Nostalgia you win again!

[Jon]

Thanks Richie!

[Jon]

First I fiddled around with the new fender, and got it to fit the car much better.

Then it was time to get those nice weather sealing strips on the front again. An amazing amount on rust behind them, but now they are covered with more of that Volvo weld primer.
Let's hope they hold up another 40 years. First a nice coating of weld primer

In the end it came out ok

[BeetleBug]

Nice work Jon and it is indeed good to see that light blue color being used 

-BB-

[sonic]

Great work Jon , the effort you put in to preserve the -03 

Rgs

[Jon]

Thanks BB and Sonic!
Again a quick spread of Volvo weld primer:

A little gentle shaping of the piece and it was time to break out the spot welder.

Quite stock looking

With a quick primer it looks stock, but without the rust...

[Gwar72]

Thanks Gwar72  

Moving right along on the car, to get the best result I brought the car over to the local body shop and we used their state of the art spotwelder

Hi Jon,

Have you any pictures on how you peeled back the outer seam when you put in the new front quarter in?? I think I'm going to have to replace both of mine and thought that if I cut 1cm vertically forward in front along seam I wouldn't have to mess with peeling it back and reforming? (I hope that makes sense?) One panel had been used (spot welded on the lip, so don't want to use that bit) Cheers  



  

[Jon]

Hi Gwar72,
I started out cutting the rail just above the panel, so I didn't need to open all of it. First i pried it open with a sharp screwdriver in the bottom, and then I used a home made tool to bring the lip up to 90° from where it started. The tool is the end of a driveshaft with a grove in it that goes from a point in a smooth curve up to a flat shape.

And after the job is done I just tapped it back down again with light taps.  
    

[Jon]

Here are some pics from the process on the other side, first opening:

Cleaning

After sandblasting primering the lip was closed again

Done

[Gwar72]

Brill, Cheers 

Is the wing spot welded to lip as well or just pinned behind fold?

Cheers
Tim

[Jon]

Next I moved on to the "new" driver side fender. It had been treated to a sickening thick layer of spray filler. And under it all... rust!
Had a hard time removing it around the bucket, so I decided to pop it out.


Didn't regret that


Cleaning up



And I primered everything and welded it back in again

[Jon]

Brill, Cheers 

Is the wing spot welded to lip as well or just pinned behind fold?

Cheers
Tim

It's spot welded every 40 mill or so, you can see the stock welds in the second photo.
 
 

[Jon]

Then it was back on the doors, in 75 VW changed out the mounting system for the window lifts. I'm still going with one-piece windows so I need to be able to use the older mounting to be able to fit the double supported type from 68(?)

First I welded in a piece from a older door

Then I cleaned up a older bracket

And spot welded it in.

And then the doors were done.

[Gwar72]

Brill, Cheers 

Is the wing spot welded to lip as well or just pinned behind fold?

Cheers
Tim

It's spot welded every 40 mill or so, you can see the stock welds in the second photo.
 


Cheers Jon :-)
 

[Jon]

I started restoring another hood for the car. Had to fix the front part of the hood, and exercise my TIG welding skills... or lack there of.

And after welding

I had to remove the hood handle to, and while I generally liked my old solution I decided to reinforce the hood on the inside.

And then weld that to the hood

[Jon]

The final little part of changing the front quarter panel was to braze up the gap between the the new panel and the cowl like original.
I got my friend Atle to do the job as he is a highly skilled TIG welder.



Came out great in the end.

[Jon]

Had to repair the bumper mount, I had a professional fix it back when I was sixteen (didn't have the guts to do it myself)
He made a mess of it in my eyes.

There was nothing really wrong with the part, so I cut it of cleaned it up and welded back in the right way and in the right place.

In the end it came out ok and I got to try the new removable back apron.

  

[Jon]

One of the things I have been worrying about on this project is the roof gutter rust. I know it comes form the inside of the gutter but I have feared to go inside in the past.
But there needs to be a first time for everything.

Here we go

Under way, rust starts falling out from the gutter as it's opened

It's nasty in there!

Rust from start to end, ready to pop out when the paint is on  

Open, now it's time to clean

Half way thru sand blasting the snot out of it...

Then the light coat of primer it never received at the factory

Then a little inotech sealer to fill any potential gap once closed.

Then it was time to tap it right back

Time to clean up the inotech excess

After cleaning up



Came out very nice in the end, won't spend another minute thinking about this problem... except the time it's going to take med to do the other side. ;-)
 


 

[Steve67]

great work!
what tools did you use for opening and closing it, the result looks awesome

[Jon]

Thanks Steven! You see the tool I used to open with in post #186. I used a pen hammer and dolly to close it up.

[Jon]

Warning: this topic has not been posted in for at least 120 days.
Unless you're sure you want to reply, please consider starting a new topic.


 
Nah I think I stick with this one. It seems most of the pictures are gone too... great!
Well, the car is painted and it came out ok, considering I did the bodywork and prep myself.
I have been driving a little with the MOT 1600 cc engine, and that will hopefully change right after SCC.

Here are a few pictures with the "track shoes". [ Attachment: You are not allowed to view attachments ]
[ Attachment: You are not allowed to view attachments ]
[ Attachment: You are not allowed to view attachments ]

[nicolas]

one word: YES!

 

[Nico86]

Awesome car!!

[Jon]

Sooo... I have fixed all the broken links so the pictures are back for the time being. And due to a small engine fire I’m back in the paint booth. This gave me the opportunity to clean up and paint the engine bay. 

[ibg]

a beautiful car, what size wheels and tyres are you running?

[Jon]

Thanks! The wheels are 8” in the front and 9” in the rear. Tires are 195/50-15" and 225/50-15" in the rear. Stock fenders.

[richie]

#
 

And due to a small engine fire I’m back in the paint booth. This gave me the opportunity to clean up and paint the engine bay.

 

Wow Jon came out of hibernation  

I feel you pain on the engine fire, hope it wasn't to bad    


cheers Richie