The Cal-look Lounge

I bought my oval last year, when i sold my daily 190bhp T2a single-cab.
Now the oval is my daily, and in the weekend i am giving it the TLC it needs.

The progres is to be seen at my blog.

http://fast-air.skynetblogs.be/

Cheers Paul.

Looking very good there Paul!

What engine you have in there?  ;D
and what plans do you have?

Typ 4 for shure ;D

Michael

Hi Walter,

As your  ;D tells us, you now already. Yes its a 2.0Ltr type 4 with a csp type1 conversion kit.
This engine has a 296deg. cam, ported heads (valve size??), RVS B.A.S. exhaust with home made end piece, B.A.S. oil thermostat, external oil cooler, 44 Weber's. all in all good for 120 reliable Bhp.

Paul.

He that's no cal look  ;D

bumpers, trim  8)

 ;D ;D nice car.

Greetings mycha

Yeh I know, it LOOKS like shit :'( :( in some areas.

It's in English now.

Yeh I know, it LOOKS like shit :'( :( in some areas.
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hell no, it's one nice ride and will be cooler every time i see it, your working hard on it  :)

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Thanks, i'll do the best i can. :-*

Again a few updates, the blog is almost LIVE now. ;D

Again more updates   8)

http://fast-air.skynetblogs.be/

This weekend, after 2 day's working on the right heater channel, I changed my plan. When i want to keep working on high standards this can no longer be a daily.

I am going to strip it completely and build it up as a street legal 1/4mile cal-look oval.

When I find a good (new) daily, I will post the progres of the new plan.

Cheers, Paul.

Cool another oval dragracer in holland,

Keep us posted

Michael

Thanks Michael, how was youre weekend?.

The story of this 56 rag cal-looker wil be told right here ;D

Hey dude where are the updates?????

Michael

Hold your horses dude, i am (as you call it) an old guy ;D

The new daily is bought, the '66 is cut and the oval is ready to go 8)

Before I could start with the '56, i had to cut my '66 so i had some room.

Today i started to take it appart.
Hopefully it goes boddy-off on thuseday.

why did you cut up the 66...??!!!!!  ???
it looked pretty solid?

crazy europeans ;D

It indeed was pretty solid but Paul needed the space ;)

Michael

As Michael say's,
and it had a lot of bad welds, even one of the heaterchannels didn't fit the pan.

have you still got the interior mirror mount from the '66 shell? I need one ;D

Sorry, sold it with the rag-top.

Hey Guy's

I am thinking about painting it grey with a red seat (yep, just one), anyone know what collor this is? what whould be a good grey oval collor?

finaly found the time to split the body from the pan .
Look how exited Tiki is :P

You should give your car a name,how about CRUSTY RUSTY ;D ;D ;D

Michael

Today Tiki and I cleaned up our work space, now it's realy time to start working on the pan.

Yesterday I started to strip the pan. Also ckecked the difference between the old and new rear suspension.

Nice color on the brakes  ;D :P

It's gone be tide with the brakes/wheels and the wings, but you will fix it  ;)

seeya

Nice project dude. 8)

It is gonna be tide indeed, but with the gearbox higher and the assembly points further to the middle those 7"s will (just have to) fit unther the original wings.
One way or the other, IT WILL FIT ;)

Paul.

Thanks JeePee,

It is a big project, but it will be a nice street/strip ride 8)

There is now way back now :o, tonight I started to fit the 944 alu arms. the plan is to make it exactly as wide as a standard oval.
It is just a mock up and i still have to do some small changes, but you get the idea.

This morning it was oval time again.

Took out the IRS assembly points again, the where tacked to drive circles only :o

I made them fit with a jig on the original IRS place. Then made a slide-jig, this way I could slide them into place without messing with the angle.
In total I slided 16cm, this way I have an original oval width.
After mounting the alu arms I was wondering how it all whould fit (since I dont want to cut the body). The Tiki leftovers came in hand.

Tiki Leftovers ;D

Paul.

Yesterday I started to make the rear a bit narrower
Left side is ready and tacked, 9,5cm narrower 8).
next week i will do the right side.

There is no way back now old guy ;D ;D ;D

Looking good dude.

Michael

Thanks mate, in the past i was helping someone with his project wich learnd me a thing or two ;)

Paul.

Looking forward to seeing what happens with this.  :)

Stiil got a few tricks up my sleeve, got lots of plans and trying to do things different.

Paul.

From what little I know of it from our conversation I love it, great thinking. Have fun putting it togther. 8)

Thanks,

I am having fun allready. Driving/racing a finished car is nice, but building it (with a couple of friends looking over your shoulder) is the best part.

Paul.

Yesterday the right side had an angle grinder treatment ;D

Cut out 9,5cm, put in an extra strenght pipe and welded the left and right side.

Paul.

I like the look of this, I`ll be watching the progress 8)
Cheers,
Kev

Thanks Kev,

There are a few things more that i whant to try.

porsche 914 gearbox, kabelshift, .......

Paul.

Worked on the uniball suspension today.

Paul.

Nice work, I'm looking forward to seeing the front end too.  :)

Im liking this too , right up my street  8) more pix please  :-*

Thanks,

The front suspension idea's are way out of the box ;D, hope it will work/fit.

Paul.

I'll try to work every theusday evening and saturday morning, so there will be pic's on wednesday and sunday ;)

Paul.

If it doesn't work I'm sure I can help dispose of a couple of the parts from it.  :)

;D ;D :D

Happy to help out wherever I can.  :D

Some new parts arrived today, the wish list is two items shorter 8)

I was wondering what you are going to do with that.
Rear suspension looks good already. Uniball also.
Welding done by you guys (tiki and you) looks so easy, but when I try something at home it is not going the way I want it to be.
Maybe I have to try more and harder..

Kind regards Edgar

Hi Edgar,

Tiki and I do the welding ourselves, I worked some time as a welder and as a truck repair man I did al lot of welding as well.
That is why it looks easy and most of the time for me it is easy.

Paul.

Fixed the right uniball yesterday, both sides are ready now.

Paul.

This morning I started working on the crispy left corner, the rightside of the pan has the same (little) problem.
Also cut off the shoktower, with the narrowing it did not fit under the innerwings.
After all that was done I went and have a look in my storrage place, the last time I was there was 3 years ago.

And look what I found 8) it's a dogleg (is that for good luck :P)

Paul.

Another dogleg picture.

Wouldn't it be Better to run a Double Uniball setup more like a 4 link? to me at seams like there would be a great amount of Torque and twist on a Hard Burn out  off the Line? the uniball only looks to be about the size of a 10mm bolt? I would think it would snap under a Load

Wouldn't it be Better to run a Double Uniball setup more like a 4 link? to me at seams like there would be a great amount of Torque and twist on a Hard Burn out  off the Line? the uniball only looks to be about the size of a 10mm bolt? I would think it would snap under a Load
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Hi Shubee,

I am not sure what you mean by double setup. If you mean two uniballs above eachother, that won't work than you have 3 turningpoints.
These are special suspension uniballs (57 Euro each), the bolds are 14mm and will be replaced by 14mm 12.9 bolds.
I think they will hold, but thank you for thinking with me ;)

Paul.

Yesterday I started cleaning the barn I was renting for 20 years.
I found a lot of nice (porsche) goodies for my project oval 8)

Yesterday evening I started fitting the gearbox, to have a measurement point i welded the horns back in place.

Tha plan is to mount the gearbox a bit lower and further in the car.

Just won a pedal assembly on ebay ;D

Hey did you see that you have to hang them in order to operate them?

Michael

Yes i did, but I will fix it ;)

Paul.

Today I started where I left off the last time "fitting the gaerbox", after I took out half the axle tube, a piece of the IRS mounting point and grinding some unused gearbox ribs, the gearbox is in it's final place.
de framehorns are gone again and the gearbox is fixed with some temporary supports.

Then I started fixing a support that goes under the bellhouse, I used original rubbers for measuring but in the future they will be replaced for the strong yellow type.

The last picture shows how I plan to mount it to the cage, this way I can do some small hight adjustments.

Paul.

After I was happy with the angle of the IRS brackets, I started welding the back.

To make the gearbox fit I had to cut a piece of the right IRS bracket. In the first, second and third pic. I am closing the piece that I earlier cut out.
This pic. also shows that the torsiontube is cut in half and the holes where the the frame horn use to be.

The fourt pic. shows that the torsiontube is welded shut.

Paul.

In this last pic's you can see that the holes where the frame horn use to be are shut.

Paul.

Turned the pan yesterday to do some welding on the underside.

I welded the IRS brackets on the inside, welded the middle of the torsion tube, welded the torsion tubes where they were narrowed and welded the holes where the framehorns use to be.

I had some T2a motorrubbers laying around, so I thought wy not use them to mount the gearbox.
First I made a cardboard bracket.

Paul.

Made the brackets for the gearboxrubbers out of steel and tackwelded one of them.

Paul

Today I finished the brackets for the gearbox rubbers and welded them to the torsion tube.
Then started to fabricate the bracket that goes on the gearbox, but that's not ready for pictures yet.

Paul.

The US of A pakage is finally arived 8)

looking good paul....nice plans... ;D i like to see all those mod's

Thanks Hans,

I will show you mine, if you show me yours? ;D

Paul.

Good help is hard to find now a day's, but help is on it's way. 8)

A work in progress then  :D

I hope he won't be jinxing your stuff,he looks pretty mean ;D ;D

Michael

He is now at the chapter; how can I brake it before my dad can fix it. ;D I must say, he is pretty good at it. :D

Paul.

The left side of the new gearbox nose bracket is finished, next on the list is the right side and then weld L+R together into one bracket.

Paul.

The leftside of the gearbox bracket was ready but I still wasn't happy with it. today I gave it some weight saving treatment ;D, now it's finished.

Then i took out an extra little peice of the right IRS mount, now the gearbox is clear.

ALso started with the rightside of the gearbox bracket. When this is ready I will weld Left and right together and also fix it to the top of the gearbox, this way I have one bracket that is fixed to the gearbox with 6 bolts and I finaly get rit of the rustet bracket.

Paul

Are you not going to use framehorns Paul?  What will support the weight of motor/trans?

No framehorns, the gearbox will be hanging on the rollcage, and the motor will have an extra mount to the rear bumper bolts.

Paul.

OH, is that what thats for. I must have missed some of this thread. :-X

Again someone at the door with a package 8)

A plastic batterybox and a main/safety switch.

Paul.

Did some work on the gearbox mount again yesterday.
I was not satisfied with the rubbers I used, so I had to modify the mounts to make the new rubbers fit.
Also welded the left and rightside together and removed the rusty bracket. Just need to fix the top of the gearbox mount and then it's finaly ready :P

Time for the next step. 8)

looking good, very nice bracket "profi"  ;)

Thanx It's almost ready and with a bit of powder coat it will look like it left the factory with this bracket 8)

Paul.

I love power coating  ;D

I can use all the power I can find :D ;D

Finaly the gearbox mount is ready, now I can move to the next step (cage and coilovers)

Cheers Paul.

Nice piece of work,good job!  ;)

Thanks, I am pretty pleased with it myself.

Paul.

Not much of an update this time.
Mounted the gearbox and trailerarms to see how it all fits. the trunk floor will be raised by +/-2,5 inch, this way I have room for the gearbox, rollcage and coilovers.

Paul

The rear is narrowed quit a bit, and I did not whant to fuck up the inner wings.
Here's the plan, widen the mounts where the inner wings are bolted to the pan.

Paul.

Hey dude you are making it way too heavy.Now you really need a big hairdryer ;D :P

Michael

It's getting pretty heavy indeed, first I am making it save and driveble then it's engine time. ;)
This is a STREET/strip car, 1/4 mile must be fast but first I have to drive 300KM's to get there 8)

Cheers, Paul.

Here are a few pic's of yesterday morning.
1) Started with widening the right innerwing mount.
2) Then I had to make the inside of the rearshock mounts flat so that i could weld a pipe there.


Paul

3) Bend a pipe to go over the gearbox an welded it in.
4) started to try an shock mount idea.

Paul.

Worked on a new idea again. I do not have the framehorns anymore but I still need something to mount the gearbox to.
Under the gearbox is no space with the IRS points this close to eachother and over the gearbox is difficult with the starter and coilovers.
This new set-up combines the framehorn replacements and shock mounts. the framehorn replacements will be attached to the cage (in the trunk area)

I am still thinking about this set-up, not sure it will stay.

Paul.

I think the upper mounting point for the coilover is too much forward to be able to work properly. ;)

Why don't you get a hi-torq starter,they are shorter and lighter and leave you more room for the shocks.

Michael

You could be wright :-\, in a few minutes I am going to bed and think of this plan some more ;D.
Between pleasing the wife and a little sleep, the best palns are made ;D

Paul.

Way too much information there!  :o

That said it's starting to take shape and's looking good for it.  :)

If this is too much, don't search you tube ;D

Thanks, Paul.

 :o


 ;D

Bin working on the gearbox mount some more. Made new upper pipes and changed the pipe that goes under de bellhouse, made some gearbox height adjusters with left & right thread and tacked it all together.


Paul.

My MM special IRS bolts are in, thanks Marco.

Paul.

Nice!

Couldn't you use the Porsche ones? We did and it works fine.

Good luck with the project!!!

gr
Wout

Don't know wich porsche bolts you mean, I don't think that porsche had an eccentric set-up like this.

Paul.

They look like regular ones (not with the extra disc on it), but they're exentric. As far as I know they're from a 944.

I'll try to take a picture tomorow.

gr
Wout

Started on the upper shock mounts, there will be several mounting points so that i can choose wich one is the best set-up.

When i am completly satisfied I will weld them in there final position.
Also fitted the IRS bolts that I bought from Marco, Never tought that there was this much adjustment possible with these bolts 8)

Paul.

And again I worked on the rear shocks, it's almost getting boring :P

Drilled holes to mount the top with bolts, I will drill some more holes to choose the right set-up.
Then made a bracket to mount the bottom of the shocks in the right angle.

Don't mind the temporary bolts :-[

Paul.

After a 2 week holiday in the south of France and an even more exhaustive weekend at EBI#3, I found a little time for the car again.

First fitted the hi-tork starter that i ordered i the USA.
Made the lower shock mount for the right coilover and picked-up a piece for the new front suspension.

Paul.

Today I finnished welding the rear construction on all the reachable points, took out the gearbox and trailing arms, fliped the pan and welded the rest.

Time for the next project; Porsche 914 frontsuspension with 944 brakes mounted on a '56 pan :o.

Paul

Porsche 914 frontsuspension with 944 brakes mounted on a '56 pan

Now this I want to see(http://i243.photobucket.com/albums/ff84/49-rag/eatingpopcorn.gif)

Stay tuned and you'll see  ;).

Already did some measurements and it does looks better as I thought.
First I have to machine the 944 hubs to fit the 914 spindles. (it seems that the spindles have the same measurements as my type1 1300 spindles)

Here's how to modify the spindles to accept bug beerings. 8) sorry, it's dutch :-[

Paul.

Cool , Im looking forward to seeing how your gonna get the Mcfearson stuts to work on the oval inner wing's .

They are not Mcphearson stuts, that are the shocks, the tubes pointing forewards are the torsion bars (in the lenght of the car) Same as early 911's 8).

I use the original front of the 914 to check measurements.

Sorry my mistake forgive my ignorance  ::)

Wow!

You're crazy.... in a good way!!! Nice work....

 8) :o ;D

Amazing work awsome looking project, Alex

I'll take that as a compliment ;) Thanks.
I like to do things different and I had an almost complete 914 laying around 8)

Paul.

Thanks,

These kind of post is what you need now and then to keep going.

Cheers, Paul.

Not much done this week, to manny things to do in to little time :(

I took a picture of how the Porsche arms whould sit with the wright space between front and rear wheels. The torsion bars are to much to the front of the car, I will try to replace the A-arms on the torsion tubes and mount the whole suspension further back.

Received the new Porsche balljoints, and left the 914 spindles and 944 hubs at our machinist to make it fit.

Paul.

Today I bought a 2th set of wheels, they have fresh paint and I could't leaave them for the money. 8)

anyone has more info about these wheels?

M.A.G. product 6J 15" and 5*130, made in England.

Paul.

I wasn't happy with the gearbox height adjusters, so I had our machinist make a new set.

The new set has the same radius as the cage and has a smaller part to fit inside the cagepipes.

Most of my "bug-time" was used to meassure and do some thinking yesterday. Finaly I took out the angle grinder and cut one of the Porsche A-arm's.
The plan is to weld the A-arm futher forward on the torsionbar tube, this way the porsche arms can be mounted further backwards, have the original beetle wheelbase and don't stick out the front of the car.

Today I tack welded the modified a-arm, it looks like it will fit now 8)
Next thing weld it and start with number two.

Here's a pic with the original on the left and midified on the right.

Still working on the Porsche A-arms.

Did some repairwork, changed the second arm and welded both of them.
On the pictures they look worse as they are in real live. Saturday I will receive the machined 944 hubs, than I can start measuring again.

Paul.

Today the parts to fit 944 brakes on the 914 (same as beetle) spindles arived  :D

The 944 hubs are shortend and the inside is machined to make the special bushes fit.
The hub has to be heated and the bushes go in the freezer, this way they will fit and stay in position. (shrinkfit)
With these bushes the 944 hubs will except original beetle beerings 8)

Paul.

127 posts (mostly my own) and 5154 viewers. :-\, makes you wonder.

to technical or just out of words after reading my plans and seeing my pic's ;D

Paul.

nah, we just don't want to keep you of your work and keep the good things going  :P

 ;D ;D ;D

2nd`d ;)

It's nice work, so there's not much to add ;)

Thanks guy's,

I thought I was talking to my self. 8)

Paul.

I've been keeping an eye on here too. You already know I like the plan, looks like it's coming on nicely. :)

Hi Mat,

It's coming on, step by step (small steps)

Paul.

Dont worry were still here  ;) Can't wait to see the front end all together  8)
Your putting in some clever work with them front A arms  8)

Good to know. 8)


Can't wait eighter, but this is something I can not rush.

Paul.

Last night I finished some work at the gearbox cage that I started last saturday, after that it was time to cook ???.

I heated the 944 hubs, put the rings and bearingshels in the freezer. When all the parts hit the wright temperature the rings and bearingshels droped right in 8)

Result; 914 legs with 944 hubs and rotors ;D

Cheers Paul.

Narowing a beetle front is so 2008, time to do a Porsche front 8)

First I cut the Porsche beam.

Then I sandblasted the 2 halves and tackwelded them. The steeringbox brackets are still there to fixate the beam wile I weld it.

Narowing a beetle front is so 2008, time to do a Porsche front
couldn't agree with you more  ;) dorked beams are for low riders

Here's the beam ready. Compared with an original beetle front, this is 6cm narowed. It's laying on the undersite of the chassis.
Already removed the framehead site plates.

After a lot of measuring I finally had the guts to start cutting (fucking up) the '56 framehead. :o

  :P ;D

This is starting to look interesting , its so alien from what Im used to seeing at the front of a bug floor pan  :)

Thats why I like this idea so much 8)

Paul.

Good work "old man"  :o  ;D nee ff serieus goed bezig man.

paul you also got me looking every time
i like what you are doing.....

You lazy kids?, seems like the old guy's have to do all the work ;)

Cheers,
Paul.

Thanks Hans, appreciate it.

Looking forward to your update.

Paul.

The beam sits on its final place, just tackwelded for now.
Closed the bottom of the framehead and fliped the pan again.

Paul.

I had to do some measuruing again, just to be sure ;)

Put on the new urethane bushes and placed the a-arm, the front mounts wil be in the spare wheel area.

Paul.

After I dropped the Porsche beam in the frame head, I had some gabs tp fill.
Made 2 pieces out of 3mm sheetmetal and welded them around the beam.

Paul.

Now it is time to build a jig so that I can copy the Porsche mounting points to the beetle pan.

 

Left front, back and upper mounting point where it should be.

Paul.

are the upper strut mounts going to clear the hood?? looks high in the picture

I sure hope so :-[ . It only looks high in the picture, the original (Porsche 914) is verry low at the front.

Paul.

Shubee2's post made me a little worry, so yesterday I started measuring again  :-[.
All looks good the hight and even the width fits in/unther the innerwings.

Then I finished the right front suspension mounting points (and did the left side over again :-[) then I cut the 914 innerwing piece to the wright width and welded it together.
Fixed the innerwing piece with some temp. steel and bolted the complete right suspension on.

I must say, I am pretty pleased with the result so far. 8)

Impressive!

Thanks, progress is slow but i'll get there.

Paul.

After I finished welding the Porsche innerwings together and smooted the weld, it was time to take a piece of '66, bolt a fender to it, start cutting and see how it all fits.

Again; I am so pleased with the result 8)

Paul.

Good work Leepu!! ;D ;D ;D

Michael

Nice , that looks like it grew there  8)

It did, now I am waiting till the rest of this beetle will grow on. ;D ;D

Paul.

I went to the zoo for some inspiration ;D

Paul.

It was time to start with the steering and ride hight, but first it seems like a good idea to see it on the ground with 4 wheels on it.

And indeed, this was a good plan :'(
The first problem i saw when it was on four wheels; this thing is pretty narrow for a circuit/drag/street car :o
Second problem; a bid of camber is nice, but this is cray :o, Back to the drawing board. :-[

This is what I want;
   
Camber =>  Front -1 deg   - Rear -1.5 deg
Caster   =>  Front 6-7 deg - Rear  N/A
Toe      =>  Front 0 deg    - Rear -15' (toe-in)

Paul.

Hi Paul,

Just a thought, is the distance between the strut tops & lower wishbones standard?
Also has the angle of the struts (forward & back) been retained?
If you can keep the distances and angles `factory` the camber etc should be ok, if the track width has been modified it should still work as long as the upper & lower mounting points have been moved an equal amount (within reason), although bump steer may become an issue if the steering rack pivot points no longer correspond with the wishbone pivots.
Thats when it becomes an engineering job way beyond me! ;D
A set of wheels with a different offset will cure the `narrow` look though.

Cheers,
Kev

Hi Kev,

The track width has been modified and the upper & lower mounting points have been moved an equal amount, at least thats what I thought I did :-[
When all the wheel angles are like I whant them to be, I will start with the steering. This will be special made to avoid bumbsteer. The width can/will be adjusted with offset and spacers.

Paul.

Hey,

Just wanted to say this is such an awesome thread! Love following this! Really hope it all works out!!

Cheers,

J

Thanks J,

It will work out, just need to do things slow and sometimes twice :-[

Paul.

PS. still don't want to tell me what collor your car is? ;D

Hahahaha! Was that you!!

Hehehe It depends who gets to paint first!!  ;D

I know its silly, just dont want to be accused of copying someone, anyway your a little way off needing paint just yet  ;) When your closer to to needing paint lets talk  ;D

What your doing is awesome dude! Loving the build!

Cheers,

J

Yep that was me :D

Indeed I don't need paint yet, don't worry when I need paint (and I still haven't chainged my mind) we will talk :-*

Thanks again.
Paul.

Amazing work and innovation, never heard of anyone doing this before! Good luck, I'm impressed!

Thanks.


Thats one of the things why I like this idea 8)

Paul.

To fix the camber problem I was thinking of narowing the lower beam and fill it out with spacers, after measuring this meant that I needed 4cm spacers on each side :o. I DON'T WANT 4CM SPACERS >:(.

I started measuring the oval body again, and I seem to have 6cm width more than I thought :P.
I widened the upper strut with 6cm and after some fidling with the upper adjusting I have a -1deg. camber reading on my digital angle thing. 8)

That looks better  8) how are you planning on mounting the forward A arm mounts ?
 Would think this is gonna need quite a substantial bit of engineering bolted up to the frame head  ;)

They will be welded in the spare wheel area and bolted to the cage.

Paul.

Nice project!!
When I look at your work and your innovations it motivates me to go on with my plan för my car.

/Josef

Thanks Jozef,

Sometimes you need some motivation, I usualy get it at DDD, EBI etc.
Can we see your project somewhere, Always nice to see other projects ;)

Cheers Paul.

I have som photos from my project but they are taken before the digital era.
If I got the time i will try to make them digital.
New pics will be posted under my "Sleeping beauty" thread.

/Josef

Oh, Is that your trhead.
I will keep my eye on that one. 8)

Today it was time to start with the steering.
The plan is to use a 1303 pivot to avoid bumbsteer. First I had to make a steeringbox arm fit the pivot, to do this I used a piece of an old steeringbox axle.

Time to try some things 8)

Welded a piece of pipe to the framehead and bolted the steering box, the steering rod is exactly horizontal and perpendicular to the chassis.
Also tacked the pivot in place, the plan is to connect the pivot with the steeringbox, and have a smal rod to the spindles.

Paul.

Why not use a Rack & Pinion instead of a stock steering box?

This way I can make the width exactly as I want it to be, an original rack&pinion will be to big, I want the place where the rods are attached to the steering box exactly above the center of the circle that the wheels make when they move up and down.

Paul.

Hey Paul,

Realy nice work! Very impressiv! I´m looking forward to see some more pictures!!!

Sven

Thanks Sven,

As soon as I have time to work on it, I will post again.

Paul.

between drinking beer, smoking sigarets en talking about DDD#7 (couldn't be there this year :(), I found a little time for the oval.

Made a longer pipe to mount the steering box at one side and the pivot on the other side, and welded it in place.
It needs some more work, but it's a start.

Paul

Did some more work on the steering today. To make sure I can remove the pivot when the car is finished, I drilled the trhead out of the pivot and welded nuts on the pivot bracket, This way it is bolted from the outside. Then I shortend the two short steering rods by cutting more thread and then cut it the wright lenght. The longer (middle) rod is cut in the middle, shortend and, after I put in some massive stee,l welded together again.

Hope it works :-\

Wouldn't  it be better to flip the pass side arm with the tall side in? that way the Wheels turn the same and it would center the center link evenly??

After looking at my own pic's I was thinking the same, probebly do that ;)

Cheers, Paul.

I wasn't satisfied with the steering (the rod came in line with the spindle wile the wheels should steer some more), so today I cut out the beam where the steeringbox was mounted on, and placed it further to the front of the car. Now, even when I steer al te way, the rod still has an angle with the spindel.

Paul.

He Paulskie,

hello from the usa, looks good  ;)

Greetings mycha

Thanks Mych,

How's Vegas?

Paul.

While I am still waiting on the last parts for the front suspension, I started with the gearshift system.

I am using a 901 box with the selecter on the undersite of the box, that is why I was thinking to use a cable shift system.
I bought a VW Corrado shifter, and today I started trying some things, it's not finished but you'll get the idea.

Did some more work on the shifting today.
Made two brackets and installed them, needs some adjusting but I think it can work 8)

Paul.

When the car is ready I will probebly run it with my type4 2.0 120HP engine, this egine runs very well and is ready to go.
But in the near future I (offcourse) want to be faster, and because the car is not one off the shell the motor also will be different.

So I started collecting some parts;
WBX 1.9 engine.
Megasquirt motor management system.
A probebly to small turbo (golf 1.8 20V)
Water to air intercooler from a Mercedes
Porsche 964 100mm nikasil P/C
Scat split-ports with twin spark (airplane)
And lost of small parts.

Paul.

Hey paul how are you going to make all those different parts to work together?
Put everything in a kettle and cook it for half an hour and see what will come out? ;D ;D

Seriuosly you bought xsome nice stuff hope it will work together.

Michael

Don't these parts fit :'( I thougt it was a plug and play thing, you say it's more plug, pray run and hide ;D ;D

Wow, those heads look like they've got some serious potential! Lose the twin spark and get some bigger valves in there!  ;D
Love what you're doing. Not an easy project. Good luck!

The valve size is 40 and 35,5mm i think it's good for a 2,1 turbo.
It's not easy indeed, but it's nice to try something different 8)

Paul.

Today a bought an 2,1 WBX engine, just for the 76,4mm crank  :o

So the new engine will be a 2,4 8)

Paul.

Today a bought an 2,1 WBX engine, just for the 76,4mm crank  :o

Together with my 100mm Porsche nickies this will make a verry nice 2,4 8)

Paul.

How do you plan to cool the heads when driving on the street? ...not a lot of cooling fins on those things

/Jacob

Not sure yet, when i have them in my hands (the are still in the USA) i'll see. ;)

Paul.

This is how the cranck looks like at the moment. ;D

This week I picked up the brackets to mount the front brakes, and today I put them on.

Paul.

Love it!!

Still following this thread like a hawk! ;-)

Where did you get the caliper brackets made up? Would it be cool to PM me some details?

Awesome stuff!!!  :o

J

Thanks J,

A friend of us started his own business, If the race parts you need ain't for sale, he makes them.
he's on the lounge as well (John CNC aka The Wizard), check his site www.mebejo.nl.

Paul.

Today I decided not to use the cableshift, instead I am gonna use a Porsche shifter.

I had a Porsche shifter, shiftrod and tunnelpiece laying around, so why not use IT :)
I used a 914 seat to find the wright position for the shifter.
Before putting in the shiftrod, I had to remove all the pipes that where in the tunnel.

The postman was here again. I see him a lot lately, hope my wife understand our relationship is pure business :P

I like to mix the race theme with a little callook flavor. ;)

This week the postman was here again ;D

Porsche 964 H5 headlights this time 8)

Today I found some time to work on the shift system again.

First I turned the shiftstick, it was the wrong way around :-[
Then I made the piece of the shiftstick, that is under the hinge, longer. this way the shifting is shorter and the movement at the gearboxside is better.
Then I made the shiftingrod at the wright length, last thing to do was; find the wright place/position of the shiftrod bush.
The place of the shiftrod bush is essential with these sideshift gearboxes, it took me several attempts but it works 8)

Because te tunnel was cut open pretty far, I took out all the pipes (there where more pipes in there then I thought) and then cleaned and painted the inside of the tunnel.
I planned the new alu fuellines outside the tunnel, but I opened the tunnel to install the shiftrod and porsche shifter, so why not fit the fuellines inside the tunnel ;)

Then I started closing the tunnel again.

Paul.

it's looking good paul...weight saving rustprotection and new fuell lines in one... ;D  way to go...stil enjoying your built..

After I remembered that I was gonna use an hydraulic clutch, I opened the tunnel again :-[ and placed the clutchline in it.

Then I started closing the tunnel again and fit the shifter mount nicely.

You forgot some holes ;D
it's starting to look like a decent floorpan again.

You should come by soon and check out the Tiki ;)

Michael

Yep, still lots of holes to fill :P  I will come by soon, drink your beer wile looking at your car with my hands in my pockets  ;D

Somehow I've never seen this thread until today. I just looked through the whole thing.... that's a lot to take in!! :o
And I thought we used a lot of Porsche bits on AssHull's car... we've got all the cute and fuzzy parts, but you've got it Porsche to the core!

Fantastic work!

Thanks for the kind words. it helps to have a complete Porsche 914 as a donor car ;)

Paul.

There's beer in "Gilze" to  ::)
it's getting time that "De boxer" will open his doors in the evening  8)

Greetings Mycha

OK, Monday I will be with my wife and kids drinking coffee, Tuesday I will be at De Boxer Fixing my oval and drinking beer, Wednesday I will be in Gilze just looking and drinking your beer wile you're working, Thursday I will be at Tiki's place drinking his beer wile he's working, Friday is wife and kids day again, Saturday it's oval time again and sunday is for the lord. Does this suite you guy's ;D ;D

Paul.

Yeah sounds good or we can go to THE SHACK next wednesday and drink their beer!! ;D

Michael

I'll check with the misses, maybe I can do the shack on Friday's :P

BEER?


Arent we friends anymore? >:(

OK, I'll drink yours as well ;D

PS still have some WBX heads laying in my car for you.

Paul.

Today I finally closed the tunnel for the last time (I hope). I welded back all the pieces I cut out a few weeks ago, finished the gearstick mount and closed the handbrake hole.

I wanted to install the fuelline bulkhead connections, so first I had to take out the gearbox, weld the "attheendofthechassis" plate further in the car and shorten it.
[attachment=1]


After that I could drill the holes and fit the bulkhead fittings.
[attachment=2]
[attachment=3]


Paul.

When I was working on the gearshifter, I reinstaled the (not used) heatingknob.
After looking at this knob I thought ???....I should do something with that.
[attachment=1]

Here's the plan; use the knob for the emergency shutdown ::)
[attachment=2]

I made a hole in the tunnel (again)  :o and installed the emergency switch inside the tunnel.
[attachment=3]

It's installed, working and the shifter has enough space 8)
[attachment=4]

The screws will be replaced by little bolts, the knob will be engraved and there will be a cable attached (to the outside of the car).

Paul.

Well that's a tricky mod on the heaterknob ;D

You should try sleeping at night instead of thinking out these ideas ;) ;D


Michael

Yeah you probably right, this one came last night ;)......well at least something came ;D

Paul.

To get trough the boring Christmas day's I went surfing the net. I finally found the brakeline clams I was looking for.

And again a new hole :o
[attachment=1]

While the "oh shit" switch is in the tunnel, the cable from the battery has to go trough the tunnel as well ;)
[attachment=2]

Paul.

Nice!!!

Michael

Thanx, next on my list; handbrake :P

Clever use of that old knob  8)

Hope I'm not gonna use it ;)

After a lot of thinking about using aftermarket sheetmetal or use as much original as possible, I finally choose to complete replace one pan half instead of repairing it.

I Will try to get THE stagebrake on monday. It looks like you need it soon.

Michael

Thanx dude,
Start working on Monday again, so progress will be slow.

Paul.

In my new steering setup, I have to mount some rods upside down. so it was time to drill the steering arms, freshen them with some grid and weld the inserts.

Original
[attachment=1][attachment=2]

Drilled
[attachment=3]

Cleaned
[attachment=4]

And inserts welded in
[attachment=1]

Paul.

Really enjoyed reading about the progress you've made so far. keep it going.

Jamie

Thanks Jamie,

I will keep it going, no way back now :D

Paul.

Nice work!!

Still really enjoy following this build!!

Almost looks like youve done all the hard stuff on the chassis!? Whats next once its almost done? Body work to make the body fit to the chassis?

Progress on my 54 seems slow at the moment but the 56 Im fiddling with in my spare time is coming along  ;)

Cheers,

J

Thanks J,
The chassis is almost done, but there are always Manny little things ;)
Next thing  is fitting, changing and restoring the body, it has a lot of rust and has some bad (old) repairs.
You better hurry with yours, I am still waiting for that color number ;D

Paul.

I know, I cant wait for mine to progress, but its ok Im busy fiddling about with the other car so that keeps me happy.

Yes I can imagine there are a lot of little bits to finish on the chassis, but its great fun for us to follow this thread! Loving your fresh ideas!

Dont worry my friend the colour code is safe with me  ;D I will let you know  :) At this rate I reckon yours will be finished before mine!! Hehe

Im hoping to sign up for a 10 week welding course tonight  ;) Maybe my next project will be a bit more advernturous like yours!  :o

Cheers,

J

After thinking about to buy a cheap (thin) or expensive (original thickness) floor, I bought the expensive one.

I had to grind and hammer to make it fit, but I like the fact that it is thick material.

Here's the testfit.
[attachment=1][attachment=2]

And after grinding, hammering, measuring and welding.
[attachment=3][attachment=4]

My oilcooler use to hang on the left side of the gearbox, but that is not gonna fit anymore :(
After some thinking, yea sleepless nights again :P I came up with the following idea ;)

The floor after the driverseat will be raised to make some room to fit the cooler under it.
[attachment=1][attachment=2][attachment=3][attachment=4]
Paul.

Crazy work dude :)
i like to do some engineering;
but you take it to the next next next level :)

Thanks Peter,

Al these "special" mods where never planned, but ones the grinder is out ;) during the build the plans get bigger (more difficult) and constingly changing.

Paul.

That Must be One Big Ass Cooler??? ;D ;D ;D

It is not that big, but i am placing it in an angle to get some airflow.

Paul.

The new oilcooler place is all tacked in place now, but I am not sure if I like it :-\ . then I sprayed it all in one color to have an idea of the end result, and I am still not sure :-\

The space I created is good so I will go on.

Paul.

It's a big booby  ;D

MMM Na I don't like it. ;)
I think it is going to look very odd when you have the body on the pan.you get the heaterchannel next to this "thing.
Why not make the sides and make a removable lid once the body is on?

My 2 cents old guy ;D ;D

Michael

just a thought , All these mods they will be accepted at the tech inspection before dragracing ???

I have bin to a few races, and did DDD once with my 190HP T2a and once with this oval. I don't think inspection will be a problem.
Remember this will be a street legal car (not a 10sec car) and it Will be in a much better state then most (serious) racers.

Paul.

I here you, little fella. but I think that when the body is on and the driver seat is in, you won't notice :-\

Cheers

Want to borrow my glasses? ;D ;D

Michael

Never look back, keep your eyes on the road little fella :D

Paul.

A few weeks ago I welded a bracket to the steeringpivot, today I looked at it again and wasn't happy with the way it looked.
[attachment=1]

So I took out the weight saving tool  ;D and now it looks much better.
[attachment=2]

Paul.

Time to flip the pan once again and weld the hunchback from the underside.
[attachment=1]Oops, wrong pic. :D
[attachment=2]

Here's the plan.
[attachment=3]

from the side you can see that there's nothing sticking out 8)
[attachment=4]

Paul.

Did some more work on the hunch :P
Did some welding again, grind ed some welding and fixed the oilcooler brackets. I decided to mount the cooler the other way around, I think it Will catch more air this way.

Also welded the shiftrod bearing thing.
I can definitely say this is a manly pan :D

Today I started doing the oilcooler brackets again :-[, I was't satisfied cos it wasn't level.
Then I started fixing my adjustable gearbox mount, it's only tacked but you'll get the idea.
[attachment=1][attachment=2]

After that I found some time to engrave my "emergency" OH SHIT! knob 8)
[attachment=3][attachment=4]

Paul.

Finished the brackets to mount the coilovers under an angle, placed new uniballs in the coilovers and test fitted it again.

Looks mean 8)

This is going to be one heavy car!

Yep, it needs serious power ;D

Hey paul what was the name of those coilovers again? ;D ;D ;D

Michael

All I can think of, is guy's whit white hats :D

Looks good Paul 8)
You obviously enjoy the fab work ;D
Cheers,
Kev

Thanks Kev,

Ones you started some custom fabrication, nothing original fits anymore. Looking at your thread, you know what I am talking about ;)

Paul.

Looking good Paul , like the top mount for the rear shocks  8)

Very true! ;D

Thanks,
I like it to, hope it works with this angle.
The last photo, with the shocks, gearbox and trailing arms just looks mean 8)

Paul.

I know what you mean about them working on the angle as Ive had issues with this before , but Ive seen them used on race cars and hot rods at angles around 45 degrees so why not .
Doe's look mean as hell  8) 8) 8)

Super thread! And inspired work!
Have you checked what the angle will be with full compression on the rear suspension...?

Thanks

No, i did not :-[  I think I'll have to redo the upper mounts to have the wright height ;)

Paul.

Mechanical emergency brakes.........how needs them ;D Just a little weight saving ;)
[attachment=1]

While the Porsche front is narrowed 2,5" I had to modify the stabiliser as well.
I just gave it a try, and to my surprise it worked very well. 8)
[attachment=2][attachment=3]

Paul.

Finlay I received my stainless brake (hard) line. Time to sort out where to mount things.

I placed gear shift again, took place at the driver seat and try-ed to reach the gearstick and emergency brake.
while the front and rear main brakecylinders are both 1", I also needed a brakepress. reduce valve. In the pictures the reduce valve is mounted against the emergency brake bracket.
[attachment=1][attachment=2][attachment=3]

A lot of words to say that i did not do that much :P

Paul.

Night not be that much, bit its still awesome work! I enjoy every update!  ;)

J

Thanks J.   8)

After I was tyred trying to make the (home made) gearbox mount to fit. I ordered a new one, modified it to my standard and ideas, welded the adjusters and mounted it.
[attachment=1][attachment=2]
Paul.

As shown in earlyer pictures, the emergency brake had to move backwards. to mount this brake I needed a piece of flat steel.
So I lengthened the small flat piece from the original mount.
[attachment=1][attachment=2]

And here it is with the brake on it.
[attachment=3][attachment=4]

Paul.

The gearbox adjusters take care of the up/down forces, but with the missing forks it also need someting to take care of the length forces.
Cos I can adjust the height, these new length rods had to be able to turn and adjust.
[attachment=1][attachment=2]

Will you please start working on the body THISdecade ;D ;D ;D

Michael

 ;D ;D ;D
Body is just for looks, it's the inside (underneed) what matters :P

Paul.

I had second thoughts about the uniballs I used, so I ordered bigger/stronger uniballs.
[attachment=1][attachment=2]
M18 (18mm)
Static strength (Co kN) 81,5
dynamic strength (Co kN) 64,0

Paul.

Started to find the position for the new (hanging) pedals. I still have no idea how to mount them.
[attachment=1][attachment=2]

Paul.

Hi Paul

Good to see the car coming along and something a little out of the ordinary.

Keep up the good work

Jamie

Hi Jamie,

It's coming along, but it's a slow process ;). it's different, that's for sure 8)
I will keep going, some day it will be ready :-\

Cheers, Paul.

You're insane! Keep it up! ;D

Be interested to see how you do this Paul , I'd like to do this to mine but it looks to be a fair bit of cutting and Fab work involved  :-\

I'll take that as a compliment ;)

Thanks and; I will.

Paul.

You don't want to do this with your car, I saw a picture somewhere of a bug with hanging pedals without cutting. I'll see if I can find it for you.

Paul.

Here's an other guy doing some insane fabrication, scroll down the first page and you'll see his hanging pedals.
http://www.germanlook.net/forums/showthread.php?t=10369

Paul.

Started to find the wright position for the line-lock coil, made a bracket for it and tack welded it to the chassis.
Yesterday i thought this was a good position, today I am not so sure. :-\
[attachment=1][attachment=2][attachment=3]

Bin playing with the pedals again. After trying a few positions and checking the seat position, this is what it is going to be.
[attachment=1][attachment=2][attachment=3][attachment=4]

Paul, the king of mad- modifications  ;D
Nice work.

Greetings mycha

just wondering, but why are you using the VW steering arm and rods with the 914 front suspension?

You don't expect this to be in standard configuration now do you  ::)  Have a look through the thread and you'll see how the steering has already been adapted.

The 914 front suspension is narrowed about 2,5", this is why the original 914 steering didn't fit anymore.
I made a new steering setup using old bug parts, hoping to set bumbsteer to a minimum.

Paul.

I am not a standard guy  ;)

Cheers, Paul.

Are those pedals aftermarket Paul?
Cheers,
Kev

Hi Kev,

I bought these on Ebay, it's a Tilton set. (not sure for what car it is :-[)

Paul.

Thanks mate,

After seeing what you are doing to your Westy, I can't wait to see the modifications you have planned for your "Nasty Fasty" :o

Paul.

I'm looking for a pedal assemby myself right now ::)
Have you got a slave cylinder for the clutch yet?

yes, I'm not sure it fit's but I am trying to use an hydraulic bearing from an Opel Vectra.

Cool pic!  ;D

 ;)

I wasn't sure about the line-lock position, so back to the drawing board >:(
To feat the brake lines down to the front suspension, I had to go inside (the fueltank is in the way). So I thought why not use the line-lock as an 90deg. line fitting.

[attachment=1][attachment=2][attachment=3]

After all the brake parts where fitted in there final place, I could start with the brake line.

Stainles brake line and anodised brackets 8)
[attachment=1][attachment=2][attachment=3]

Paul.

Paul is it to late to make it a Right Hand Drive LMAO ;D ;D

doesn't look original to me  ;D

i like it paul...a lot

Everything is possible. How about putting the steer in the middle, we both be happy. ;D

Paul

Thanks Hans. Just had a peek at your update, and "I like it a lot" is an understatement. Keep the good work going 8)

Paul.

Did some work on the pedals again.
[attachment=1][attachment=2][attachment=3]

Paul.

I wasn't happy with the 14mm uniballs that i used for the rear suspension. So today I made a startwith the modification.

New 18mm (very strong) uniballs, M18*1,5 (left/right) adjusters and M18*1,5 weldnuts.

The plan is to place the uniballs between the outher plate and chassis, put a urethane bush in the torsiontube and weld a M18 nut in the pipe that goes in the urethane bush.
[attachment=1]

Of course the uniball has to go further in.
[attachment=2]

Here you see the plan; 14mm nut (has to be changed to 18mm), outher plate, 18mm uniball, plate to weld to the pipe, pipe that goes in the torsion tube and original rubber that will be replaced by a urethane one.
[attachment=3]

Paul.

Bin playing with the rearwheel setup again today. It looked a little out of line so I found a way to check it. After mounting a laserpointer to the brakedisk, I saw it was only a few METERS out of line :o :-[ :-[
I looked for the exact middle of the pan (front and rear), the welded some steel profiles to it, wrote a scale on the profiles, mounted a laserpointer to the brakedisk, cut one side of the IRS bracket and started playing with the alighnment.

[attachment=1]
Here are the two profiles welded to The chassis.

[attachment=2]
Laser mounted to the brakedisk and pointed to the first profile.

[attachment=3]
Laserpoint at first profile.

[attachment=4]
Laserpoint at second profile.
It's not 100% waterproof, but it's a good start.

Paul.

Yesterday it was time to align the left side.

First I cut the mount.
[attachment=1]

Then after some measuring, tacked it again.
[attachment=2]

Check, double check with the laser.
[attachment=3]

And welded it together again. 8)
[attachment=4]

Paul.

Almost finished one of two rear adjusters (version two) 8). The spindle has to be shortened a bit and then I can start with the second one.
[attachment=1]

Here you can see how it's going to be mounted, the outher-plate is mounted with 10mm bolts on the original place and the urethane bush is going in the torsiontube.
[attachment=2]

Paul.

Both sides are finally ready and mounted. only the 10mm 8,8 bolts have to be replaced by  10mm12,9 ones.
[attachment=1][attachment=2][attachment=3]

Paul.

looking good paul , with this set up it will be more likely to survive  ;D
and as I told before i like the new way of doing things....the way the front steering looks....finish the car and let me try

My thoughts exactly


One of the things I wanted to do is; doing things different 8)

Paul.

Today I did the last, technical, things to the chassis 8)

I welded the bottomcorners to the torsion tube again.
[attachment=1][attachment=2]
Made a fixatering to fixate the IRS bolt when its in place. (aftermarket bracket don't have the fixatering)
[attachment=3][attachment=4]
Paul.

And now it's finally time for the body 8)

[attachment=1][attachment=2][attachment=3][attachment=4]

Paul.

cool man


rady for scc  ;D

Thanks Fredy,

I will probably not make it to SCC ;D , but I really want to go there sometime.

Paul.

And again something fell of ;D
[attachment=1][attachment=2]

Paul

I love this tread, you do awesome work ;)

Thanks Kris,

I love doing it ;)

Paul.

Bin cleaning the innerwing area some more and then started to cut the donor wing. The donor wing is a '66 but it is hard, never welded and I'm sure I can make it fit ;)
[attachment=1][attachment=2]

The spotweld guy must have really loved his job, damn even the doorpillar had 8 spotwelds.

Left gone.
[attachment=1][attachment=4]

and sparewheel thing and gastank support gone.
[attachment=2][attachment=3]

Paul.

Nice work!

Spot welds are a nightmare! I only had to deal with about 15 this weekend, but that was enough!  ;)

So are you gonna run the body shell like that?  ;D With little clear plasic pannels so that we can see yout feet?  :D hehe

Its moving along nicely Paul!

J

Hi J,

The spotwelds are not so bad, just a lot :(
Clear plastic is an option, but I think I'll keep it all VW steel ;)

Cheers Paul.

Took out some more metal, not much left now 8)

Time to make something out of new and old metal that looks original.

Took out the last prats today.
Wiper motor, wiring loom, switches, Speedo, windows etc. only thing left is the ragtop.
Then it was time to hang the body on top of the chassis and see where it goes wrong :)

Next thing I want to do is to make the chassis rolling, so that I can roll it out of the way when working on the body.

Paul.

And is it? ... Going wrong I mean.

Nothing that can't be solved I'm sure.

Of course it is going wrong....but hey, like you said; nothing can't be solved. ;)

The heater tubes (underneed the backseat) where in the way and the body mounts (on the torsion tube) don't fit. nothing that a grinder and welder can't fix.

Paul.

First thing I had to do now was hang the body, this way I can remove the pan, work on the body and roll the pan back in it's place again.
[attachment=1][attachment=2]

Found some old repairs "DDR Style"  ???
[attachment=3][attachment=4]

Took out the right heaterchannel.
[attachment=1][attachment=2]

The body mount had to go, i need this space for my wheels. The mount will be welded back on the inside of the wing.
[attachment=3][attachment=4]

Paul.

Great work  :o 8)

Thanks Nico, but this is the easy part ;)

Paul.

Yo Paulskie,

There’s not much oval left  ;D
your working hard...... love it.
Keep up the good work, greetings from Norway (at the moment) Mycha

Yeah I know, I was better of just buying a roof with oval window ;D

Have fun and greets to the misses :D

Paul.

I want to use the doorpillar from my '66 as a donor So I took some tape, placed it on the '66, draw some lines on it, took it of and placed it on the '56.

I found out that the difference is on the window side only, the window is smaller (of course) but the rest is the same. 8)
[attachment=1][attachment=2]


Tried this at the door hinge place as well, only difference is the fourth hole.
[attachment=3][attachment=4]

Paul.

Pieces keep falling of this baby ;D
[attachment=1][attachment=2][attachment=3][attachment=4]

Paul.

After all the chassis work the body will be easy for you anyway ;)
Cheers,
Kev

Yeah....I wish, I think it's more the other way around. ;)

Paul.

While you're in there, might as well loose the defroster vent!

Looking good!

That will be replaced as well ;).

Paul

Didn't you work on the car last tuesday?I bet it was too hot ;)

Michael

is it ever too hot to work on your car :)
Yes, it was hot and I did not do much. bin working on the donor piece.

Paul.

PS. how's the wife doing?

After a short period without inspiration, I started to do some work on the car again.

Cutting the donor piece, try fit it, meassure it and cutting, testing and me measuring again. It's a long and boring job, but I don't want to cut to much.
[attachment=1]
[attachment=2]
[attachment=3]

Paul.

Hey Paul if I was you I would stop working on thiis car and buy Tekken's split and get that through an mot ;D
Michael

Is it the dutch heat, do you have soccer nerves or is it the almost fathership that makes you talk like my wife ;D ;D

Good luck this week. Paul.

I don't think she would recomment you to buy such a great piece of engineering ;)

Michael

It is just an other old beetle to her ;D

spend my day grinding, sawing and fitting again. It almost fits 8)
[attachment=1][attachment=2][attachment=3]

Paul.

Went to Spa this weekend, very nice being there again, and got the change of loaning a very nice '58 ragtop 8)
When I got home I abused the car to make a mold for the door opening.
[attachment=1]
[attachment=2]
[attachment=3]

Paul.

Then it was time to use the mold on my oval.
On the left side of the dooropening the body was standing on the heaterchannel, but the dooropening was to high.
So I lifted the body again, changed the underside of the body and placed it back on the heaterchannel.
[attachment=1]
The front had no connection to the heaterchannel but still it was to high as well. A piece of rope to pull the roof down fixed this.

Now the dooropening has the same size as the '58 loaner. After sawing and grinding the donor piece for the last time, it finally has some spotwelds 8)
Next thing to do is; hammer everything in the wright shape, weld a few more spotwelds and then fit the door.
[attachment=2]

Paul.

After I spot welded the pillar by using the mold. It was time to try the door.
In the past this car has had an accident on the right front, this gave me some problems. The window pillar was to close to the door and the roof sat to high.
[attachment=2]

I pushed the window pillar out using an hydraulic cylinder. and while the cylinder was on I pulled the roof 1cm down. Now the gab seems OK 8)
[attachment=3][attachment=4][attachment=1]

More amazing stuff!

You make it all look so easy!!!  ;D

J

You're wright. Looking at the pictures, and reading the few lines it looks easy. But it is my first time doing this, and I can tell you....it is not easy (you probably know)
It takes a lot of time (which I don't have), but I am satisfied with the outcome so far.

Paul.

Very nice work! Crazy!!  :o

Grtz Roel

Nice Job So Far Paul  you are going to have the only oval that takes a One Piece Late VW Hood Seal with the corners ;D ;D

It is not easy being different these day's ;D

Paul.

This corner is giving me headage's. At first i thought that it was almost the same shape as the original oval pillar/corner, man was I wrong >:( The Oval had an accident on the right front and the 66 donor has a slightly different shape, this means working without reference points.
it takes a lot of sawing, modeling and welding, but I will win this fight ;)
[attachment=1][attachment=2]
[attachment=3][attachment=4]

Paul.

Dont Ya Just Love Body Work Paul?  lol ;D ;D   Body Work is a P.I.T.A.     pain in the a** ;D

It really is a P.I.T.A, Heavy steal and >200amp welding is more my thing ;)

Paul.

Burn many holes yet??  I have a 180 Amp Mig Welder  its easy to burn threw if you dont watch it I had a 140 Amp before it worked better on sheet metal

Filled all the holes today ;D
[attachment=1]
[attachment=2]
[attachment=3]

Here's a pic I took when I first found out there was some sh&%#t under the paint
[attachment=1]

This is how it is now, a whole lot better...don't you think?
[attachment=2]

Paul.

Is that the final color ?:-)

Michael

Sssssst :-X

Great job  8)

Thanks. :-*

Paul.

Put the anglegrinder at work again.

First cut the donor.
[attachment=1]

Checked the panel and doorline.
[attachment=2]

make it fit.
[attachment=3]
[attachment=4]

Before I weld the outher panel in it's place, I want to replace the innerpillar. The innerpillar had some old repairs, and it didn't look to good. (I wish I left it allone >:( :()

[attachment=1]
[attachment=2]

Today I started with measuring the body, pushing, pulling and lifting it in shape and Finlay fixate it.
Then I started fixing the pillar that I wish I didn't take out :-[ but in the end I am almost satisfied with the outcom. It only needs a bid more welding and some grinding.
[attachment=1]

After I tag welded the pillar piece I sanded the inside of the 1/4 panel (you can not reach it anymore) and sprayed some protection on it. Then it was time for the outher panel. It's a slow process, but it's process ;D
[attachment=2]
[attachment=3]
Paul.

paul as said before ...RESPECT.....

For an oval they even don't sell the bad fitting repro sheet metal. The only thing I could do is restore the old metal.
Together with some Tikimadness leftovers I will try to fix it again.
[attachment=1]


With these 2 holes the body is mounted to the torsion tube. My torsion tube is about 9cm narrowed (each side) so these holes needs to be moved.
[attachment=2]
[attachment=3]
[attachment=4]

Paul.

Here's the difference;

This is also ready, only needs some lead filler 8)
[attachment=1]

Nice work!
Here is a little tip about Wolfparts new part:
(http://www.wolfparts.com/shop/images/DSC03119.JPG)

That really looks good, but I can weld a lot for € 197,-- each side ;)

Paul.

I hear you loud and clear :D

not much done lately. vacation and a little boy's birthday on my weekly beetle day, but the biggest time goes to restoring the corner on the end of the heaterchannels, what a PITA.

The original form was long gone, so I had downloaded some pictures and started modeling metal.
(http://www.keversite.nl/fotoalbum/fotos/97971.jpg)
(http://www.keversite.nl/fotoalbum/fotos/97972.jpg)
(http://www.keversite.nl/fotoalbum/fotos/97973.jpg)
It's a corner you can't see when the car is ready, but I like it to look original.

Paul.

Finally finished the left corner. When the body is back on the channels I will cut the corners at the wright length.
(http://www.keversite.nl/fotoalbum/fotos/98100.jpg)
(http://www.keversite.nl/fotoalbum/fotos/98102.jpg)

Nice fit, only have to grind the welds down and use some lead to smooth things.
(http://www.keversite.nl/fotoalbum/fotos/98099.jpg)
(http://www.keversite.nl/fotoalbum/fotos/98103.jpg)

On to the right site.
Paul.

Hi Paul Are you going to Hook up A Heater? are you going to need to Relocate the Heater Channel Tubes looks like are going right in to the torison housing?

Heating is for sissy's, I cut the tubes on the outside and will weld them shut (rear suspension is in the way) on the inside they will stay for the original look ;)

Paul

I will Remind you of that when you are freezing your a** off LMAO!!  ;D ;D

;D

I live in the warm south of the Netherlands. :P

I've only just joined this site, and have spent a thoroughly interesting hour reading through your thread, it's amazing work.

Thanks, and welcome.

Paul.

After 3 week doing nothing on the car, I finally started again.

The left crosmember is ready, so it is time to start on the right side.
This is where I started with.
(http://www.keversite.nl/fotoalbum/fotos/98621.jpg)
(http://www.keversite.nl/fotoalbum/fotos/98622.jpg)

And the result after hammering, grinding, bending, cutting and welding a few hours.
(http://www.keversite.nl/fotoalbum/fotos/98623.jpg)
(http://www.keversite.nl/fotoalbum/fotos/98624.jpg)
Almost there 8)

Paul.

Finally the crosmember is done, When the body is on it's place i will modify the endpieces of the crosmember and probably do the bumb over again.
(http://www.keversite.nl/fotoalbum/fotos/98846.jpg)
(http://www.keversite.nl/fotoalbum/fotos/98847.jpg)

The heaterchannel was to long on the front and to short on the rear, I did not want to redrill my floor so I had to dismantle the channel.
(http://www.keversite.nl/fotoalbum/fotos/98849.jpg)
The bottom of the channel will be mounted on the floor and then make the top fit.

Looks nice on the inside
(http://www.keversite.nl/fotoalbum/fotos/98848.jpg)

Now that I opened the channel, I bare metaled the bottom and I will put some decent paint on it
(http://www.keversite.nl/fotoalbum/fotos/98850.jpg)

Paul.

Wise move, and as always, great work!

I am also glad I did this, Thanks.

x2 !

 :-*

Sanded the inside of the heaterchannel, thought about polishing it but went for paint instead ;D. Also welded some extra strength in the seatbelt mount, I am not sure I am gonna use it tough.
(http://www.keversite.nl/fotoalbum/fotos/99060.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99061.jpg)

(http://www.keversite.nl/fotoalbum/fotos/99062.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99059.jpg)

After I painted the inside and bottom of the channel, I sprayed antirust on it and some inox spray on the welding areas. Now it was time to fit it in it's new position..
I placed the channel 1/2 an inch backwards on the bottomplate.
(http://www.keversite.nl/fotoalbum/fotos/99223.jpg)

Back fits like a glove now.
(http://www.keversite.nl/fotoalbum/fotos/99193.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99194.jpg)

The firewall can be mounted without a problem
(http://www.keversite.nl/fotoalbum/fotos/99195.jpg)

Paul

Finally the channel is ready, but after welding and grinding it was torn a lot >:(
(http://www.keversite.nl/fotoalbum/fotos/99461.jpg)

So I fixated the channel and fired up the torch, after it was heated I tried to torn it back.
(http://www.keversite.nl/fotoalbum/fotos/99464.jpg)

And that worked.
(http://www.keversite.nl/fotoalbum/fotos/99467.jpg)

Next step is the firewall, I decided to use and repair the leftovers Tikimadness donated.
(http://www.keversite.nl/fotoalbum/fotos/99471.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99473.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99475.jpg)

Paul.

Today I cleaned up the firewall that was cut out of a '54. The firewall or innerwings where replaced or repaired in the past, it was not spotwelded but had a lot of welds around the edges. But it came out pretty nice.
(http://www.keversite.nl/fotoalbum/fotos/99541.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99542.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99543.jpg)

This firewall was cut out because of it's weight, but the heaterchannels had to stay. this is why I had to repair the corners, it was not rusted but cut around the heaterchannels.
(http://www.keversite.nl/fotoalbum/fotos/99545.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99547.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99549.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99544.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99546.jpg)

Paul.

Done 8)
(http://www.keversite.nl/fotoalbum/fotos/99742.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99743.jpg)

Paul.

After some grinding, bending, drilling and a lot of hammering, the left channel fits properly.
(http://www.keversite.nl/fotoalbum/fotos/99903.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99906.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99907.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99905.jpg)
(http://www.keversite.nl/fotoalbum/fotos/99904.jpg)

Super neat work

I love these updates!!!

Coming along beautifully!  ;D

J

Found some time to work on the car again 8)

The underside of the left doorpillar was bad, of course >:(
time for a Hoekie of Hooky :)
(http://www.keversite.nl/fotoalbum/fotos/101713.jpg)
(http://www.keversite.nl/fotoalbum/fotos/101714.jpg)

First I had to shorten it, this way the bracing could stay in it's place.
(http://www.keversite.nl/fotoalbum/fotos/101715.jpg)

fitting
(http://www.keversite.nl/fotoalbum/fotos/101716.jpg)

It only needs some welding. 8)
(http://www.keversite.nl/fotoalbum/fotos/101719.jpg)

Paul.

This morning it was time to finish the doorpillar.

Welded the hooky piece.
(http://www.keversite.nl/fotoalbum/fotos/101822.jpg)

Normally you can not reach the inside, mine is still open and it is double sheetmetal so I also welded the inside.
(http://www.keversite.nl/fotoalbum/fotos/101823.jpg)

Then I dismantled the door (this is very heavy with all the parts and glass in it) and checked the gap, I must say ; I am very pleased with it.
(http://www.keversite.nl/fotoalbum/fotos/101824.jpg)

Paul.

Not much time lately, but still a Little progress.
This piece of the trunk was a little thin, also the holes didn't mach the new kick panel. so I replaced the top of the kick panel by a wider piece, this way I can close (weld) all the holes.
(http://www.keversite.nl/fotoalbum/fotos/102726.jpg)

(http://www.keversite.nl/fotoalbum/fotos/102727.jpg)


Paul.

All the holes are closed again. before paint I will put some lead filler on it and it will be as new again, offcourse I will do the corners first.

(http://www.keversite.nl/fotoalbum/fotos/102880.jpg)

I'll say it again but it's an impresive bodywork  8)

Thanks Nico. The trick is, when your not satisfied, get the grinder and start over again.

Paul.

GODDAMN Paul, you have patience and skill.

Hey Paul!
Build threads been quiet lately but you've obviously been keeping busy ;)
Good work ;D
Cheers,
Kev

No Harry, just patience and guts ;)

Hey Kev, Yes it was quiet. I had a ski trip to the alps with "the guy's", I have bin ill and had some motivation problems. Today I worked on my wife's new car (twingo :-[), and from now I will be updating again 8)

Paul.

Stop talking Harry, time to drive this baby to EBI this year

If i make it lets race. Street versus Drag. Fun.

That would be nice 8), I will be there but my car will not be ready this year that's for sure.

See you at EBI.

Today I did some more work under the hood. This is one of the holes to fix the gastank, needs some work ;D
(http://www.keversite.nl/fotoalbum/fotos/103184.jpg)

This looks a whole lot better.
(http://www.keversite.nl/fotoalbum/fotos/103185.jpg)
(http://www.keversite.nl/fotoalbum/fotos/103186.jpg)

The channels are welded, so Finlay it was time to take out the climbing frame
(http://www.keversite.nl/fotoalbum/fotos/103188.jpg)
Looks better already
(http://www.keversite.nl/fotoalbum/fotos/103189.jpg)

After I welded the channels to the body I lifted the body again, now I can stand in it and weld all the seems.
(http://www.keversite.nl/fotoalbum/fotos/103190.jpg)
(http://www.keversite.nl/fotoalbum/fotos/103191.jpg)

Paul.

Started on the Tilton set yesterday.

Find the wright place to cut.
(http://www.keversite.nl/fotoalbum/fotos/103683.jpg)

mounted the steering column and cut the hole.
(http://www.keversite.nl/fotoalbum/fotos/103684.jpg)
(http://www.keversite.nl/fotoalbum/fotos/103685.jpg)
(http://www.keversite.nl/fotoalbum/fotos/103686.jpg)

And made the side panels.
(http://www.keversite.nl/fotoalbum/fotos/103687.jpg)
(http://www.keversite.nl/fotoalbum/fotos/103688.jpg)

Paul.

looking great ouwe knutselaar..... ;D

Thanks Hans,
How is your '67 comming along? have you sold the notch?

This morning bolted the body back on to check the pedal-steer-seat position
First I checked the old with the new pedal position, look good to me 8)
(http://www.keversite.nl/fotoalbum/fotos/103730.jpg)

Then fitted the seat and for the first time in a few years I took place behind the wheel ;D
(http://www.keversite.nl/fotoalbum/fotos/103731.jpg)

When I place the steering wheel 5cm closer to the seat, the position is spot on. The steering column can be moved 5cm without cutting or welding, how cool is that.
(http://www.keversite.nl/fotoalbum/fotos/103732.jpg)

Before I weld the channels, I had to be sure that the trunk still fits. And it fits like a glove.
(http://www.keversite.nl/fotoalbum/fotos/103733.jpg)

The gearbox and engine are raised, so the trunk has to be raised as well. After some measurement it seems that the trunk needs to be raised by 12cm.
(http://www.keversite.nl/fotoalbum/fotos/103734.jpg)

Paul.

this piece gave me many headages
(http://www.keversite.nl/fotoalbum/fotos/96675.jpg)

After a lot of hammering, grinding, welding and swearing, this is what I made of it. The plan is to give it it's original strength again
(http://www.keversite.nl/fotoalbum/fotos/104033.jpg)
And when that is finished, build the mountingpoint for the rollcage around it.
(http://www.keversite.nl/fotoalbum/fotos/104038.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104037.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104036.jpg)

This way I can still mount the back seat (I will probably never fit it). now it is time to read the official cage requirements, maybe I will need it in the future. :wink:

Paul.

I choose to not only spotweld, but to weld all round all edges. my goal is to make the welds close to invisible.

Welded the (ex)spotwelds (left-rear), and tried to make it invisible.
(http://www.keversite.nl/fotoalbum/fotos/104176.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104177.jpg)

Also started doing the same to the right site.
(http://www.keversite.nl/fotoalbum/fotos/104178.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104179.jpg)

Paul.

Worked a few hours on the Tilton box today, unfortunately all the hours and effort can't be seeing.
First I made the pedals 100% fit in the box, then I took away all the sharp edges, changed the windings to metric windings, welded the box allround and grind-ed the welds.
When to box was to my standards I welded it to the body, just a few cm to go.
(http://www.keversite.nl/fotoalbum/fotos/104235.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104236.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104237.jpg)

Paul.

Made a hole for my bias adjustercable, damn i wish i had done this before welding.
(http://www.keversite.nl/fotoalbum/fotos/104407.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104408.jpg)

Also started finishing the left doorpillar.
(http://www.keversite.nl/fotoalbum/fotos/104409.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104410.jpg)

Paul.

When I was working on the left pillar today, I noticed that the right pillar (out of a '66 car that already was welded to the heater channel) had a different shape, Damn... how Manny differences can you have >:(.

The left pillar is ready, well maybe a few tab's with a hammer away from being ready.
(http://www.keversite.nl/fotoalbum/fotos/104552.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104554.jpg)

On these picture's you can see that the pillar out of the '66 car has a sharp bent, a '56 car does not have this bent.
(http://www.keversite.nl/fotoalbum/fotos/104555.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104556.jpg)

So after I finished the left pillar I took out the grinder again and started to make the '66 look like a '56.

The result; '66 metal that looks like a '56. 8)
(http://www.keversite.nl/fotoalbum/fotos/104558.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104561.jpg)

Paul.

Keep going like that and it will get finished..........................................eventualy ;D

No seriously looking good.You are finally making progress on the body.

Michael

Ps did you convince your wife we have to go to Hangover? ;D ;D

Thanks buddy,

I am afraid Hangover is not gonna happen :'(

This week my new brake fluid reservoirs arrived from the UK, black anodised billet aluminium. 8) Now I have to think about how and where to mount them.
(http://www.keversite.nl/fotoalbum/fotos/104641.jpg)
It looks damaged, but it's just dust.
(http://www.keversite.nl/fotoalbum/fotos/104642.jpg)

Started to prep. the new left wing.
(http://www.keversite.nl/fotoalbum/fotos/104643.jpg)
(http://www.keversite.nl/fotoalbum/fotos/104644.jpg)

Paul.

NICE  :o love it, keep up the good work (respect voor je doorzettingsvermogen)

Greetz mycha

Thanks mate, ik blijf het leuk vinden....vandaar ;)

Removed more useless metal from the (new   :D )inner wing , Damn the VW spotweld guy went crazy on that wing. The piece of wheel well that is still on there can stay for now.
(http://www.keversite.nl/fotoalbum/fotos/104947.jpg)

Dare to go where no man is gone before   :o (I think)
(http://www.keversite.nl/fotoalbum/fotos/104950.jpg)
The plan is to drill out the spotweld that hold the inner plate to the pillar, cut the pillar halfway the drilled holes and weld the new wing to it.

This is the cutting line.
(http://www.keversite.nl/fotoalbum/fotos/104951.jpg)

Paul.

Had a day off today, this meant I was still working only not at the office >:( sometimes I hate customers.
Between telephone calls I did some work on the oval.

cut the pillar along the line and left the inner plate.
(http://www.keversite.nl/fotoalbum/fotos/105007.jpg)(http://www.keversite.nl/fotoalbum/fotos/105009.jpg)

I had to cut out some more rust.
(http://www.keversite.nl/fotoalbum/fotos/105010.jpg)

a little test fit, when it all fits I can weld on a piece of flat with the inner plate underneed.
(http://www.keversite.nl/fotoalbum/fotos/105011.jpg)

some more test fitting.
(http://www.keversite.nl/fotoalbum/fotos/105012.jpg)
And where getting close.
(http://www.keversite.nl/fotoalbum/fotos/105013.jpg)

The innerwings are different to the original oval wings, but i have to cut out the most to make room for the 914/911 front suspension..

More quality workmanship going on there  8)

Thanks Pas, on the pic's it's almost done but i am far from satisfied.

Paul.

Some jobs take more time than expected, these innerwings are that kind of a job.
The holes from drilling the spotweld had to be welded, they did not match with the new location. In the past someone mounted an emergency switch, this had to be closed as well.
After welding the holes, I smoothed them and I cleaned the area that can't be reached later on.
(http://www.keversite.nl/fotoalbum/fotos/105199.jpg)

And before you know it....time's up.

didn't want to do body work today, so I did some work on the chassis.

I was not satisfied with the place where the fuellines came out the chassistube. again a hole was made :P
It does not show on the pictures, but the hydraulic clutchline is now near the fuellines.
(http://www.keversite.nl/fotoalbum/fotos/105645.jpg)
(http://www.keversite.nl/fotoalbum/fotos/105646.jpg)

Paul.

New package arrived from the US of A :)
(http://www.keversite.nl/fotoalbum/fotos/105664.jpg)

If you do that then nobody can see them

That's the idea ;)

Today I started on making the anti rollbar brackets, This Anti rollbar started it's live on a pink "killer Kitty" opel.

(http://www.keversite.nl/fotoalbum/fotos/106422.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106423.jpg)

Paul.

First fitment test of the anti-rollbar, I think it needs a little modifications.
(http://www.keversite.nl/fotoalbum/fotos/106671.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106672.jpg)

Paul.

Did some sway-bar work today
Welded the new sway-bar brackets to the upper front axle tube, narrowed the tube to the chassis head width and closed the end of the tube, this way I have some strenght in the brackets and still have the original body mounts.
(http://www.keversite.nl/fotoalbum/fotos/106758.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106757.jpg)

Test with 90deg. turned uniball.
(http://www.keversite.nl/fotoalbum/fotos/106762.jpg)

The 90deg. turned uniball works great, so I made a new bracket (needs some more welding).
(http://www.keversite.nl/fotoalbum/fotos/106763.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106764.jpg)

Put the grommet in and did a new test. The movement I can make without hitting anything is much bigger as the movement the shockabsorber can make.
(http://www.keversite.nl/fotoalbum/fotos/106755.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106756.jpg)

Paul.

Bought myself a nice donor body, this '58 Will speed things up 8)
(http://www.keversite.nl/fotoalbum/fotos/105514.jpg)

Paul.

Right side of the sway bar is now ready too.
(http://www.keversite.nl/fotoalbum/fotos/106933.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106934.jpg)

To make sure all the fittings of the fuel line are ok, I checked them with some air pressure.
(http://www.keversite.nl/fotoalbum/fotos/106932.jpg)

On original oval has special floormat fasteners, so I welded these back on the floor.
(http://www.keversite.nl/fotoalbum/fotos/106935.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106936.jpg)

Paul.

Is that a stock steering box? Wouldn't a rack & pinion be easier at this stage, and more benificial?

Hi Zach,

I did this because i could not find a rack&pinion with the wright width. the points where the A-arms rotate are very close to eachother, so to avoid bumb steer I made this set-up.

On one side there is an original steering box and on the other side there's an extra arm (1303) that follows the moves of the steeringbox.
(http://www.keversite.nl/fotoalbum/fotos/84585.jpg)

Do you still follow me.
Paul.

Got it ;)

The devils in the detail  8) 8)

 ;)

Picked up the '58 donor for the oval today.
(http://www.keversite.nl/fotoalbum/fotos/106986.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106987.jpg)

Looking good.
(http://www.keversite.nl/fotoalbum/fotos/106988.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106989.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106990.jpg)
(http://www.keversite.nl/fotoalbum/fotos/106991.jpg)

And a bus full of rust free '58 goodies
(http://www.keversite.nl/fotoalbum/fotos/106993.jpg)

It's almost a shame to cut this to pieces, but it will happen. :twisted:

Paul.

Was thinking the same  :P.

Good luck with the build!

gr
Wout

Time to take out the old grinder again :o. I really need the parts for my oval, but still it was difficult to cut up this nice '58.

No way back now.
(http://www.keversite.nl/fotoalbum/fotos/107543.jpg)
(http://www.keversite.nl/fotoalbum/fotos/107544.jpg)
(http://www.keversite.nl/fotoalbum/fotos/107545.jpg)

Paul.

 :'( sad to see that  :'(

His soul will live on.

After a lot of drilling, the dash is out.
(http://www.keversite.nl/fotoalbum/fotos/107626.jpg)
(http://www.keversite.nl/fotoalbum/fotos/107627.jpg)
(http://www.keversite.nl/fotoalbum/fotos/107628.jpg)

Paul.

the EBI weekend was superb, but now it is oval time again.
Al the old repairs are cut out of the donor front and today I started cleaning the underside of it.

This is a very good piece of German metal. :)
(http://www.keversite.nl/fotoalbum/fotos/108994.jpg)
(http://www.keversite.nl/fotoalbum/fotos/108995.jpg)

Paul.

Good work Paul 8)
Any more donor body's like that turn up can you give me a shout? ;)
Cheers
Kev

Paul are you stil feeling good ?
and is my oval save in my garage or should i put it behind bars  and lock it for the KASTANATOR??
I ll already sended  a sms alert to the near dub pre 67 owners  ;)

henri

It's just a rust free '58, nothing special ;D

Better watch it, nothing pré '60 is save for my grinder :D

Paul.

Finally did something visible again.

Complete parafan removed.
(http://www.keversite.nl/fotoalbum/fotos/109330.jpg)

Took a wile to find the currage, but it had to be done.
(http://www.keversite.nl/fotoalbum/fotos/109331.jpg)

Both doorpillars removed :shock:  :shock:
(http://www.keversite.nl/fotoalbum/fotos/109329.jpg)
(http://www.keversite.nl/fotoalbum/fotos/109332.jpg)

Paul.

a few holes.
Looked at an original , never welded body and then circled all the original holes. The rest has to be welded.
(http://www.keversite.nl/fotoalbum/fotos/109503.jpg)

How it should be.
(http://www.keversite.nl/fotoalbum/fotos/109504.jpg)

After storage for many years, this all original (only the exhaust cutouts are not original), rust free and never welded oval is my workshop neighbour. now i can check it if I need to know how things should be. (i am not aloud to touch it ;D)
(http://www.keversite.nl/fotoalbum/fotos/109505.jpg)

Paul.

Some times little things take so much time >:(

The frontshield corners and the fresh air vents where pretty bad.
(http://www.keversite.nl/fotoalbum/fotos/109527.jpg)

After some drilling, grinding, hammering, cleaning and trail fitting. I am halve Way there.
(http://www.keversite.nl/fotoalbum/fotos/109528.jpg)

Paul.

Damn, i was on page 2. time for a little update ;D

Replaced the right windshield heater thing and repaired the left one.
[attachment=1]
[attachment=2]

In the past someone drilled a lot of holes in this car, today I fixed it. This is a difficult to reach area, so while I was in there I might as well bare metal it.

(http://www.keversite.nl/fotoalbum/fotos/110727.jpg)
(http://www.keversite.nl/fotoalbum/fotos/110728.jpg)

Paul.

Thats a load of work Paul but you're getting there!
Any more of those rust free oval shells going spare?? ;D
Cheers
Kev

Hi Kev, yes I have had better jobs before :P
If i find a shell laying around, I'll let you know.

Paul.

Getting close 8)
(http://www.keversite.nl/fotoalbum/fotos/111218.jpg)
(http://www.keversite.nl/fotoalbum/fotos/111219.jpg)

Paul.

Satrting to look good.
(http://www.keversite.nl/fotoalbum/fotos/111244.jpg)

Right side is getting there as well.
(http://www.keversite.nl/fotoalbum/fotos/111245.jpg)

Paul.

Looks good! But I have to say that I have seen easier ways to get rid of yellow paint ;)

 ;D :D

Well? What's up with all the delay? This thread is one of the reasons I keep coming back to the Lounge  8)

Sorry, not much time lately. I have done some work but not worth mentioning. I will be back. 8)

Paul.

especially for you Dr. Jeckill
Between family live, work and some work on my daily passat, the oval is going forward as well (slowly).
Bolted the nose on the body, now i can see better what to do and where to do it.
It looks like the right is OK.
(http://www.keversite.nl/fotoalbum/fotos/113087.jpg)
(http://www.keversite.nl/fotoalbum/fotos/113090.jpg)

On the left I had some fitting problems, probably the welds from the pedalbox where to hot. I cut out the piece that did not fit and welded in a bigger piece instead.
(http://www.keversite.nl/fotoalbum/fotos/113088.jpg)
(http://www.keversite.nl/fotoalbum/fotos/113089.jpg)

Still needs some welding, grinding and sanding.

Paul.

Today I started making the '58 parafan look like an '56.

Here is the difference between the '58 and '56.
(http://www.keversite.nl/fotoalbum/fotos/113341.jpg)

Time to cut again.
(http://www.keversite.nl/fotoalbum/fotos/113343.jpg)

Cutting, and trying.
(http://www.keversite.nl/fotoalbum/fotos/113345.jpg)
(http://www.keversite.nl/fotoalbum/fotos/113342.jpg)

The result of a few hours work.
(http://www.keversite.nl/fotoalbum/fotos/113346.jpg)

Paul.

Today I worked on the wipers again.
Just to be sure I mounted the mechanism and it fits. (sorry for the crappy phone pic's)
(http://www.volksforum.com/albums/files/2/2/6/5/56Ruitenwissrs.jpg.jpg)
(http://www.volksforum.com/albums/files/2/2/6/5/56Ruitenwissrs.jpg1.jpg)

To mount the mechanism I had to weld this bracket as well
(http://www.volksforum.com/albums/files/2/2/6/5/56Ruitenwissrs.jpg2.jpg)
(http://www.volksforum.com/albums/files/2/2/6/5/56Ruitenwissrs.jpg3.jpg)

Paul.

Not much....but it is progress.
(http://www.keversite.nl/fotoalbum/fotos/113657.jpg)
(http://www.keversite.nl/fotoalbum/fotos/113659.jpg)

all welded and smoothend, also welded the hole for the screen washer.
Paul.

you are mad man. good work

Thanx.

Wile the front is removeable, I have good access to drill the cage holes.
(http://www.keversite.nl/fotoalbum/fotos/113728.jpg)

Never thought the hole would have this shape.
(http://www.keversite.nl/fotoalbum/fotos/113729.jpg)

The cage can not hit the pedalbox, innerwing and fueltank, and has to end in the sparewheel well to be welded to the Porsche frontwheel mounts.
(http://www.keversite.nl/fotoalbum/fotos/113730.jpg)
(http://www.keversite.nl/fotoalbum/fotos/113731.jpg)

The cage will also run under the dash, this will fit perfect later on.
(http://www.keversite.nl/fotoalbum/fotos/113732.jpg)

With this piece of cardboard the hole on the right will be easier.
(http://www.keversite.nl/fotoalbum/fotos/113733.jpg)

Paul.

Took the doors from the attic and dismantled them (they weigh a ton with all the windows etc.).
trail fitted the left door, fixated it with the wright gabs and made the first welds
(http://www.keversite.nl/fotoalbum/fotos/113906.jpg)
(http://www.keversite.nl/fotoalbum/fotos/113908.jpg)
When the right door is fixated and the pillar is tackwelded as well, I will start on the window surrounding.

Paul.

You should name it the FRANKENSTEIN OVAL ;D ;D ;D

Looking good buddy ;D

Michael

Frankenstein would be a good name indeed. lol

 VWorrible #1 Bug !!!!

VWrankenstein  :D

And the right is getting there as well. Its not easy fitting a door in a shell that is not welded and bin appart completely
(http://www.keversite.nl/fotoalbum/fotos/114151.jpg)
(http://www.keversite.nl/fotoalbum/fotos/114152.jpg)

Paul.

Nice ;D ;D

So you can finish the welding on saturday? Maybe you can race it in bit burg in september after all. :D

Michael

You're a funny guy ;D

Time to restore the window corners, this is not easy cos this is where the '58 is different from the '56
First I had to cut some more of the '56, and then I started to make my own '58 - '56 puzzle.
The before picture.
(http://www.keversite.nl/fotoalbum/fotos/114399.jpg)
Cut a piece of '58 in to the wright shape to follow the '56 windowl line.
(http://www.keversite.nl/fotoalbum/fotos/114400.jpg)
I had some leftovers from the '56, they came in handy now.
(http://www.keversite.nl/fotoalbum/fotos/114401.jpg)
after a lot of testfits, I am a happy man.
(http://www.keversite.nl/fotoalbum/fotos/114402.jpg)

Paul

The right is tacked as well, doesn't look like much but this took me several hours.
(http://www.keversite.nl/fotoalbum/fotos/114620.jpg)
(http://www.keversite.nl/fotoalbum/fotos/114619.jpg)
(http://www.keversite.nl/fotoalbum/fotos/114618.jpg)

Paul.

If it has to be good, it has to be worse first. So the hole had to be bigger.
(http://www.keversite.nl/fotoalbum/fotos/114954.jpg)
(http://www.keversite.nl/fotoalbum/fotos/114956.jpg)

I used a piece from the '56, but is was pretty rotten at the vertical edge.
(http://www.keversite.nl/fotoalbum/fotos/114957.jpg)

Made a new vertical piece (Real PITA) and welded it in. took me all morning but it's done.
(http://www.keversite.nl/fotoalbum/fotos/114953.jpg)

Paul.

Keep at it, it's all coming together!

when is this gonna happen ??? ;D ;D

Thanx Kev, I will.

Hahaha.

Probably never, I have an other color in mind.

Starting to fit pretty well.
(http://www.keversite.nl/fotoalbum/fotos/115026.jpg)
(http://www.keversite.nl/fotoalbum/fotos/115027.jpg)

Paul.

After a testfit of the windshield is was obvious the left corner wasn't wright.

So, out with the grinder again.
On my way again.
(http://www.keversite.nl/fotoalbum/fotos/115480.jpg)

The stuff I ordered at Hooky's wasn't in yet, so the corners are done for now.
Just 4 fun, played with the front suspension 8)
(http://www.keversite.nl/fotoalbum/fotos/115481.jpg)
(http://www.keversite.nl/fotoalbum/fotos/115482.jpg)

Paul.

Hooky delivered some nice parts 8)
To fix the window corners I ordered these repair corners.
(http://www.keversite.nl/fotoalbum/fotos/115496.jpg)

Wile I was ordering at Hooky it made sense to order the weber-windows as well.
(http://www.keversite.nl/fotoalbum/fotos/115497.jpg)

Paul.

Yesterday indeed was a good Friday, finally had some time to work on the '56.
Windowcorner left is ready.
(http://www.keversite.nl/fotoalbum/fotos/116173.jpg)
(http://www.keversite.nl/fotoalbum/fotos/116172.jpg)
On the pic it looks rough, but IRL it is pretty smooth.

Leftside of the dash is finished as well.
(http://www.keversite.nl/fotoalbum/fotos/116171.jpg)
Ready for a thin layer of lead.

Then it was time to do the innerwing. It didn't fit to the heaterchanel and it was to short due bad repairs in the past.
(http://www.keversite.nl/fotoalbum/fotos/116174.jpg)

Paul.

after welding and cooling it was time for some precision grinding ;)

it's almost straight, just needs a minimum of lead.
(http://www.keversite.nl/fotoalbum/fotos/116480.jpg)
(http://www.keversite.nl/fotoalbum/fotos/116481.jpg)
(http://www.keversite.nl/fotoalbum/fotos/116482.jpg)

Took me a few hours, but is's worth it.
Paul.

Today I started fixing the left quarterpanel
I couldn't find a good donor, so I had to make the best of it with the repro panels.

First I shortend it.
(http://www.keversite.nl/fotoalbum/fotos/117428.jpg)

After taking some measurements from an original '54, I started hammering.
(http://www.keversite.nl/fotoalbum/fotos/117426.jpg)

Just needs a little massage
(http://www.keversite.nl/fotoalbum/fotos/117427.jpg)

Paul.

Getting closer to paint now 8)

Not really, its one step forward and two steps back at the moment. I started repairing the 1/4 panel, after adjusting the new sheetmetal, fitting 4 different fenders and adjusting the new sheetmetal again, it looks like I stepped one forward without stepping back :)

Cheers Paul.

I think my oval needs service  ;D
(http://www.keversite.nl/fotoalbum/fotos/118260.jpg)

After some welding and grinding, i am very happy with the result
(http://www.keversite.nl/fotoalbum/fotos/118256.jpg)
(http://www.keversite.nl/fotoalbum/fotos/118258.jpg)

I still had doubts about the home made steering and changed my mind. I am going for "rack n pinion".

This Peugeot 404 steering will do the trick, the round couple rubber which is original for this Peugeot as well, even has the same bolt width 8)
(http://www.keversite.nl/fotoalbum/fotos/118259.jpg)

Paul.

Looks almost like original.
(http://www.keversite.nl/fotoalbum/fotos/118333.jpg)
(http://www.keversite.nl/fotoalbum/fotos/118369.jpg)
(http://www.keversite.nl/fotoalbum/fotos/118370.jpg)

Paul.

Lookin' good Paul . . . you do very nice work!

Thanks.

The left is ready, time to start on the right side.
First clean the shop then turn the car and level it. I was very glad I was ready on the left, and now I can start all over again. DAMN this is a lot of work :-\
(http://www.keversite.nl/fotoalbum/fotos/118446.jpg)

Paul.

just keep on going....and keep sending pic's   like it a lot

I will Hans, no turning back now.

I heard a rumor saying your fenders are made and ready to be collected within the next few weeks ;D ;D ;D

Michael

Thats good news, thanks.

I repaired this corner a few months ago but i am not satisfied, so it's time to do it again.
(http://www.keversite.nl/fotoalbum/fotos/118754.jpg)
(http://www.keversite.nl/fotoalbum/fotos/118753.jpg)
(http://www.keversite.nl/fotoalbum/fotos/118752.jpg)

Paul.

First I tried to fit the door. As expected that didn't fit, not in a milion years.

After a lot of thinking, pushing and stretching, it was time to use my hydraulic friend. Finally it fits like a glove.
(http://www.keversite.nl/fotoalbum/fotos/118943.jpg)
(http://www.keversite.nl/fotoalbum/fotos/118944.jpg)
(http://www.keversite.nl/fotoalbum/fotos/118945.jpg)

Paul.

I think I wil make a phone call to the guinness book of world records for the longest time ever to swap a heater channel ;D ;D ;D

It looked good today at you shop ;D

Michael

Good work takes time ;)

New parts arrived
"race weight" oval wings
(http://www.keversite.nl/fotoalbum/fotos/119117.jpg)

Very good quality, it even has the hump at the runningboard
(http://www.keversite.nl/fotoalbum/fotos/119118.jpg)
(http://www.keversite.nl/fotoalbum/fotos/119119.jpg)

Paul.

almost there.
(http://www.keversite.nl/fotoalbum/fotos/119120.jpg)
(http://www.keversite.nl/fotoalbum/fotos/119121.jpg)

Paul.

Some more weight saving, once I am finished with this "single skin" hood it will look original.
(http://www.keversite.nl/fotoalbum/fotos/119351.jpg)
(http://www.keversite.nl/fotoalbum/fotos/119352.jpg)
(http://www.keversite.nl/fotoalbum/fotos/119353.jpg)

Paul.

The first attempt failed, so here's the second attempt of repairing the Right 1/4 panel.
after some hammering and grinding.
(http://www.keversite.nl/fotoalbum/fotos/119818.jpg)

Hammering the oval shape in it.
(http://www.keversite.nl/fotoalbum/fotos/119819.jpg)

Starting to look original.
(http://www.keversite.nl/fotoalbum/fotos/119821.jpg)

Paul.

I see the motivation is back ;DWait till after Das drag day and you will have so much enthusiasm that you'll be finished in time for Bug-in 5 ;D ;D ;D

Michael

 ;D stuff like DDD will give me new motivation for sure, can't wait to go.

After the new sheetmetal was in shape, It was time to make "the notch"
(http://www.keversite.nl/fotoalbum/fotos/119999.jpg)

Made a notch and tacked it in place, it looks a bit odd but the shape is like the original.
(http://www.keversite.nl/fotoalbum/fotos/119997.jpg)

And again some trial fitting.
(http://www.keversite.nl/fotoalbum/fotos/119998.jpg)

Paul.

goe bezig  ;D

Dank U ;)

Your going to run out of things to weld eventually ;D
Looking good though 8)
Cheers
Kev

No welding :o :o what to do then??? ;D
Thanks Kev, how's your project going? DDD#10 :D

DDD#100 at this rate ::)

Next week I can Finlay work on the car again. the trailer is completely level and the car is welded on it at the wright height.
(http://www.keversite.nl/fotoalbum/fotos/120528.jpg)

Paul.

Finlay did some work to the car again :)
(http://www.keversite.nl/fotoalbum/fotos/120711.jpg)
(http://www.keversite.nl/fotoalbum/fotos/120712.jpg)

Paul.

1/4 panel is welded up now. IRL it's pretty strait, even without filler.
(http://www.keversite.nl/fotoalbum/fotos/120927.jpg)

Also started repairing the innerwing, here it's almost finished
(http://www.keversite.nl/fotoalbum/fotos/120928.jpg)

Paul.

Innerwing is done.
(http://www.keversite.nl/fotoalbum/fotos/120976.jpg)

Paul.

looking good...

;)

Is wasn't easy to get the dash near the doorpillar. I finally managed it and it looks good if I say so my self.
(http://www.keversite.nl/fotoalbum/fotos/121673.jpg)

Paul.

Right innerwing is almost done, only the marked pieces need some love.
(http://www.keversite.nl/fotoalbum/fotos/121705.jpg)

Paul.

After the innerwing was done, it was time to start with the Porsche front beam.

Porsche sheetmetal underneed the spare wheel well
(http://www.keversite.nl/fotoalbum/fotos/122028.jpg)

When the car is finished it should not have rake. Now it has a 3,6deg rake, this is why the arm has to be 3,6deg. as well.
(http://www.keversite.nl/fotoalbum/fotos/122027.jpg)

Bend and shaped 3mm steel tacked in.
(http://www.keversite.nl/fotoalbum/fotos/122025.jpg)

The innerwing has to come out a bid to reinforce the a-arm mounting point.
(http://www.keversite.nl/fotoalbum/fotos/122026.jpg)

Paul.

Why the 3 mm plate? Are you welding the bracket to it or are you going to make it a bolt on affair?

Michael

The Porsche bracket Will be welded to this plate and The roll-cage will be welded on The other Side.

The sheet metal you are working with here will take a huge amount of weight/force during heavy braking. I guess the torsion bar mounts to the chassis in the other end.
I would suggest to either box a structure all the way to the front firewall or even tie in the cage down there.  As the weakest point would be in the body between the notch for the stock beam and the tank hole. Please keep sharing this cool project!

Hi JHU,

The sheet metal is just the piece you see in the picture, there now is a piece on the right in the spare wheel well and when I am finished it has one on the left as well. I don't see how these small pieces will give problems during braking. When the new engine is ready, I will probably need more weight in the front ;)
The cage will also be welded to the new sheet metal you see in the spare wheel well. This is a '56 beetle, it has no tank hole ;D


I will, thanks

JHU, Here's the other end of the A-arm mount. this picture was taken way waaay back ;D
http://cal-look.no/lounge/index.php?action=dlattach;topic=7217.0;attach=33163

As I told earlyer, I had to widen the innerwing a bit, so I had to try it with cardboard first.
(http://www.keversite.nl/fotoalbum/fotos/122088.jpg)

When the cardboard fitted, I made it out of sheetmetal and welded it in.
(http://www.keversite.nl/fotoalbum/fotos/122091.jpg)
(http://www.keversite.nl/fotoalbum/fotos/122092.jpg)

Then I tack welded the Porsche bracket in place. I just had to try the shockabsorber.
(http://www.keversite.nl/fotoalbum/fotos/122095.jpg)
(http://www.keversite.nl/fotoalbum/fotos/122094.jpg)
(http://www.keversite.nl/fotoalbum/fotos/122096.jpg)

Paul.

I am guessing that you will tie the upper strut mounting to the roll cage also?
Nice work . . . glad to see your progress!

You guessed Wright, the plan is to mount the upper too the cage as well. The original Porsche upper mounts will be welded in the inner wings and attached to the roll cage. ;)

Looks like you're coming to the end of the main fab work now though ;D
Is it mostly finishing off type jobs now before starting body prep?
Cheers
Kev

Still a long way to go Kev. but where getting closer. 8)

there's a hole in the innerwing ;D. I am going for 6-7deg.caster, -1camber and 0 toe in/out.
(http://www.keversite.nl/fotoalbum/fotos/122136.jpg)
(http://www.keversite.nl/fotoalbum/fotos/122134.jpg)

Inside of the innerwing, not much space there.
(http://www.keversite.nl/fotoalbum/fotos/122135.jpg)

And ofcourse I needed to test a wheel.
(http://www.keversite.nl/fotoalbum/fotos/122137.jpg)
(http://www.keversite.nl/fotoalbum/fotos/122138.jpg)

Paul.

Looks like you need to put a wing on it to see how it looks ;)

Michael

That is tempting indeed ;)

I'm loving this concept / project , almost make's me want to tear my 49 apart and start again .
Keep it up really looking forward to seeing the end result  8)

Thanks for the kind words but please don't tear yours apart, it's almost finished.

I am looking forward to the end result too.

Cheers Paul.

As am I, but I’m inspired in the craftsmanship you are displaying in the process!

Thanks for the compliment, stay tuned  ;D

Unfortunately I had to little space to move the spindle up n down. after some internet searching, I found out that the golf1 inserts will fit the Porsche strut and is 2" shorter. so I bought a used set to test fit.
(http://www.keversite.nl/fotoalbum/fotos/122216.jpg)
if it fits I can shorten the complete strut by 2".

Paul.

Are you driving it to Bug-in ;D ;D ;D

Michael