welding up the indicator holes which were huge. Careful welding reqd here to avoid distortion.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D96D3941-04A9-479D-B482-E5920FB893E6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D96D3941-04A9-479D-B482-E5920FB893E6.jpg.html)

Making sure the running boards fit took time too.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/E3FB41B3-3BE7-4B94-A726-A06EF991ACC2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/E3FB41B3-3BE7-4B94-A726-A06EF991ACC2.jpg.html)

It turned out that the ones on the car were genuine. I've blasted them and bought new genuine covers.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/839075C1-4CA9-4540-A00A-85EE21295BA5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/839075C1-4CA9-4540-A00A-85EE21295BA5.jpg.html)

Been fitting doors and bonnet too.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0B056C58-C183-4C36-9ED6-1FCA34004159.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0B056C58-C183-4C36-9ED6-1FCA34004159.jpg.html)

Door fit seems nice. This is without the striker plate , just hung.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4C61A482-6EDE-4E5F-9EA9-53F4D2DE213A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4C61A482-6EDE-4E5F-9EA9-53F4D2DE213A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0303E585-17BA-4F2F-B65C-57A0D4189942_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0303E585-17BA-4F2F-B65C-57A0D4189942_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/4CE2C0F1-1D0A-4EA4-B070-55F27147147B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/4CE2C0F1-1D0A-4EA4-B070-55F27147147B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/1791D2BC-BE60-4E7D-91FB-011623075739.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/1791D2BC-BE60-4E7D-91FB-011623075739.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/C8865DF0-87F1-4958-9E54-A7E44D2AD63F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/C8865DF0-87F1-4958-9E54-A7E44D2AD63F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/85C43FB8-B55A-4B80-BCFE-54448D1250F2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/85C43FB8-B55A-4B80-BCFE-54448D1250F2.jpg.html)

After this , it was a hundred and one little welding jobs, small holes to plug or holes to drill for this and that. Got to remember to get it right now rather than later after its painted. Even drilling the hole for the antenna etc is so important. Mistakes can be fixed now but not later. I just hope I've remembered everything as I've finished the welding on the shell. It's been such a long job , so many hours I've lost count.

I've heard that painting over weld thru primer is a no no. In some cases it can react and lift so I wasn't going to take that chance. I've had to blast the shell again in all the areas that I've worked on to remove the primer and re etch the body. There was no way I was going to blast it upstairs so I had to fork lift it down from the mez floor again. Not something I enjoyed doing but it had to be done.

Got it down safe

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/3DFB0824-9D81-49CE-AAD3-3E3788C489E7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/3DFB0824-9D81-49CE-AAD3-3E3788C489E7.jpg.html)

Big milestone to finish the body welding!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/68250CCB-D4AD-481F-B794-D707D5173696.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/68250CCB-D4AD-481F-B794-D707D5173696.jpg.html)

A super exciting video of me shitting myself on a fork lift. High octane action.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/th_EDAF9955-089D-4C65-874F-A9E4E2EA65A0.jpg) (http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/EDAF9955-089D-4C65-874F-A9E4E2EA65A0.mp4)

Re blasted

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2C90D31B-AC30-404E-A08D-CAA09F5E1AC0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2C90D31B-AC30-404E-A08D-CAA09F5E1AC0.jpg.html)

Re etched primed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/50A6F9A7-8C56-4B2F-98C2-2E10F3D4969B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/50A6F9A7-8C56-4B2F-98C2-2E10F3D4969B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/69EF7AEF-0F30-4385-B5F9-B011D6F27458.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/69EF7AEF-0F30-4385-B5F9-B011D6F27458.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/51284794-FB98-4ECA-BFC7-19793F20D1D1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/51284794-FB98-4ECA-BFC7-19793F20D1D1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5A41C40B-DF60-4A63-990D-30472E880A46.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5A41C40B-DF60-4A63-990D-30472E880A46.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/9163EE68-1385-47F2-8947-7C76630DC8C9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/9163EE68-1385-47F2-8947-7C76630DC8C9.jpg.html)

Expoxy coat

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/0B55FA36-2EAA-47FD-BE3C-33E0188BFFE2_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/0B55FA36-2EAA-47FD-BE3C-33E0188BFFE2_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/01992A23-99C1-4265-8E7B-C576267700E0_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/01992A23-99C1-4265-8E7B-C576267700E0_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/D3AE81B2-4F26-4847-B272-B201C078220F_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/D3AE81B2-4F26-4847-B272-B201C078220F_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/2F293C70-D9D1-46FE-8FFF-53618CDD6AF9_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/2F293C70-D9D1-46FE-8FFF-53618CDD6AF9_1.jpg.html)

Absolutely stunning piece of work you are doing!
But one little question, how long time has gone between etch primer and epoxy and what type did you use?
Reason I ask is because I have many times seen when painting with epoxy over etch primer that they start to react because the epoxy is almost air tight and that’s not something the etch prime likes...

But this is something you will see in the next weeks if so. ;)
best of luck and keep up the posting, beautiful work!

Thanks. I "baked" it as much as I could and left it for a few days and to be honest it was a really thin coat of etch , more of a wash. That stuff goes off really quickly . This is only the first base coat of epoxy. I`ve got to start all the filler work yet. I`ve never had a problem with this combo (touch wood)  :)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/2A20A6B3-885F-48D2-A6EE-459695614D71.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/2A20A6B3-885F-48D2-A6EE-459695614D71.jpg.html)]

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/20630816-2429-44BF-A46F-19F8A24DA952_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/20630816-2429-44BF-A46F-19F8A24DA952_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/D770D9B3-0218-4E86-AAFD-2A4236B78788_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/D770D9B3-0218-4E86-AAFD-2A4236B78788_1.jpg.html)

Amazing Skills..!!  8)
Getting inspired to start my project but will be a shadow of this build..!! Loving your detail..!!  :)

Thanks, post up some pics of your build. The more the merrier.

Nothing much in the way of exciting progress , it's just been a solid two months of bodywork flatting , every inch , every seam , every nook and cranny.  I'm aiming for crisp lines and smooth everything.  Still lots to do before it's ready for paint but it's getting there.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/B02C7290-2594-4A6A-B257-F7679E64595C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/B02C7290-2594-4A6A-B257-F7679E64595C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/AFE1D169-7D94-41F8-B60F-472901A0EDA1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/AFE1D169-7D94-41F8-B60F-472901A0EDA1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/4D4ABEA1-36D2-4226-BC46-3D7FB02AE9F0.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/4D4ABEA1-36D2-4226-BC46-3D7FB02AE9F0.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/68568CD9-94B4-43FE-891E-07A9FEAC26C1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/68568CD9-94B4-43FE-891E-07A9FEAC26C1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/47CFFFC6-8B06-4F34-A21B-F5A5A537C36D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/47CFFFC6-8B06-4F34-A21B-F5A5A537C36D.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/F4705073-8B80-47A3-8F44-DD377A8166BA.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/F4705073-8B80-47A3-8F44-DD377A8166BA.jpg.html)

In the meantime, the seat frames are causing me headaches!

Its all fun and games here. On the high build primer stage and its nothing but fun. Hour upon hour of flatting is getting monotonous but no one said its easy. The body has been back on the pan to check a few final details and recheck the door fit etc. Not far off a trip to the paintshop. About a month off I reckon.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/A094E628-148A-4AE8-AAE3-415FDB194FF5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/A094E628-148A-4AE8-AAE3-415FDB194FF5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/BCABEE67-5590-4374-9489-2FC50A1C7F78.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/BCABEE67-5590-4374-9489-2FC50A1C7F78.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/7CFF8F08-EEE4-4E1A-BE34-055CD49D2C46.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/7CFF8F08-EEE4-4E1A-BE34-055CD49D2C46.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/67EFF01E-DF71-4E21-A656-0F486E79A132.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/67EFF01E-DF71-4E21-A656-0F486E79A132.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/81D317EA-268B-4F27-A8E2-CD00AF8E7C51.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/81D317EA-268B-4F27-A8E2-CD00AF8E7C51.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/9537DD6B-7A48-470F-B204-12A5C55637FE.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/9537DD6B-7A48-470F-B204-12A5C55637FE.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/5F414274-9F2A-4972-BAE6-184B810F6A56.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/5F414274-9F2A-4972-BAE6-184B810F6A56.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/FDD92368-7A1C-48BA-91B3-B373BDD9F33A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/FDD92368-7A1C-48BA-91B3-B373BDD9F33A.jpg.html)

Big Airfix kit

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/99B0CB67-FA40-45B9-8C8C-05B50AD7C644.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/99B0CB67-FA40-45B9-8C8C-05B50AD7C644.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/8B024D2F-88B2-4A66-B1CF-101657F74031.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/8B024D2F-88B2-4A66-B1CF-101657F74031.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/5D565056-EF28-4C38-9B7C-1AE803711355.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/5D565056-EF28-4C38-9B7C-1AE803711355.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/792D2259-7C9E-4343-B59B-5E759480C46F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/792D2259-7C9E-4343-B59B-5E759480C46F.jpg.html)

Another face melter of an update. That decklid with the subtle scoop in is  8)  8)

Ha cheers. The scoop has a story in itself. When I used to use the car as my everyday car back in the mid nineties I used to park it in the street. One morning I went out to drive to work and "someone" had kicked a huge dent in the deck lid and my wipers looked like spaghetti  (something to do with me having it away with a jealous blokes ex woman ;)  )   I tried to straighten the lid but to no avail so I made a scoop instead. I must remember thank the jealous bloke.  ;D

 love your updates, keep ´em coming!

Well after six solid months of blocking it's ready for paint.  ;D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/BC659C6B-C504-41EE-B759-3A312E91942C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/BC659C6B-C504-41EE-B759-3A312E91942C.jpg.html)

Made a frame for the chassis to sit on.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/62C08C2E-F86B-4D40-99BA-4EBCC7044864.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/62C08C2E-F86B-4D40-99BA-4EBCC7044864.jpg.html)

Made a sponge gasket to protect the body from the chassis

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/68C509B1-0AEF-45F2-83C8-31F7911F190F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/68C509B1-0AEF-45F2-83C8-31F7911F190F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/B2DAE718-6920-4DE0-A9A3-B8A0EFC4E2C1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/B2DAE718-6920-4DE0-A9A3-B8A0EFC4E2C1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/1F816594-4A14-473C-B869-357DCE305845.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/1F816594-4A14-473C-B869-357DCE305845.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/51055C06-A2C6-4E72-856F-5413A9E04D6A.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/51055C06-A2C6-4E72-856F-5413A9E04D6A.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/17E5DE3D-6A0C-431B-8659-FFFAF5C23C31.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/17E5DE3D-6A0C-431B-8659-FFFAF5C23C31.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/A7DDAADF-62D8-4675-B98C-5DFCF748ABE3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/A7DDAADF-62D8-4675-B98C-5DFCF748ABE3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/2489B6EB-41F0-48AB-A629-DCF6C2754A44.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/2489B6EB-41F0-48AB-A629-DCF6C2754A44.jpg.html)

So here goes. I'm looking forward to seeing it in paint, I've done the best I can and been over the whole thing not missing a mm.

fantastic, cant wait to see the next post of it in paint, stunning work well done

Thanks, appreciate the comments.  I've still got the floor pan to finish then the fun begins.

Awesome work..!! Can't wait to see it in paint..!!  8)  8)  8)

Ugh!
Killin' me..

Don't tell me they are doing like all of these other shops, and leaving it out in the rain for months!  :P

It was all ready to shoot, right?

Don't hold out! :D

No, it's being well looked after, they are the consummate professionals. I'm confident of the finish

This is gonna be incredible when done,  kudos to the workmanship already done and good luck with the rest of the  build.

What colour you going with?  I love the primer colour looks almost fontana grey.

Cheers , I did toy with the idea of changing colours but who am I to argue with sea blue. The factory got it right first time.

So while the body is away I can get on with the chassis. The frame head is in good condition after blasting, there is pitting but nothing that warrants cutting out and replacing. The amount of shitty factory welds and non aligning seams is unreal. It's taken a lot of work to clean all these areas up so everything is smooth and lines up. I've run a 3/8 solid fuel line down the tunnel with AN-6 fittings either end and had to make a boss for the lock nut to sit properly on the frame horn. This was my first mod which I did over two years ago.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/6B8FD9AA-0242-4DBF-BF4A-5D8A6A4C6659.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/6B8FD9AA-0242-4DBF-BF4A-5D8A6A4C6659.jpg.html)

I cut a section out of the frame horn to modify it and to pass the new fuel line through then built up the section so there is a flat area for the nut to sit on neatly

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7DEC94B2-7E87-4129-88C1-63C8BC95AF91.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7DEC94B2-7E87-4129-88C1-63C8BC95AF91.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BC538C39-8EAC-4E11-B4C5-E6E2728D830B.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BC538C39-8EAC-4E11-B4C5-E6E2728D830B.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/47FEC4C1-BDEA-4EEA-B2D3-67553E252731.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/47FEC4C1-BDEA-4EEA-B2D3-67553E252731.jpg.html)

Mass produced bird shit

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/70EF69BC-8D50-4248-B1DE-234203F1BEE7.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/70EF69BC-8D50-4248-B1DE-234203F1BEE7.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/5AEEC97E-3A2C-4D71-8FA8-D9A6409F64ED.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/5AEEC97E-3A2C-4D71-8FA8-D9A6409F64ED.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/BF7FD6A8-9D99-4DB4-91FA-54CA35C43811.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/BF7FD6A8-9D99-4DB4-91FA-54CA35C43811.jpg.html)

Rewelded and smoothed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/7DF7E284-F742-4429-9953-036996A015F3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/7DF7E284-F742-4429-9953-036996A015F3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar64/8D5CF8B0-C8CA-42F0-BFEB-6DBBD8A1C8D2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar64/8D5CF8B0-C8CA-42F0-BFEB-6DBBD8A1C8D2.jpg.html)

Lots of cleaning up welds like these

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/E5F21C37-1D0C-4DD7-A1EE-540A9D615D8F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/E5F21C37-1D0C-4DD7-A1EE-540A9D615D8F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/93380647-0B22-402A-8FE1-1CDD5746A748_1.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/93380647-0B22-402A-8FE1-1CDD5746A748_1.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/3D59BBA8-660D-4161-BA96-E7BE1C5A3461.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/3D59BBA8-660D-4161-BA96-E7BE1C5A3461.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/70712429-415E-4CFE-A958-D5B4C7320DFF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/70712429-415E-4CFE-A958-D5B4C7320DFF.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/C06E56B1-FF90-43F8-8DDD-4A3F83CBCD76.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/C06E56B1-FF90-43F8-8DDD-4A3F83CBCD76.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/EAD88804-B995-4A6B-BB12-99597BFC8CDF.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/EAD88804-B995-4A6B-BB12-99597BFC8CDF.jpg.html)

This weld took an age to make straight

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/ACDB0F48-037D-4615-81FC-75CA580DDF58.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/ACDB0F48-037D-4615-81FC-75CA580DDF58.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/1F611FFC-D045-4CE0-BDFE-92D1025DF2A4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/1F611FFC-D045-4CE0-BDFE-92D1025DF2A4.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/13AEB46D-1AFC-4FBB-874D-3E5510B6E9BC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/13AEB46D-1AFC-4FBB-874D-3E5510B6E9BC.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/16DBB4B7-DB80-44BB-9C6E-681433E95B15.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/16DBB4B7-DB80-44BB-9C6E-681433E95B15.jpg.html)

Nearly ready for reblasting and then the blocking can begin.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/411CC8B2-BD5D-4D73-85AF-D48B9F286545.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/411CC8B2-BD5D-4D73-85AF-D48B9F286545.jpg.html)

Can you call over to mine and make my fuel lines look like yours?   

Nice work as usual  8)

Wow, every time I see an update on this tread I`m impressed more and more. Awesome skills!  :o
Thank you for the detailed pictures. Very intersting and inspiring.
I hope I´ll see this great car in real when it`s finished.

Thanks very much.
More of this sort of stuff. Factory glued on....

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/E1391291-6078-48A0-ACFC-2790E9B36A49.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/E1391291-6078-48A0-ACFC-2790E9B36A49.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/21DD853F-CEE0-4FE9-B66C-7A1F5EC621A9.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/21DD853F-CEE0-4FE9-B66C-7A1F5EC621A9.jpg.html)

Made my own

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/D2DD621C-E6CA-4726-865E-D417692A569D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/D2DD621C-E6CA-4726-865E-D417692A569D.jpg.html)

Not running heaters so I cut the cable tubes off

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/EE5D2061-BA21-43D0-935B-D2A86854383E.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/EE5D2061-BA21-43D0-935B-D2A86854383E.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/1156BEEA-8134-402E-B534-7BD3D6547102.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/1156BEEA-8134-402E-B534-7BD3D6547102.jpg.html)

Torsion mount

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/57273882-F310-46CC-832A-B1FB63BF9CDC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/57273882-F310-46CC-832A-B1FB63BF9CDC.jpg.html)

Re welded and smoothed

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/1D090C11-8B79-45D3-9767-CB8B033642C6.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/1D090C11-8B79-45D3-9767-CB8B033642C6.jpg.html)

Rear trans mount looks ugly from the back so I made a cover to beautify it

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/64763C7E-5262-43C8-9544-4F432087F94C.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/64763C7E-5262-43C8-9544-4F432087F94C.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/BB296B06-AEFB-49B8-A8D1-7B5AF02EFDF5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/BB296B06-AEFB-49B8-A8D1-7B5AF02EFDF5.jpg.html)

It needed lightening. Welded on and smoothed.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/2FF3D475-B9F9-4DEC-B339-F03458BD1170.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/2FF3D475-B9F9-4DEC-B339-F03458BD1170.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/FF35B63D-3C2A-46A5-B7E8-0438C472424F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/FF35B63D-3C2A-46A5-B7E8-0438C472424F.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/02B4B591-AA5A-498C-BB3F-66E9DE1BE0BD.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/02B4B591-AA5A-498C-BB3F-66E9DE1BE0BD.jpg.html)

Started to clean up the rear shock stays. Lots of flash to remove .

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/B756641E-2D45-46C2-90BD-A34479D03CD4.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/B756641E-2D45-46C2-90BD-A34479D03CD4.jpg.html)

I will carry on and blast the chassis this weekend so I can re etch prime it and start the filling etc... :)

amazing stuff dude.....  :)

Thanks Jick,  building the other seat frame at the mo.

Not a stone unturned or ANYTHING overlooked on your car / Project. Looking at all of your pictures you can clearly see how all the panels of a beetle are put together to form a complete car. Amazing amount of thought and care. As Gene Berg once said - NO ONE will put the care in to building your engine (car in your case) as you will (the person that owns it - you in this case). Awesome work, I hope the painter does your car the way it should be done. 8)

Cheers, I`m kind of gutted that I`m not painting it myself but the lack of a proper heated spray booth etc makes the job impossible for me to do it.  I did as much as I could myself but I guess some jobs are better left to the pros.

judging from your work, you are a pro  ;D

Any news from the paint shop??  ::) ;D 8)

Yes, its in progress. All of the bolt on panels are nearly done and look amazing. The main shell is next.  I`m a couple of days away from finishing the pan which has been an immense amount of work, and I vastly underestimated how much work it has taken to get to this. On the final 800g stage now . The pan will be going to the paint shop soon too. I might make you wait until the debut to see the paint etc, I want it to be a surprise :)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/061FB766-C482-4995-BC54-C1FB4C636DB5.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/061FB766-C482-4995-BC54-C1FB4C636DB5.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/BF408326-5B67-432A-AAB1-E339FA255332.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/BF408326-5B67-432A-AAB1-E339FA255332.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/6BF30BEC-986E-4B34-A9D1-C3822BD6D734.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/6BF30BEC-986E-4B34-A9D1-C3822BD6D734.jpg.html)

Ok , just a snippet then :)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/1AB2D9F3-E099-43B2-A367-9AB0CA2EF597.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/1AB2D9F3-E099-43B2-A367-9AB0CA2EF597.jpg.html)

WOW Look at that floor pan..!! :o 8) 8) 8)

Shiny paint..!!  8) 8) 8)

That's just amazing. The car is going to be top drawer.

Cheers, its all the other stuff that's taken the time too. Every single piece has to be up to scratch, no casting marks, no rough edges, even the bloody steering damper has taken time to make it look right.  The gearbox is my favourite piece so far.

I realy liked the colour the first time I saw it years ago...
Would like it on the fastback in some time.... Care to share the recipe?

jesse

L360 Sea Blau    

The pan is a work of art!

Thank you, I'm sure it will look even better painted neon pink. :)

Stunning work mate  8)

Thanks mate, appreciate it.

The previous owner posted a few pics of my car on FB, it wasn't a bad car really !!

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/C84AB5D2-F487-45C8-A7BB-9B717384E1C3.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/C84AB5D2-F487-45C8-A7BB-9B717384E1C3.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/D9CC3E54-C821-441C-A449-57228AAA6697.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/D9CC3E54-C821-441C-A449-57228AAA6697.jpg.html)

Amazing thread , nice into depth work , a true restorer  :)

Rgs
Erich

Well this is it for now. Chassis done and loaded onto its carry frame for delivery tomorrow.  Plenty more of the other parts to get on with in the mean time. Cheers for the comments, means a lot.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/8B358FF1-97EF-40E7-9DF5-91BCBB90E3BB.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/8B358FF1-97EF-40E7-9DF5-91BCBB90E3BB.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/77AB4D12-33A9-4D01-91C9-14BDE2F9E858.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/77AB4D12-33A9-4D01-91C9-14BDE2F9E858.jpg.html)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/DBE29184-7ABA-42F0-A6ED-AA64612EDF27.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/DBE29184-7ABA-42F0-A6ED-AA64612EDF27.jpg.html)

Pan looks great. Are your mid mount brackets upside down or are mine?  :D

I've made my own mid mount so it's right for my gearbox.

Do we have any update? is it in paint for xmas?

It is painted yes, he is buffing it as we speak. Looks fabulous. Cheers

hope to see pics soon!

Llawn cachu.

Another password to remember !

Good job though, see you soon

We want updates!  ;D

Patience , I`m up to my eyeballs in Fubar  ;) ;D

This is pure metalporn ;D AMAZING!!

Thanks, I'm just getting on with all the other bolt on  parts. I'm finding that I'm refinishing a lot of the parts I detailed two years ago as the standard wasn't up to scratch. The shell and chassis are not back yet but it's given chance to detail a whole load of parts. I broke my collarbone in February and that put me out of action for six weeks which was very frustrating but I'm back getting on with everything now.
I wasn't planning on updating the thread until the end of the year where there will be a part 2 concentrating on the final build and the restoration and detail of every part and the engine and gearbox etc.

Hi vwhelmot hav you got any up dates  :D

Hi
The floorpan is virtually built that's about all I can tell you.

Why ???

Ok mate.Look forward to seeing more updates

The project has come to a bit of a halt at the minute. Hope to still get it ready for next years volksworld show but that might be a push.

Pull your finger out ffs ;)

I'm actually happy you not posting progress pics, makes it easier for me to hit standards I'm happy with :)

 :D
I want some of it to be a surprise. These days everyone knows what the finished projects look like before the debut. I'm really happy with the floorpan,  it's gone together hassle free.

Eee arrrr. Have a pic of the drilled and chromed clutch adjuster nut  :)

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/F227A86A-1A4D-43BA-A935-CF9274F1A12D.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/F227A86A-1A4D-43BA-A935-CF9274F1A12D.jpg.html)

since i have seen more  ;D - belive me, it will be worth the wait. just take your time, buddy

Looks like all the pictures on this thread will disappear soon. Photobucket want a stupid amount of money to allow me to host so I have no choice unless there is another option.  >:(

I use imgur , its still free for time being at least. Ball ache copying all the pics across but would be a shame to lose such a great thread.

Hmmmm, got a Flickr account but I’m not having much luck with it. Copying all the pics from this thread ain’t going to happen, not enough time, I’ve got a car to build  :(

how about a teaser  ;D ?

Here`s a brake line  :D

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/23E4067B-5687-42B0-82FE-E4BA7716C92F.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/23E4067B-5687-42B0-82FE-E4BA7716C92F.jpg.html)

 ;D

Cant. Wait....

BTW Assume youre still single??  ;)  ;D

Not single and currently rebuilding a house too with a move out date of my home of 18 December.  All this ain’t helping the rebuild progress at the minute and I’ve booked my place at the volksworld show next year too. Pressure on big time!  Body going on the chassis next week

Bloody hell! Not one to give yourself an easy time then mate... 
Fingers (and toes) crossed we see you at Volksworld
;D

 ;D
I do like the pressure, gets things done. The trouble with saying things like "I don`t do writing on my fixings"  don`t help  :D         In the meantime , here is a chromed ring on my boot.

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/84F0455B-215F-406D-A16D-2CC6C3EC9CFC.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/84F0455B-215F-406D-A16D-2CC6C3EC9CFC.jpg.html)

It's cool to see a car that has a few details, BUT, this car have them ALL  ;D

I would LOVE to see it in flesh someday!

Cheers, that was my plan to detail every part of the car whether it be just the nuts and bolts to the casting marks and basically refinishing every single component.  Sticking to that ethos has been a challenge to say the least in many ways. 

Good on you, makes me feel better about my obsessions with various things :)

Lyndon, in the nicest possible way, you are a pervert. Chromed rings on balljoint boots is just wrong! Deviant even!

By the way, I can't wait to see the car in the flesh!

The chromers did look at me funny.  It’s all about the details

(http://i98.photobucket.com/albums/l242/vwhelmot/Fubar%202/1E7558D0-3B85-4BCE-9353-E0FF093031A2.jpg) (http://s98.photobucket.com/user/vwhelmot/media/Fubar%202/1E7558D0-3B85-4BCE-9353-E0FF093031A2.jpg.html)

Yep, you're a wrongun! Seriously, you're detailing parts I'd never even think of doing. I remember the car first time round when you'd removed the panel under the vents at the bottom of the window and thinking THAT was excessive! I love what you're doing because I know I never could. Hats off to you!

 :D The only reason I removed the air vent panel under the back window was to get access to remove the rust at the seam at the bottom. It was only then that I thought about making it a bolt in panel so took advantage.

Thinking about it I might as well carry on updating this thread instead. I`ve added some pictures to my instagram account so I thought I should update here too.  Here is a couple of pics when I got the pan back from paint.

(https://farm5.staticflickr.com/4233/34826121834_4aba36ad1f_k.jpg) (https://flic.kr/p/V4sYGs)Untitled (https://flic.kr/p/V4sYGs) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Bolted on the cover after installing the shift rod

(https://farm5.staticflickr.com/4088/34826111754_da184b6d07_k.jpg) (https://flic.kr/p/V4sVGE)Untitled (https://flic.kr/p/V4sVGE) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Satin cover after some love with a dimple die

(https://farm5.staticflickr.com/4263/35279972050_b89a5a3e7a_k.jpg) (https://flic.kr/p/VKz5yb)Untitled (https://flic.kr/p/VKz5yb) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4161/35667274045_dc98f8d2b5_k.jpg) (https://flic.kr/p/WkN6WM)Untitled (https://flic.kr/p/WkN6WM) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Pipe holder, chromed.

(https://farm5.staticflickr.com/4134/35280086120_b1c1a93286_k.jpg) (https://flic.kr/p/VKzEsU)Untitled (https://flic.kr/p/VKzEsU) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

 :D

(https://farm5.staticflickr.com/4130/35536739541_13b0015207_k.jpg) (https://flic.kr/p/W9g5zT)Untitled (https://flic.kr/p/W9g5zT) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

 :o :o :o

 :P now i am not gonna like my pan when i get it from the blaster this week

Hahaha,  its all about how far you want to take it .

Seriously dude,
You need to make a lexan body to go on that pan!!
Will be such a shame to cover it up

 ;) ;D

 :D I did think about displaying the finished chassis if I didn’t have time to finish the complete car. Body is fitted

Some pictures of the gearbox. Its taken two attempts to get the look I wanted. I first blasted it and used a file etc to smooth off the casing as it was quite rough, lots of flash from the casting. Many hours of smoothing and filling and I ended up with a painted black case.

Blasted

(https://farm5.staticflickr.com/4680/39114424781_e5661311cc_k.jpg) (https://flic.kr/p/22ApDLa)Untitled (https://flic.kr/p/22ApDLa) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Casting marks

(https://farm5.staticflickr.com/4731/39114302381_0016c65056_k.jpg) (https://flic.kr/p/22Ap2nP)Untitled (https://flic.kr/p/22Ap2nP) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4542/24954250268_804116fd6b_k.jpg) (https://flic.kr/p/E284dh)Untitled (https://flic.kr/p/E284dh) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4517/38826589021_6c27bfe2c2_k.jpg) (https://flic.kr/p/229YqdD)Untitled (https://flic.kr/p/229YqdD) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Then the hours start

(https://farm5.staticflickr.com/4532/38110771624_254450f824_k.jpg) (https://flic.kr/p/214HEDo)Untitled (https://flic.kr/p/214HEDo) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4579/37940397565_92c1aff20b_k.jpg) (https://flic.kr/p/ZNEsnB)Untitled (https://flic.kr/p/ZNEsnB) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4520/38110723384_fd4d43d888_k.jpg) (https://flic.kr/p/214HqiE)Untitled (https://flic.kr/p/214HqiE) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4540/24954215958_af9141e397_k.jpg) (https://flic.kr/p/E27T1J)Untitled (https://flic.kr/p/E27T1J) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Slowly getting there. Primed again to see what it looks like. Still more to go.

(https://farm5.staticflickr.com/4568/24953104108_d9bae7c815_k.jpg) (https://flic.kr/p/E22buU)Untitled (https://flic.kr/p/E22buU) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4573/27049380459_fd220e7053_k.jpg) (https://flic.kr/p/Hdg9qB)Untitled (https://flic.kr/p/Hdg9qB) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4515/24953095138_b4aad312d7_k.jpg) (https://flic.kr/p/E228Qf)Untitled (https://flic.kr/p/E228Qf) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4547/23960870417_090967e903_k.jpg) (https://flic.kr/p/CvkHZt)Untitled (https://flic.kr/p/CvkHZt) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

More sanding....

(https://farm5.staticflickr.com/4533/37939061345_090f753af6_k.jpg) (https://flic.kr/p/ZNxBak)Untitled (https://flic.kr/p/ZNxBak) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Coat of satin

(https://farm5.staticflickr.com/4576/38669044862_c9e6b6d712_k.jpg) (https://flic.kr/p/21V3XQ3)Untitled (https://flic.kr/p/21V3XQ3) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

....which was flatted again

(https://farm5.staticflickr.com/4585/24828894008_4153ce055f_k.jpg) (https://flic.kr/p/DQ3zas)Untitled (https://flic.kr/p/DQ3zas) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

another coat of satin

(https://farm5.staticflickr.com/4556/38645975976_6548df557b_k.jpg) (https://flic.kr/p/21T1JfC)Untitled (https://flic.kr/p/21T1JfC) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Then I polished the ribs as I`ve always liked this look

(https://farm5.staticflickr.com/4520/38729272192_de76b495aa_k.jpg) (https://flic.kr/p/221nDjh)Untitled (https://flic.kr/p/221nDjh) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4553/24887263128_ea878afd7d_k.jpg) (https://flic.kr/p/DVcJgA)Untitled (https://flic.kr/p/DVcJgA) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Then I thought about how to stop the shine on the polished ribs from tarnishing over time. I made a big mistake in giving the whole gearbox a coat of metal sealer. It looked terrible and quickly realised that I had wasted all my time so far. >:( 

Only one thing for it. Blast it again and start all over.

Blasted again and a coat of primer added

(https://farm5.staticflickr.com/4563/37814047595_7245395f7a_k.jpg) (https://flic.kr/p/ZBuSVR)Untitled (https://flic.kr/p/ZBuSVR) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4569/38646390546_b6bf4364b2_k.jpg) (https://flic.kr/p/21T3Ruo)Untitled (https://flic.kr/p/21T3Ruo) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

This is the reason why some restos take longer than others, I`ve made many mistakes like these and this is the only way to learn what`s right and wrong. Because of the level of detail I want to achieve , the shitty gearbox finish would have played on my mind and I would have always thought that I could have done better, so I pushed myself to be happy with every part of the car.

So , I restarted and repeated what I had done and got back to this stage.

(https://farm5.staticflickr.com/4566/24828696098_9a3e525ad6_k.jpg) (https://flic.kr/p/DQ2ykd)Untitled (https://flic.kr/p/DQ2ykd) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4539/37983858694_6fa3bec762_k.jpg) (https://flic.kr/p/ZSvcRq)Untitled (https://flic.kr/p/ZSvcRq) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

It took some head scratching, I didn`t know how to seal the bare metal on the ribs to stop them from corroding as the case has a magnesium content and will easily corrode if not protected. That's when I thought about using silver leaf. Never done it before but in for a penny....

(https://farm5.staticflickr.com/4526/37983688664_aa6a3bae95_k.jpg) (https://flic.kr/p/ZSukiS)Untitled (https://flic.kr/p/ZSukiS) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4532/26925524859_bf76285a7a_k.jpg) (https://flic.kr/p/H2jmte)Untitled (https://flic.kr/p/H2jmte) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Applying the size (glue) was the trickiest part

Getting there. Lots of cleaning to do

(https://farm5.staticflickr.com/4570/37983686044_eb7467f2a8_k.jpg) (https://flic.kr/p/ZSujwG)Untitled (https://flic.kr/p/ZSujwG) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4577/37813504135_62fc512899_k.jpg) (https://flic.kr/p/ZBs6nR)Untitled (https://flic.kr/p/ZBs6nR) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

More

(https://farm5.staticflickr.com/4551/26924721249_93a27b3e28_k.jpg) (https://flic.kr/p/H2fezT)Untitled (https://flic.kr/p/H2fezT) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4515/38668145672_057970b89a_k.jpg) (https://flic.kr/p/21UYmwL)Untitled (https://flic.kr/p/21UYmwL) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Added a gold pinstripe edge

(https://farm5.staticflickr.com/4543/26924147209_fec1665d12_k.jpg) (https://flic.kr/p/H2chWD)Untitled (https://flic.kr/p/H2chWD) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4547/38667838512_cd3a7fb08d_k.jpg) (https://flic.kr/p/21UWMdU)Untitled (https://flic.kr/p/21UWMdU) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4552/26924149999_4709a850e9_k.jpg) (https://flic.kr/p/H2ciLK)Untitled (https://flic.kr/p/H2ciLK) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

I was then able to 2K laquer the whole case which I couldn't do before as the laquer doesn't stick to bare metal.

(https://farm5.staticflickr.com/4548/37811947955_8bb16237b8_z.jpg) (https://flic.kr/p/ZBj7Ma)  (https://flic.kr/p/ZBj7Ma) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4551/24689670008_6ddaf84bb4_z.jpg) (https://flic.kr/p/DBK1HE)  (https://flic.kr/p/DBK1HE) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

More shiny shit

(https://farm5.staticflickr.com/4567/38505208546_b637aaf78f_k.jpg) (https://flic.kr/p/21EzfZY)Untitled (https://flic.kr/p/21EzfZY) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4566/26785959109_759ebc1999_k.jpg) (https://flic.kr/p/GNZ3rc)Untitled (https://flic.kr/p/GNZ3rc) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Ok ok... I´m absolutely amazed.  :o  :D
I´ve never ever seen so much detailing. This is mind-blowing.
That has to be the best detailed beetle ever. I really want to see your car in person.
And thanks for documenting so well and keeping us updated.

cheers, Tobi

Looks fantastic , great work  :)

pretty crazy! hope you dont scratch it upon assembly  :o

 :D I managed to install it with no scratches. The floorpan went together without a glitch to be honest, it’s been a pleasure to build so far.
Thanks for the kind comments people. 👍

Fantastic work!

Have you allready lowered the body on pan? Do you have a steady plan on how to do it without scratching one or both?  ;D

😂 yeah it’s all bolted together. I just protected the shock towers front and rear with towels/tape etc and got some friends to lift it over and drop it down. Went on fine with no damage whatsoever. People make a big thing about this part but it’s easy to be honest.

Running out of things to say 're this build it is mind blowing there detail and length you are going to I remember seeing this car years ago with the gold rims it looked good then, I really can't wait to see this fully finished, absolutely stunning

Cheers, its definitely going to be at volksworld, its mostly in one piece now, wings and the bonnet need fitting and the engine will be fitted in a couple of weeks and then its just making sure that everything is clean etc before the debut.   Its the small jobs that you think will take minutes that take hours to get right.

Above and beyond anything I've seen as always. Haven't been to volksworld since 2004 but this car makes me want to go.  :o

I think the car was last displayed at volksworld in 2004  :D

Cheers for the kind words.

I thought my OCD was bad, but seriously I can not wait to see this car. The bar has been raised

All I want to do is hit the bar on that weekend!
Cheers

You definitely deserve a pint or two  ;D

Yeah, I’m getting sick of it now. It’s taken over my life , mentally, emotionally and financially for the last four years.  It’s not like I’m going to drive the bloody thing when it’s finished either. Bloody show pony  :D

Gibbs is great for bare mag, did that to my last case in 1999

ACF50 is great for protecting Mag too but its just an anti corrosion gel.

Congratulations :)
I'm just amazed at this car in front of me at volksworld.
Lee

Well in that case, we need pictures!

Sorry Neil, I took none :(
If it don't win best of show then something is very wrong

X2 😉

I agree with Leec, surely best of show  :)

My only criticism would be, could have had a few more lights and mirrors. Knowing all the exceptional details in this car from this thread, some were perhaps lost or hidden - I wanted to see MORE !!

An amazing car though, all credit to you sir

Darren

yep agreed, best car there, although the green ghia comes close.

The valve covers are awesome.

Deffo best of show!
Didnt take any photos (sorry) as my phone wouldn't have done it ANY justice.

As Lee(?) said just a shame that it wasn't lit better and a bit higher as you couldn't really see the undercarriage that clearly.
Stunning though especially as weve seen the work that Lyndon has put into it.

Lyndon, when will it be in Volksworld??

Well deserved win , fantastic car built to an amazing high standard, congratulations !  :)

Not my pic but guessing this is it?

Yep, that's the car Richie

It won best of show, whilst sitting down I thought to myself the only way to better this is to fully detail a car and not assemble it.  Just lay out all the component parts for people to look at.

Sounds like a good idea  :D

Thanks everyone. My dream has come true.

Congrats for the show win! The car was truly amazing, we stood and watched it go round for at least 5 minutes in awe of all the details!

- DWL Crew / Finland -

Well Done Sir ....... Magic Car !

You deserve it fella, the work you have put in to achieving your goal is truly outstanding/mind blowing

So what's the next project your doing  ;D

Congrats on the win! Look forward to seeing more of it

For now I’m not going to do anything 😂 I’ve always fancied an early 60s ragtop

I will finish the build updates in a week or so.

Congratulations on getting the car finished..!! Looks amazing  8) 8) 8) 8)

Fixed it for you!  ;)

 :D that’s about right

A few shots from the weekend

(https://farm1.staticflickr.com/868/40328357454_d41a825060_b.jpg) (https://flic.kr/p/24rFnDQ)Untitled (https://flic.kr/p/24rFnDQ) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm1.staticflickr.com/886/40143756915_543363185c_b.jpg) (https://flic.kr/p/24anfkV)Untitled (https://flic.kr/p/24anfkV) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm1.staticflickr.com/798/39228365780_1c044e5a0d_k.jpg) (https://flic.kr/p/22LtCs9)Untitled (https://flic.kr/p/22LtCs9) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm1.staticflickr.com/822/40143795265_5a3ff1a15c_b.jpg) (https://flic.kr/p/24anrK8)Untitled (https://flic.kr/p/24anrK8) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Congratulations Lyndon, it looks amazing. I haven't seen any other pictures of the show, but I can't imagine that anything else would be as good!

Exceptional job, buddy! I like the wheels ;)

Cheers,  I love the wheels too mate. Thanks for selling them to me  :)

The green Karmann Ghia was clever

Amazing car, but I am sad to see that this thread jumped from tie rods and a transaxle to a finished car in one page.
I believe there are so many beautiful details that we all want to see and hear about.

Any possibilities to keep updating the thread with some detail pictures?

 :D yeah I will post up all the build when I get a bit of time. Cheers

cant wait!

OK.
 So I`m going to have to gloss over the remainder of the build as I`m sure you are not that interested in seeing pictures of every single part that I`ve worked on.
 
The axles are not the originals, after I blasted the tubes and stripped the bearing housings off the end I realised that the tubes were not good enough to chrome. I fortunately had a pair of short axle tubes that were in great shape which I sent off to the chrome shop and then fitted with a pair of non split boots and a pair of Limebug bell housings which look great and are much stronger than the original tin pressed ones. The bearing housings took a lot of work to smooth.

(https://farm5.staticflickr.com/4585/26611509589_455da8d327_k.jpg) (https://flic.kr/p/GxyWER)Untitled (https://flic.kr/p/GxyWER) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Airkewld rear brake bracket after lots of love

(https://farm5.staticflickr.com/4549/38332520826_86bdf725f4_k.jpg) (https://flic.kr/p/21pjbXu)Untitled (https://flic.kr/p/21pjbXu) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4579/24516656348_c95b8b4461_z.jpg) (https://flic.kr/p/DmsgMw)  (https://flic.kr/p/DmsgMw) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Race axles

(https://farm5.staticflickr.com/4582/38332519226_d1c143449d_k.jpg) (https://flic.kr/p/21pjbtU)Untitled (https://flic.kr/p/21pjbtU) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Fitted up with billet bearing seal housings and chromed bolts

(https://farm5.staticflickr.com/4537/38356611272_05502f7033_k.jpg) (https://flic.kr/p/21rrEd1)Untitled (https://flic.kr/p/21rrEd1) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4571/38387281311_fae145ca80_k.jpg) (https://flic.kr/p/21u9RkM)Untitled (https://flic.kr/p/21u9RkM) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4561/38387283051_c222c82387_k.jpg) (https://flic.kr/p/21u9RRM)Untitled (https://flic.kr/p/21u9RRM) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

The rear brakes I bought were unused second hand off someone on volkzone. I had quickly opened the box and checked that all the parts were there , then carried on with the resto of the car. A year or so later, I started to see what was involved with making the calipers look nice when I found out I had two right hand one FFS.  Fair play, Airkewld sorted me out with a LH one but its shit like this that holds you back.

(https://farm5.staticflickr.com/4517/38360031432_4dbbc5acf0_k.jpg) (https://flic.kr/p/21rKbUh)Untitled (https://flic.kr/p/21rKbUh) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

As you can see, the calipers needed a huge amount of work to get them to look nice

(https://farm5.staticflickr.com/4532/26613530099_cdd6b3676b_k.jpg) (https://flic.kr/p/GxKiie)Untitled (https://flic.kr/p/GxKiie) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4584/38389630941_5d96839bf0_k.jpg) (https://flic.kr/p/21umTND)Untitled (https://flic.kr/p/21umTND) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4574/38358536392_b579a764f0_k.jpg) (https://flic.kr/p/21rBwtJ)Untitled (https://flic.kr/p/21rBwtJ) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4576/38358530362_b35facc7c0_k.jpg) (https://flic.kr/p/21rBuFL)Untitled (https://flic.kr/p/21rBuFL) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4526/37674761704_4ecfb86a98_k.jpg) (https://flic.kr/p/Zpc15Y)Untitled (https://flic.kr/p/Zpc15Y) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4556/37674699574_b822c5109d_h.jpg) (https://flic.kr/p/ZpbFBL)Untitled (https://flic.kr/p/ZpbFBL) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4522/24518409778_b2b9d589b2_h.jpg) (https://flic.kr/p/DmBg25)Untitled (https://flic.kr/p/DmBg25) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4550/38356619732_bda2d4e655_k.jpg) (https://flic.kr/p/21rrGHS)Untitled (https://flic.kr/p/21rrGHS) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4570/24516438348_7226f66849_k.jpg) (https://flic.kr/p/Dmr9YU)Untitled (https://flic.kr/p/Dmr9YU) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4551/26611202039_f1f3534b2f_k.jpg) (https://flic.kr/p/Gxxnfg)Untitled (https://flic.kr/p/Gxxnfg) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Handbrake mech was modified and chromed

(https://farm5.staticflickr.com/4522/24516291528_745102b6f2_k.jpg) (https://flic.kr/p/Dmqpkw)Untitled (https://flic.kr/p/Dmqpkw) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4534/38356204832_aa5b1c6853_k.jpg) (https://flic.kr/p/21rpzoq)Untitled (https://flic.kr/p/21rpzoq) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

absolutely blown away by the level of detail. Just out of curiosity who did you use for the chrome work.

A company in Crewe. Niphos metal finishers.
Cheers

You didn't do it yourself?  :o  That's just plain lazy >:( :D ;D

Seriously, amazing amount of effort and you deserve the rewards 8), so are you actually going to use it now?

cheers Richie

 ;D  I`ve got one other show to take it to in November, after that its getting retired and then I will get it running etc.

Here is just some of the Chrome. I made several trips, taking batches of stuff for them to coat, but if anyone else is thinking about doing something similar, my word of advice would be to prep the metal as much as possible, get everything smooth with no weld pitting etc. It pays dividends in the end.

(https://farm5.staticflickr.com/4288/35498339342_f95502aba1_k.jpg) (https://flic.kr/p/W5Sgxu)Untitled (https://flic.kr/p/W5Sgxu) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4212/35280104210_1a4fb9aeec_k.jpg) (https://flic.kr/p/VKzKQN)Untitled (https://flic.kr/p/VKzKQN) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4022/35667279655_4c21e50e65_k.jpg) (https://flic.kr/p/WkN8Bv)Untitled (https://flic.kr/p/WkN8Bv) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

There was stuff I had to get done twice and the manifolds took three attempts to chrome properly without any pock marks or pin holes.

(https://farm5.staticflickr.com/4285/35280102240_72f20eb885_k.jpg) (https://flic.kr/p/VKzKfQ)Untitled (https://flic.kr/p/VKzKfQ) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

There were quite a few NOS parts that I`ve bought for this project. One of them being a NOS trip speedo. Lovely piece, but there was no way I could live with the plated cover so I stripped it down and painted it etc.

(https://farm5.staticflickr.com/4260/35536869601_b0ff8ae985_k.jpg) (https://flic.kr/p/W9gKfi)Untitled (https://flic.kr/p/W9gKfi) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4126/35498353172_1fe10a5bbb_k.jpg) (https://flic.kr/p/W5SkDW)Untitled (https://flic.kr/p/W5SkDW) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4207/34826140744_8d2239738b_k.jpg) (https://flic.kr/p/V4t5ju)Untitled (https://flic.kr/p/V4t5ju) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Painted black

(https://farm5.staticflickr.com/4085/35498341322_d117a8f98f_k.jpg) (https://flic.kr/p/W5Sh8C)Untitled (https://flic.kr/p/W5Sh8C) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4044/35667288555_f5c32d0727_k.jpg) (https://flic.kr/p/WkNbfX)Untitled (https://flic.kr/p/WkNbfX) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Other stuff that needed attention, infact every single part needed attention.

(https://farm5.staticflickr.com/4232/35498352092_d07993cd13_k.jpg) (https://flic.kr/p/W5Skkj)Untitled (https://flic.kr/p/W5Skkj) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4191/34858244973_e1867032d9_k.jpg) (https://flic.kr/p/V7iBMF)Untitled (https://flic.kr/p/V7iBMF) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4187/35627594896_768863d730_k.jpg) (https://flic.kr/p/WhhJHw)Untitled (https://flic.kr/p/WhhJHw) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Bare Chassis

(https://farm5.staticflickr.com/4266/35667271565_552e722eae_k.jpg) (https://flic.kr/p/WkN6d2)Untitled (https://flic.kr/p/WkN6d2) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

First things to bolt on. Don't scratch anything!

(https://farm5.staticflickr.com/4135/35627579346_2ecf7a1553_k.jpg) (https://flic.kr/p/WhhE6q)Untitled (https://flic.kr/p/WhhE6q) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Chromed shifter support I made

(https://farm5.staticflickr.com/4119/34826121694_63bf873009_k.jpg) (https://flic.kr/p/V4sYE3)Untitled (https://flic.kr/p/V4sYE3) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

CAE shifter. I love this shifter, not seen hardly any fitted to a bug. I had previously bought a Berg locking shifter but I changed my mind when I saw this.

(https://farm5.staticflickr.com/4287/35667258505_6de2210dd7_k.jpg) (https://flic.kr/p/WkN2jR)Untitled (https://flic.kr/p/WkN2jR) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

The gear knob is actually a coconut shy throwing ball which I turned up on the lathe  :)

(https://farm5.staticflickr.com/4240/35280084470_ac1d5d424b_k.jpg) (https://flic.kr/p/VKzDYs)Untitled (https://flic.kr/p/VKzDYs) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

The 550 speedster handbrake took a lot of work to mount and to get working , A LOT of work.

(https://farm5.staticflickr.com/4085/34826106604_071dc6cf6e_k.jpg) (https://flic.kr/p/V4sUaS)Untitled (https://flic.kr/p/V4sUaS) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4082/35536847111_6ab05947eb_k.jpg) (https://flic.kr/p/W9gCyx)Untitled (https://flic.kr/p/W9gCyx) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Optima battery box I made from stainless

(https://farm5.staticflickr.com/4210/34826029424_c06ff119ab_k.jpg) (https://flic.kr/p/V4sveb)Untitled (https://flic.kr/p/V4sveb) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Its got a hinge and quick release pin

(https://farm5.staticflickr.com/4014/35627451896_916328b66f_k.jpg) (https://flic.kr/p/Whh1d1)Untitled (https://flic.kr/p/Whh1d1) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4261/35536745661_24223f17c1_k.jpg) (https://flic.kr/p/W9g7pp)Untitled (https://flic.kr/p/W9g7pp) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Satin black linkage cover

(https://farm5.staticflickr.com/4164/35536739631_eea147fe49_k.jpg) (https://flic.kr/p/W9g5Br)Untitled (https://flic.kr/p/W9g5Br) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Master cylinder after lots of love and a coat of sparkling black metalflake

(https://farm5.staticflickr.com/4036/35536745601_c18afd434e_k.jpg) (https://flic.kr/p/W9g7on)Untitled (https://flic.kr/p/W9g7on) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Polishing each and every stainless / brass fixing has been an absolute ballache. Indexing is something to remember too

(https://farm5.staticflickr.com/4289/35498236682_8c7f290f06_k.jpg) (https://flic.kr/p/W5RK2u)Untitled (https://flic.kr/p/W5RK2u) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Man that is amazing.. :o

Didi you have a year of from work or something... that must be a lot of time spend.

Thanks
I just worked on it every night after work for nearly four years no fail. The only break I`ve had is when I broke my collarbone in Feb 2017 and even then I was trying to paint the wheels one handed not long after I fell off my bike.

 I`ve had to spent the time to get the finish I wanted.

The work involved in this is just mind blowing.   Having seen first hand how much Dude put in to build a show car I can honestly say you’ve raised the bar.   Personally I think you’re mad, but, you deserve all the accolades you receive.    The car is beyond incredible.

Agreed, amazing job, fantastic dedication, almost needs to be on permanent display, but even better driven.

 :D thanks. I’ve always wanted to win bos at volksworld, that’s the reason I’ve pushed myself to do what I’ve done. I’ve just made every part to the best of my ability and if I thought it wasn’t good enough then it didn’t go on the car. Since the show there are a few things which I will redo but I’m happy how it’s turned out. I can understand why cars like this don’t come up very often, the money and time invested is toe curling and it took major commitment from me to stick to my original idea.  It’s great that people also seem to like it, projects can go horribly wrong, vision can wane and standards can drop , people can invest lots of money into something and it still can look like a dogs dinner through something simple like colour choice.

Thanks people

The front beam is a Limebug 3" narrower item. Really nice quality to be honest but I couldn't just paint it and bolt it on. I spent quite some time modifying it, first lopping off the ugly steering damper mount then setting to it with a die grinder and smoothing every weld down. This took many hours but it was worth it.

(https://farm5.staticflickr.com/4561/38357222702_448bf1f92f_b.jpg) (https://flic.kr/p/21ruMXU)Untitled (https://flic.kr/p/21ruMXU) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

I also drilled holes in the shock towers and then had to add strengthening supports up the sides because I had weakened it  ;D. I really prefer the look though. I primed it and blocked it many times to get the result.

(https://farm5.staticflickr.com/4528/38356254302_2f2fc28825_k.jpg) (https://flic.kr/p/21rpQ6m)Untitled (https://flic.kr/p/21rpQ6m) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

I painted it myself with 2K black

(https://farm5.staticflickr.com/4583/38356253662_9fa6530948_k.jpg) (https://flic.kr/p/21rpPUj)Untitled (https://flic.kr/p/21rpPUj) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4573/38356265402_eebcea14c7_k.jpg) (https://flic.kr/p/21rpToJ)Untitled (https://flic.kr/p/21rpToJ) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Fitted up a billet mount. Much nicer.

(https://farm5.staticflickr.com/4576/38356240992_6fc427fa5d_k.jpg) (https://flic.kr/p/21rpL8S)Untitled (https://flic.kr/p/21rpL8S) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Fitted up the arms after many hours of smoothing and capping the ends. They took two attempts to chrome properly.

(https://farm5.staticflickr.com/4525/24516297688_c8455d2544_k.jpg) (https://flic.kr/p/DmqraJ)Untitled (https://flic.kr/p/DmqraJ) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Even trying to fine stainless lock nuts and finding a chrome cap took ages

(https://farm5.staticflickr.com/4515/38386864611_ba6ac0d544_k.jpg) (https://flic.kr/p/21u7Hti)Untitled (https://flic.kr/p/21u7Hti) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

The shocks are spax adjustables that I made to look like red Konis  :)  They too took a shed load of work to smooth the mounting rings etc.

(https://farm5.staticflickr.com/4244/35498346632_f823f1a5ed_k.jpg) (https://flic.kr/p/W5SiHb)Untitled (https://flic.kr/p/W5SiHb) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4259/35280112150_41e5b5a282_k.jpg) (https://flic.kr/p/VKzNcG)Untitled (https://flic.kr/p/VKzNcG) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4284/34858250613_562f7199af_k.jpg) (https://flic.kr/p/V7iDsV)Untitled (https://flic.kr/p/V7iDsV) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Fitted up with ARP bolts and the spindles etc

(https://farm5.staticflickr.com/4544/38356171102_1466607d3e_k.jpg) (https://flic.kr/p/21rppmS)Untitled (https://flic.kr/p/21rppmS) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

I was starting to enjoy watching come together at this point

(https://farm5.staticflickr.com/4555/38386803831_5bf74024dc_k.jpg) (https://flic.kr/p/21u7ppn)Untitled (https://flic.kr/p/21u7ppn) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

WOW (again)  :o

The spindles took some smoothing, they were really rough castings.

(https://farm5.staticflickr.com/4584/37672401934_112b34d742_b.jpg) (https://flic.kr/p/ZoYUBh)Untitled (https://flic.kr/p/ZoYUBh) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4557/24516399668_a879ddda0a_b.jpg) (https://flic.kr/p/DmqXu1)Untitled (https://flic.kr/p/DmqXu1) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

I had blasted these when I first restored the car.

(https://farm5.staticflickr.com/4575/38356303192_cd400278c0_b.jpg) (https://flic.kr/p/21rq5Ch)Untitled (https://flic.kr/p/21rq5Ch) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4538/24516401248_9fdb75e531_b.jpg) (https://flic.kr/p/DmqXXf)Untitled (https://flic.kr/p/DmqXXf) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Bit of bling

(https://farm5.staticflickr.com/4534/38332245766_645ade4492_k.jpg) (https://flic.kr/p/21phMc5)Untitled (https://flic.kr/p/21phMc5) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4566/38387075231_c8298af4ba_k.jpg) (https://flic.kr/p/21u8N5F)Untitled (https://flic.kr/p/21u8N5F) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4569/38356314662_3a68fd6e8b_k.jpg) (https://flic.kr/p/21rq933)Untitled (https://flic.kr/p/21rq933) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4544/38356320472_d2c95fd514_k.jpg) (https://flic.kr/p/21rqaLd)Untitled (https://flic.kr/p/21rqaLd) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4542/37672416884_0607318469_k.jpg) (https://flic.kr/p/ZoYZ43)Untitled (https://flic.kr/p/ZoYZ43) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4584/24516381218_429c133ca1_k.jpg) (https://flic.kr/p/DmqRZU)Untitled (https://flic.kr/p/DmqRZU) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Chromed link pins

(https://farm5.staticflickr.com/4208/35627447786_f53670143f_k.jpg) (https://flic.kr/p/WhgYZ9)Untitled (https://flic.kr/p/WhgYZ9) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4188/35627447216_8989a0fd1d_k.jpg) (https://flic.kr/p/WhgYPj)Untitled (https://flic.kr/p/WhgYPj) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4582/24516207458_a0b7ca663f_k.jpg) (https://flic.kr/p/DmpYm3)Untitled (https://flic.kr/p/DmpYm3) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4050/35498221162_18715f20a4_k.jpg) (https://flic.kr/p/W5REpU)Untitled (https://flic.kr/p/W5REpU) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

I really enjoyed making up the brake lines and fitting up the pedal assembly.

(https://farm5.staticflickr.com/4210/35279960130_dc0672de3a_k.jpg) (https://flic.kr/p/VKz21E)Untitled (https://flic.kr/p/VKz21E) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4191/35279961800_3c36c64c19_k.jpg) (https://flic.kr/p/VKz2vs)Untitled (https://flic.kr/p/VKz2vs) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4551/38356169432_049560cc11_k.jpg) (https://flic.kr/p/21rpoS5)Untitled (https://flic.kr/p/21rpoS5) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Fitted up the throttle with its proper hinge

(https://farm5.staticflickr.com/4515/38332035266_766f360437_k.jpg) (https://flic.kr/p/21pgGBL)Untitled (https://flic.kr/p/21pgGBL) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4552/38356159102_29d019f13c_k.jpg) (https://flic.kr/p/21rpkMY)Untitled (https://flic.kr/p/21rpkMY) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4578/38332046976_35d1bacf50_k.jpg) (https://flic.kr/p/21pgL6E)Untitled (https://flic.kr/p/21pgL6E) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4582/38331988476_2cbcf26028_k.jpg) (https://flic.kr/p/21pgsH3)Untitled (https://flic.kr/p/21pgsH3) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4578/38386734741_aa30c2a1bb_k.jpg) (https://flic.kr/p/21u73Sa)Untitled (https://flic.kr/p/21u73Sa) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4568/38386741291_23a83957f7_k.jpg) (https://flic.kr/p/21u75P6)Untitled (https://flic.kr/p/21u75P6) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Steering box

(https://farm5.staticflickr.com/4526/37672076234_1543f9d1f1_k.jpg) (https://flic.kr/p/ZoXeML)Untitled (https://flic.kr/p/ZoXeML) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4523/26610990959_0428a076db_k.jpg) (https://flic.kr/p/GxwhuX)Untitled (https://flic.kr/p/GxwhuX) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4530/38386736391_d97b9e07d3_k.jpg) (https://flic.kr/p/21u74mB)Untitled (https://flic.kr/p/21u74mB) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4562/24515982128_2962f6a9c5_k.jpg) (https://flic.kr/p/DmoPn3)Untitled (https://flic.kr/p/DmoPn3) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4551/38331813486_df627668c2_k.jpg) (https://flic.kr/p/21pfyFY)Untitled (https://flic.kr/p/21pfyFY) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

When it came to the rear suspension I got worried that I would damage paint etc but to be honest it went together smoothly. I machined up some aluminium spacers that fit between the end plate and the adjusters and polished them. The spring plates took two attempts to chrome as I forgot to round off the ends the first time so I sent them back after I modified them .

(https://farm5.staticflickr.com/4459/38186478522_120f3c9f10_k.jpg) (https://flic.kr/p/21bpFEJ)Untitled (https://flic.kr/p/21bpFEJ) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4519/24365855738_44f801f533_k.jpg) (https://flic.kr/p/D88o21)Untitled (https://flic.kr/p/D88o21) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4489/38185656122_7923da02b2_k.jpg) (https://flic.kr/p/21bktcq)Untitled (https://flic.kr/p/21bktcq) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4500/38217574871_962f1641dc_k.jpg) (https://flic.kr/p/21ea4wF)Untitled (https://flic.kr/p/21ea4wF) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4580/38218391041_77319b6456_k.jpg) (https://flic.kr/p/21eef9z)Untitled (https://flic.kr/p/21eef9z) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Gearbox fitting was a two man job

(https://farm5.staticflickr.com/4570/37506520554_555af32c6b_k.jpg) (https://flic.kr/p/Z9jHRu)Untitled (https://flic.kr/p/Z9jHRu) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4463/38161598326_27420ab651_k.jpg) (https://flic.kr/p/219daDQ)Untitled (https://flic.kr/p/219daDQ) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

I originally was going to fit a trapeze bar and had done a load of work to mock it up and polish it and smooth all the mountings etc but then had a change of heart because it looked fussy and complicated and I just wanted to try and keep it simple so after these shots I restored and painted up a standard gearbox mount and fitted that instead.

(https://farm5.staticflickr.com/4552/38185568832_72d6a4c205_k.jpg) (https://flic.kr/p/21bk2fq)Untitled (https://flic.kr/p/21bk2fq) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4498/26441087389_8e11b8bd8b_k.jpg) (https://flic.kr/p/Ghvu64)Untitled (https://flic.kr/p/Ghvu64) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4553/26441007959_333eca0d4b_k.jpg) (https://flic.kr/p/Ghv5tz)Untitled (https://flic.kr/p/Ghv5tz) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4507/37506464524_352c346e8a_k.jpg) (https://flic.kr/p/Z9jrcs)Untitled (https://flic.kr/p/Z9jrcs) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4450/24364743848_c0b4c126a5_k.jpg) (https://flic.kr/p/D82Fuu)Untitled (https://flic.kr/p/D82Fuu) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4474/24364766618_5a83d4ea20_k.jpg) (https://flic.kr/p/D82Ng5)Untitled (https://flic.kr/p/D82Ng5) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4477/38185480822_16501501e6_k.jpg) (https://flic.kr/p/21bjz61)Untitled (https://flic.kr/p/21bjz61) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4450/38217385791_156b0e20c7_k.jpg) (https://flic.kr/p/21e96jF)Untitled (https://flic.kr/p/21e96jF) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4559/26440888159_dec2737860_k.jpg) (https://flic.kr/p/GhusS4)Untitled (https://flic.kr/p/GhusS4) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4296/35349480714_4863953455_k.jpg) (https://flic.kr/p/VRHk4q)Untitled (https://flic.kr/p/VRHk4q) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Rounded spring plate edges

(https://farm5.staticflickr.com/4325/35795739870_a6f76f8e05_k.jpg) (https://flic.kr/p/Wx9wmN)Untitled (https://flic.kr/p/Wx9wmN) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4302/36052558701_b7de3f79bf_k.jpg) (https://flic.kr/p/WVQMDF)Untitled (https://flic.kr/p/WVQMDF) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4291/36144706556_e4f933def4_k.jpg) (https://flic.kr/p/X4Z4ZN)Untitled (https://flic.kr/p/X4Z4ZN) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4320/35795723440_a474105a69_k.jpg) (https://flic.kr/p/Wx9rtw)Untitled (https://flic.kr/p/Wx9rtw) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4580/38307805306_02fba8ff93_k.jpg) (https://flic.kr/p/21n8vTQ)Untitled (https://flic.kr/p/21n8vTQ) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4566/38360465411_3568587d90_k.jpg) (https://flic.kr/p/21rMpUF)Untitled (https://flic.kr/p/21rMpUF) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

First parts to go on the body

(https://farm5.staticflickr.com/4532/26560823989_3b385b0afa_k.jpg) (https://flic.kr/p/Gt6aBc)Untitled (https://flic.kr/p/Gt6aBc) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Seals n stuff

(https://farm5.staticflickr.com/4522/24441522998_e52c20c5a5_k.jpg) (https://flic.kr/p/DePcfW)Untitled (https://flic.kr/p/DePcfW) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4560/24444470458_c9c02340e7_k.jpg) (https://flic.kr/p/Df5ird)Untitled (https://flic.kr/p/Df5ird) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Stainless bolt on release cable tube

(https://farm5.staticflickr.com/4535/26541290889_5e757e0362_k.jpg) (https://flic.kr/p/Grn46B)Untitled (https://flic.kr/p/Grn46B) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4550/37595260684_c5201d687f_k.jpg) (https://flic.kr/p/ZhaxcJ)Untitled (https://flic.kr/p/ZhaxcJ) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Top of the line  !!! :)

nice
 ;)

Got invited to be part of the Meguiars Showcase at the NEC Classic Car Show earlier this month. Amazing weekend , came home with the prestigious best of show trophy.

(https://farm2.staticflickr.com/1957/30927339627_0d873279eb_b.jpg) (https://flic.kr/p/P7WGzz)Untitled (https://flic.kr/p/P7WGzz) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm5.staticflickr.com/4832/45817152342_ce968ea1ef_k.jpg) (https://flic.kr/p/2cNGT9s)Untitled (https://flic.kr/p/2cNGT9s) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

(https://farm2.staticflickr.com/1936/44049909460_c517de0d33_k.jpg) (https://flic.kr/p/2a7xipA)Untitled (https://flic.kr/p/2a7xipA) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Youre just showing off now...  ;D ;)

Awesome achievement, well done  ;D

i can always drool over the pics in your thread, Lyndon......

Cheers. I must say lifting the car down with a fork lift isn't pleasant

(https://farm5.staticflickr.com/4906/45141827814_356a27d100_k.jpg) (https://flic.kr/p/2bM2EG7)Untitled (https://flic.kr/p/2bM2EG7) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

I think I got the ride height right

(https://farm1.staticflickr.com/877/41036738701_ef7b8dd25b_k.jpg) (https://flic.kr/p/25wh1HB)Untitled (https://flic.kr/p/25wh1HB) by lyndon creamer (https://www.flickr.com/photos/150763703@N06/), on Flickr

Thank you very much f?r the Pictures! The attention to the details is incredible!
I guess I?ve mentioned before, but I?ve never seen such a high-Level build.
Hats off Sir!  :)