The Cal-look Lounge

I realise that the trend is to post pretty pics on Instagram, i do it myself and the days of long threads documenting projects is probably a thing of the past. However I did it for the 67 which is now about 11 years ago when i did that, and i think this would be a nice way to chronicle this project should Daniel ever want to read it. The 67 has evolved over many years and i fear that if i tinker anymore i will lose the vision i had for it when I built it, which was a Cal Looker with a bit of a punch that i could drive to shows in Europe and occasionally take down the strip. My lad who is now 9 is taking more interest in cars. (thankfully as he is train obsessed and has been for years) and in particular loved going to the Melbourne Drags near York. Now i could make the 67 more focused, but i took the decision to look for another project.

I've wanted a rag top for a number of years and at the start of 2023 took the decision to stop mucking about and take this seriously, The Hanz kindly looked in Europe for a suitable candidate but nothing came up, so i took the brave step (for my wallet) to ring everyones favourite purveyor of Gasser Garage Goodies, a phone calll, a return phone call 30 mins later. The oh shit moment of this looks like it's reality dependent on photos and few weeks messaging and waiting and we had a date arranged to pick it up. Given our locations in the UK, a half way spot was chosen and on Thursday 25th April the deal was done and the vehicle swapped hands.

So what had i bought? well I've the ex-Scott Bakken The One replica which is ex DKP i believe. It's a very solid base for what I have in mind, and just enough work to allow my son and I put our own spin on the car. It will not be returned to being a The One replica, but its heritage in terms of colour way will be retained, and we will put our own subtle twist on it.  I'm sure people will have their own views on what I should be doing with it, but please... this is a father and son project that I hope we have lots of fun doing and Daniel can learn how to hold a torch properly 😁

So anyway onto the pics.

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So now it is safely locked away in a secluded part of Northumberland the list has started, parts are arriving and after school monday 29th April. Daniel and i went up to see it, taking with us tools a jack (those low profile lightweight jacks, really aren't light weight) and some replacement front wheels to replace the ones fitted. There was nothing wrong with the wheels, just that they don't hold air, and as i have some  in stock...why not get Daniel to fit them. So that's what we did, Daniel gave the ragtop his approval and did ask whether we could fit Lamborghini seats, a careful "we'll think about it" meaning No, seemed to satisfy him. So new wheels fitted to the front a quick look over things and we were both smiling. We then moved onto carrying out some CAD (Card Board Aided) design to start on making a new dash plate. Once mocked up we could see that it needs to capture the line of the glove box opening and mirror that. Unfortunately Daniel ran out of enthusiasm so rather than sicken him it was wrap up time and head home with a Chippie tea. Mainly chosen to annoy the wife who had just come in from the gym. :)

And some pics:

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So that's the start of what i hope will be a fun adventure. The plan is that it is out in 2025, the engine is going to be the crux in that aspiration i think.  

Looks like an awesome start to a father son project!

Looking forward to this! Miss these threads  ::)

Rob,
I am glad you are posting on here.
We could use a good blog on here.

I don t have instagram, so much better to do on here.

Well the start is a good car, enjoy the time with your son.

Keep posting

Regards Eddie

Nice one Rob 8)   being an old fart i don't do instagram etc so appreciate when people take time to share there projects on forums still :)

Thanks for sharing looking forward to the thread! Good luck with the build.

great project and getting to do it with your son is amazing. You both will have many great memories from the build.
Larry

Thanks everyone, hopefully there should be some updates next weekend, assuming suppliers start getting me the parts i need.

What size turbo did you order? ;D :D

Great, we need more posts like this and I can relate to the fact your son wants to shim in with some "marvelous" ideas like the Lambo seats...  ;D  haha, I had a few of the same conversations with my boys in the garage.
Thx Rob, make the lounge great again!

Dem

Thanks for the comments guys, this should be fun, Richie i bought a dustbin size one, the spool is measured on a sundial  ;D

So how to get your son hooked on this,..well take him to the drags. So this weekend (11 May 2024) we went to Melbourne Raceway (York) to run the 1/8th mile. Much stress after work on friday, picking up the trailer, loading it, and early Saturday we as a family (even Sarah) headed to the drags. The sun was splitting the concrete, and everything looked to be set for a peachy day,....so obviously something went wrong. In this case i got that much wheel hop on my firsr run that i loosened an oil line, resulting in an exhibition of the size of my sump as i drained it down the end of the strip, back up the return road and back to the fire up lane before it dropped the rest of the system. At this point my wallet was puckering as I have only about 6 weeks to go until the 67 goest to EBI. So the 67 was loaded up after one run and we headed home after watching a few of the RYWB's, on getting home i found some oil, and the loose fitting, nipped that up, refilled and primed the system, did a little prayer and fired it up. It was all good and i breathed a sigh of relief.

If nothing else this has reinforced my decision to do this project. The 67 has too many good memories and emotional ties to screw it up. Anyway here's a couple of pics while I sort out what we did on Sunday.

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So onto Sunday (12th May) and I had to actually get a win on the board, (hold on i had actually beaten the golf i was paired with as I was leaking oil everywhere). But anyway I wanted to keep the momentum moving on the Ragtop, if i let things slip, then interest wanes, so whilst it's not healthy on the bank balance having small wins every week or so, keeps Daniels and my interest. There's a reason the 67 was originally done in 12 months, my utter inability to undertake long term projects.

So today i spent the morning cutting the carbon fibre for the dashboard, no pics as it's still a work in progress, then in the afternoon we headed to BossHogg's Speedshop off site location. Armed with a box of goodies, a boot full of tools and the piece of carbon to tweak to fit, Daniel and I put in a couple of hour. Ok so i put in a couple of hours, Daniel did one and then played on his Switch for the remainder, still that's one less hour of screen time.

So today the passenger door handle and radio aerial was put on by Daniel, and the steering column was bolted in place as it had been swinging in the breeze. The door handle striker unfortunately doesn't line up with the lock mech. handily i have a full set of reclaimed handles to pick up at EBI, so i can sort that later. However it gave Daniel a job today and he did well, not one scratch on the high speed finish.  He also mocked up the lucas indicators, they will need bolting in properly when the wiring loom is replaced :). So that's this weeks update, pics below:

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Cutting pieces of carbon fiber for the dash you say? I like where I think this is headed... Can't wait to see the end results!

Well you're in luck  ;D. So as the original dash had been removed to provide templates for The One rebuild, so I'm minus a dashboard, which opened up opportunities for a bit of artistic license, I thought about the original black plexi-glass, I even found a black plexi-glass with glitter in that i thought might give a cool '70s vibe, but in the end i went for carbon fibre. The gauges come from Autometer and annoyingly they all are the Black signature series apart from the Oil Pressure gauge which they don't do in that style, so i've got a slightly different bezel on that one. If i can find a busted 52mm gauge with the bezel i need i might try some surgery to swap them.

Now the key to keeping a 9yo involved is making sure you have things to readily bolt on, to keep the interest going. So to make sure we had something to do this weekend, i decided to make the dashboard afterwork. Now i still need to drill new fixing holes in the right hand side and perfect the corner radiuses, along with mounting the switches and lights, but it's 90% there and we have something to bolt up on Saturday morning. The final thing i need to sort out is the space on the far right, on the original The One this was an interior light as can be seen in the second pic, now i can either copy that and i don't think it'll look bad or come up with something else....remote shift light???

Anyway that's it for today.

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Rob, these are really good for finishing the edges on carbon sheet etc, removes the un-evenness of the fibers that are left when cutting it normally and leaves it nice and neat :)

https://www.easycomposites.co.uk/permagrit-small-sanding-block

Brilliant thanks Richie it was something I was looking to address and was wondering about a rubber finishing strip. But as I'm doing a carbon cover on the glove box as well I think it would look a bit naff on that.

Oooh, I like the idea of a remote shift light, keeps the spirit of the car alive while making it a bit more modern and unique which fits with the carbon dash concept. I can't wait to see it installed, it's gonna look great!

Very cool that you're reviving this car!

Thanks Stephen

Onto this weekends work. So on Monday i have made up the prototype panel (note the change in name more on this later) and had it almost complete apart from switch position and where i was going to put the warning light. So saturday morning (18th May 2024) Daniel and i headed out to get things fitted. Daniel ably assisted with the allen key as we bolted the dask plate in place, this allowed me to pick up a couple of missing bolt holes and sort out where the bolts on the right hand side were going to go. A bit of mucking around, including having to drop the steering column and remove the panel to drill the switch holes, we had the dash in place with gauges and switches fitted. Daniel even practiced his launches. though maybe a seat will help. (see pic below)

The first observation was.....the rev counter is not aligned to the steering column (see white line on the pic below to show correct position), so i'm going to have to re-make it as my OCD can't cope with that. It's no bad thing as some of the gel coat has chipped off the edges of the panel so this re-make will allow me to perfect the process and get a better product at the end.

The other simply bolt in place job that i was going to get Daniel to do was to fit the cruiser pedal....yeah that's not a bolt on job, but handily i have some talented friends who will get it sorted over the next few weeks when i lift the carpet. So not a big update, but some progress made. Excuse the finger prints over the panel it does look a lot better when clean. Next week i'll head up and make a new one and get it bolted in while the lad is at football.

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Ok so this is the longest running dash project ever. When i put the first panel we made in, i wasn't happy that the rev counter wasn't central with the steering wheel. So mk2 was made and we got it fitted today, there are some aspects i'm not 100% happy with, but i could spend all summer mucking on with this so a decision was made to stick with the current version. Another addition was a Momo Prototipo Heritage steering wheel, the horn will be changed for a Wolfsburg crest one in time, but i like the look. The final thing to do is to add the warning lights which will be put as shown in the pic below with the turquoise dots on it. Finally Jay came to the rescure with an OG fuel tank, that'll be away for blasting and powder coating soon, and add a VDO electric fuel sender.

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Warning Light Positions

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New Fuel Tank

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Not really an update, more of a post to capture some research. So this bug originally was built with  Bery 5 speed, then was changed to a KCR transmission when it was put on the track. What happened after it was returned to the street is a bit of a mystery i'm trying to uncover. A message to KCR on facebook said that that used to stamp the early boxes with KCR just above the starter motor. So i went hunting, all i found was a "C" but more hunting round i found Scott had signed the side plate at some point. Carlos from DKP has kindly shared Scotts email and i've sent him a message, unfortunately no reply to date. Hopefully i can find out what's fitted without pulling the whole thing out. If you know what it is please let me know

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(15th Jun 2024) My not so little buddy football training has been moved to saturdays at the moment which has hit Dad Lad time, but with the work on at the moment being a little boring it's not a bad thing. I'm currently waiting for EBI to happen so i can pick up parts during the weekend which he'll be able to fit. In the meantime it's on with the more mundane tasks. The first was fitting the Lucas warning lights to go with the Lucas style switches, as in a previous post I've positioned these above the gauges in line with the switches to fill in the gap in the upper panel. The second job was to remove all the rivnuts, from the firewall, i was prepared for a drilling nightmare, but found that they were more like a UK house cavity wall fitting than a rivnut. So 20 mins with a set of snips and brute force had them removed, certainly easier than the hour of drilling i had envisaged. The final job was to pull up the carpet in the drivers footwell, i can say it was well sealed with glue on each over lap. A bit of a fight and i had it out of the way. This is being done to allow an early style cruiser pedal to be fitted, it adds nothing to the function, I just like the style.

So that's it for the moment, the firewall will be repaired this week, so hopefully next weekend the lad and I will get the chance to prime and paint the firewall in black. We also might get into removing the wiring as a new loom is going in, so we have a known entity to work with.

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Trying to keep the tempo of something every week to keep progress going Thanks to Jay for carrying out some machining and welding to fit an early cruiser pedal. I really like the look of the linkage on these. The firewall is next.

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Great project Rob!

Love the dash you’ve made, looks very cool!

I’ll look over here more often to keep the forum alive.
Projects like these are best to follow on a place like this!

Grtz Fred

Thanks Fred  much appreciated.

So after returning from EBI full of ideas and just a little tired after a fairly full on weekend it was back into the Ragtop Project. So first on the list was to sort out the glovebox, one sourced from Dennis Kruis fitted the bill, and will ulitmately be painted the correct white, but for this week a cover panel had to be made in carbon to match the dashboard. So my not so little helper and i cracked to it, and over a couple of nights knocked something up, this meant we had something to fit on saturday.

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So to saturday and it was up to the secret Northumberland base to get some work done. Plans were to fit the glove box, a new wing mirror courtesy of Dennis again and picked up during EBI,  paint the fire wall, after Jay and Mike had filled in the various holes that had been drilled in it. The glove box lid surprisiingly fitted ok, we need to add some washers to the left had side to get it lined up better. but i think that it finishes off the dashboard. This will also come off for painting at a later date.

By the time i got round to the wing mirror Daniel had headed off to play with Mikes dog and then a bit of Nintendo switch, which left me to wrestle the old mirror off. Then do some drilling for the new mirror mounts, not nerve wracking at all, by the time i got that done, Daniel was ready to spin some spanners and help again. As you can see we had some laughs... probably a fart joke.  ;D

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and finally some pics of the completed....mocked up dash panel. Thanks for reading stay frosty and consider posting your own project.

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Keep it up!

Thanks Stephen, we have a goal and i hope we'll get there.

So not everything has to be oily and greasy, and this week we decided to fit an early rear view mirror and sun visor. However as you will know the bolt pattern is different, so we will need an adaptor, one option would be to make one by hand, the other would be to try 3d printing and a bit of rapid prototyping. Given that this a learning new skills project we decided on the later.

I have fusion 360 which in the free form is perfect for what we need, a few you tube videos later and we had an idea on how to do it. First we needed a template to upload, so a bit of tracing round the base and picking up the mounting holes we had something to start with.

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This was then uploaded to Fusion 360, first you pick up some basic features as calibration point and then adjust the sketch to size from these. We used the holes, but first learning how to use a vernier calliper.

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From there was the boring task of tracing round the shape and picking up the mounting holes. Once that was done it was time to turn it into something 3d, so some extrusion adding in the holes and we had a model.

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Now we just have to wait for it to be printed and hope the measurements are correct.  

Very cool dash buddy! Looks nice and racy😎

The young guy is good with tools as pics can tell.
Keep moving guys!

Thanks Fred, he's learning as we're going along and so am I on things like Fusion 360.

Double update this weekend as i managed to get a couple of hours yesterday afternoon (13 July 2024), the plan was to get the fire wall stripped and in chassis black which i got done. Also managed to test fit the new deck lid before i remove it and start having it modified, enjoy the pics

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The updates are a small at the moment as i work through the following areas of the project

1) Re-paint the fire wall body colour. I need to re-strip and prep the metal correctly so we can get a decent finish 
2) The fuel tank has been powder coated, i now need to seal the inside with Frost tank sealant
3) I've removed the main wiring loom to send to VW Looms to get a new one made up. Need to also strip the front right and left looks out. This should be a this weekend job (3/07/2024)
4) New interior panels have been ordered from Dorothe Patriache, can't wait to see them and due to pick them up at the end of August when on the family holiday.
5) Mr Cross AKA Dennis Kruis is making up the vents for the decklid again pick up during the family holiday.
6) Richie Webb has sent through the engine parts list, and the order for the heads has gone in today (30/07/2024)

So you ask apart from project managing and simple jobs 3 or 4 times what have you done?

Well the glove box has been stripped and is now in primer, done by my able assistant

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Some filling and rubbing to do and hopefully in white over the weekend and re-fitted.

The little adaptor plate we made for the rear view mirror came through, many thanks to KevD for the original rear view mirror, greatly appreciated. Now fitted but don't like the repo sun visor that keeps falling down so on the look out for an OG item. The original plan was to fit a carbon sheet in place of the original plastic, will see what happens with that.

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Finally, i had another look underneath and spotted the gearbox was solid mounted. Will look to replace those mounts with CB Rhino mounts.

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Nice seeing this build in detail outside of instagram! Great work!

Family holidays and not having enough free time has slowed progress down a little, but where we can we are keeping things moving forward.

The trip to the Netherlands on holiday gave us the chance to pick up the early OG rear pop outs i've been wanting. Once home it was time to strip the old seals out and fit new, then take a deeo breath and paint the frames black. Sacrilege for many, but i wanted to keep the black and white theme we have going. In addition to that Daniel helped to fit the new rear trim panels. These were made by Dorothee Patriarche and really are the business. once i get the door looks sorted we'll look to fit those and the door items.

Other work that's going on in the background, is steel EMPI vents being fitted to the desk lid, and the speedometer cable has been changed for a one with a built in Hall effect sensor to interface with the electronic Autometer speedometer. Thats it for now, hopefully the pop outs will be fitted next weekend (14th Sept)

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Who would have thought that fitting Popouts would be such a pain in the neck. Seals snapping, screws the wrong length in the fitting kits, but anyway this weekend we got one fitted to the drivers side. We also managed to get an external door handle to work on the passenger side, it required some drilling tapping and adding a bolt to lengthen the striker and allow it to operate the latch mechanism (I'll add a pic later.) Getting that done meant that the new interior door panel could be mocked up on the passenger side. We will look to fit it permanently next weekend, along with the door furniture.

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i can feel your pain, aftermarket popouts are the worst. i used a BFH to fit mine!

Did you get the US ones or BBT?
Looking good thou!

Hi Karl...and Karl.... these are original VW ones, the pain has been the aftermarket rubber seals. I had BBT first i think. the second set were from Custom and Commerical, a lot softer, but not quite as tall so might not seal as well

Pic of VW sign on the window:

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Very cool doorpanels, i love the black and white theme!

So these popouts where/are a pain in the ass 😏
But with a little struggling you’re getting there.

Great project!!!

Thanks Fred, just some patience and they fit.

So this weeks update, after Daniels football game it was up to the workshop to get the other popout fitted. As this had already been fitted a few weeks ago and hand to come off for painting this was a little easier. Plus having Daniel hold the window in place was a great help. A half hour of faffing about and we had it fitted, the latches will be done next week. The next on the list was the passenger door handle, as there appear to be so many versions of the same handle and none of them actuated the striker, I needed to alter the one we had. So a drill a tap and a bolt later and we had extended the striker and we had a working door handle. Daniel fitted and locked of the bolt in place and got it back on the door.

The final part of the session was to fit the rear side panels. again some patience with the clips and some gentle adjustments had them in place. They really look great and i'm so pleased with how they're turning out.  The list is slowly getting shorter, but there is still a long way to go over the next few weeks we'll look at getting the following done.

1) Pop out latches fitted
2) Rollcage back in place
3) Change gearbox mounts to CB Performance Yellow Mounts
4) Fit the new wiring loom and sort out the electrics.
5) Fit the decklid after the EMPI vents have been done.

For now things are ticking along nicely enjoy the pics

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Looking good Rob, a very cool car and nice to see you putting a different spin on it, especially as the original is back.
The popouts in my car are painted black too, it really makes them blend in so much better with trimless window rubbers.
I agree on the Instagram thing, I got it because a lot of car builds seemed to be migrating over there, but glad to see some good stuff going on here still!

Thanks Neil, glad people are liking an old school build thread  ;D

So this weekend was onto the rollcage, Daniel is building up his hand skills and got to grip with how to line up bolts, using a ratchet and keeping spanners on nuts as they're tightened. All sounds simple stuff, but they're skills that need to be learnt. We didn't get the drivers side in as bolts needed to be swapped for new metric ones, and Daniel ran out of a little strength to stop the bolt turning as we tried to plough through the rusted threads. I can sort that out next week with a mate.

We also took up the 67 to meet it's new stable mate and keep the Cal Look vibes rolling through into the autumn.

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That last pics is pretty damn cool Rob!
The little guy snacking something admiring the callook cars!

Keep the forum alive buddy.

I agree with FredH17. Thank you for keeping us updated with posts on this project and keeping the forum alive.

Thankyou guys your comments are greatly appreciated.

This week the deck lid got it's vents put in. The scoops were made by Dennis Kruis with the prep and welding done in the Uk by Jay Parker and Mike Hill

So Saturday rolled around (12th October) and Daniel took the weekend off helping, he had a football match in the morning in which he played really well and wanted a chilled afternoon. So i headed up to the bug as i couldn't wait to see what the modified deck lid looked like fitted. Plus i had the rollcage fit to complete.

Jay was around working on his own project for a swimming gala, but was kind enough to help me get the old imperial bolts out and replace them with some nice new M10 cap heads. This process also allowed us to line up the interface between the main hoop and the rear support and bolt that up. Then it was onto the deck lid, which bolted right up and even in it's unpainted form looks great, Jay found the metal to be a little thin as some in the past has attacked it with an angle grinder to remove the paint  >:( so that will need careful handling. Other than that i got a new fuel pump mounted and that rounded off an industrious afternoon.

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The other great revelation of the day, after months of working in the pitch black of a black on black interior i remembered it hard a ragtop,....one slide later, and let there day light  ;D oh and it's a Golde sunroof, very groovy.


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So things are slowly ticking away in the background. I had been wondering what seats to fit, going between half back buckets and Kirkey Race Seats. In the end i went with the Kirkeys, and as luck would have it a brand new one came up for sale for less than half price, and it was my size. So that was bagged, the next bit was finding something to mount the seats to, and by pure luck once again a pair of seats in tatty condition came up for sale an hour from my hour for the princely sum of £70. A couple of hours later i had them back home and stripped them down to turn into the bases for the seats. So the next job is get some cross members welded in place. I have an idea to continue the carbon theme, but will see how that goes.

Hopefully the wiring loom is done in the next few weeks and Daniel and I can get that put in.

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Another quick update to keep this moving along.

We decided to keep the carbon theme going and made some rear kick panels out of carbon. It wasn't until after we fitted them that we realised that once the seats are in no one will see them  ::) Oh well at least they worked out cheaper than buying TMI ones and at least we will know they're there.

In other news the decklid was whipped back off and the paint stripped, perfect way to keep the panel cool is to do it outside in the North East Uk, plenty cooling wind to stop warpage. It got treated to a coat of etch primer to protect it for the nexst stage which is the whole disappearing for a few weeks to sort out the pain issues.

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very nice build, looking forward for updates. My son is also 9 years old, he is very keen on helping on my 84 when it's back from the body shop

Super cool build, keep up the good work! Its hard to keep them kids interested, I have tryied and failed with two =\ so I wish you good luck!

Been following you, and this build on Instagram for a long time.
But a build is more fun to follow this way so keep the updates coming.

Thanks Steve, hopefully the Daniel keeps his interest.... he'd better as he's getting a trip to the Airmighty show  ;D


Thanks I have to keep things short and sharp or he gets bored.

I prefer doing this old skool type threads as it gives a record of what we did.

sounds good :-)
I am going to be there as well, it's a really nice show and only a one hour drive from my hometown.

Ahh brilliant hopefully i can meet you there. I went to the first one just after Covid, went with Dennis Kruis and Han Van Hegel. Had a really chilled time. I hear the last one was a lot bigger and more people turned up.

The few weeks has been quite busy, so i will update this over a couple of posts. The first update was to upgrade the safety factor of the car. The master cylinder was swapped for a dual circuit one, rather than having the usual master cylinder mounted or trunk mounted. I thought that using a 1967 reservoir in the spare wheel well would be a better option. So Jay set to work and got that sorted.

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Next on the list was the seat frame, in a previous post you'll see i found some cheap seats, and stripped them down. It was then over to Mike to make some mods to allow the seats to be mounted. I do realise that for any racing series these would not be legal, but for RWYB and the street they will be fine. Georg Schmundt-Thomas also contacted me to tell me about the CSP solid mounts. I've never met and he messaged me out of the blue with that information, you've got to love the Cal Look community for looking out for each other and helping spread the information and  Cal Look love.

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Final bit of seat related update and proof that Daniel is still involved. We had a little chat on how to make the seats fit into the theme of the car and decided that some carbon fibre closure plates in the seat frames would look good. So after a bit of CAD (Cardboard Aided Design) he marked it out and i whipped out the jigsaw and cut them out. Think they will look good when i get the frames powdercoated, that's a this week job.

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Nice to see some work still going on  :)