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 Che Castro
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| posted on December 8th, 2004 at 10:41 PM |
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mainly the front area under the pillar is rooted
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Jon
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Che Castro
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| posted on December 8th, 2004 at 10:42 PM |
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not so bad in the middle section
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Jon
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Che Castro
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| posted on December 8th, 2004 at 10:43 PM |
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at the back its rusted out. god i hate previous owners!! grrrr
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Jon
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Che Castro
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| posted on December 8th, 2004 at 10:45 PM |
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I was trying to decide whether it was worth ripping out the dodgy repair. I'm glad I did, The original heater channel floor was cut out and here it
is. Pretty much rusted and brittle throughout the entire length
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Jon
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Che Castro
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| posted on December 8th, 2004 at 10:46 PM |
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looks like i'm up for a heater channel fix up
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Jon
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Che Castro
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| posted on December 8th, 2004 at 10:47 PM |
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The upper 3 inches of the heater channel is solid and only needed a wirebrush to get it clean on the inside, the lower inch of the heater channel
sides is pitted and crap so I made some repair sections for the inner side.
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Jon
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Che Castro
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| posted on December 8th, 2004 at 10:50 PM |
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now for some pretty stuff...
got some new wheels. these are OE Porsche 17" x 7 996/Boxter rims. Even got the Porsche boxes as well 
p.s. Those phonedials will probably be up for sale once I sort out these wheels
[Edited on 8-12-2004 by Che Castro]
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Jon
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Che Castro
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| posted on December 8th, 2004 at 10:51 PM |
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seeing as I have been bugging myself to get a welder and that I have rust repair to do I bought myself a MIG and the first thing I made was a trolley
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Jon
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Che Castro
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| posted on December 8th, 2004 at 10:53 PM |
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another thing on the side is a decklid I've been working on. Im going to be grafting in some vents from a 1500 decklid to make it look like an OE
Convertible decklid.
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Jon
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Che Castro
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| posted on December 8th, 2004 at 10:56 PM |
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The base of the decklid has a few holes in it. Personally I think the drainage detail at the base of the early decklids is an absolute rust trap!
Crap design. The late ones rarely rust out here. I hand beat some repair sections which will be grafted on at some stage. Started as a flat steel
sheet and beat it out on a block, then slowly beat it and flattened it into shape all the whilst checking the fit from templates I took. Man this is
time consuming! And my arm got very sore from beating it hours on end.
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Jon
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Chewy
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| posted on December 8th, 2004 at 11:01 PM |
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Good work dude!
Whats the course you're doing at tafe?? I just finnished a Cert II in automotive but thats next to useless for bodywork, so I think I'm gonna go
back and do a night course in panel beating..
Keep up the good work.
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Che Castro
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| posted on December 8th, 2004 at 11:31 PM |
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the course I'm doing is "Car Restoration" at St George TAFE. Its 3 hrs a week on monday nights. Basically u come in with your panels and you ask
the tutors how to fix 'em and they show you. Great thing is that the TAFE has sheet metal folders, rollers, spot welders, TIG, swaging machines.
Everything you need to fabricate panels. Its about $200 for 9 weeks worth of lessons and you can do it as many times as you want. Ive done it twice
already.
Jon
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Che Castro
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| posted on January 8th, 2005 at 05:43 PM |
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The brake fluid and washer recess was a bit rusty on the underside and had a few holes messily punched in the place so i decided I would replace it.
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Jon
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Che Castro
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| posted on January 8th, 2005 at 05:46 PM |
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after gathering some advice about doing the A pillar and screwing up the door alignment, I decided I would go ahead with it and brace up the section
by welding members across the A and B pillar...
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Jon
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Che Castro
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| posted on January 8th, 2005 at 05:47 PM |
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and from LHS A-pillar to the RHS A-pillar. Probably didnt need this one but didnt want to risk having a door that wouldnt shut properly!
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Jon
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Che Castro
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| posted on January 8th, 2005 at 05:49 PM |
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The replacement A Pillar sections only have 3 holes for the hinge where pre 61 models had 4 screws that fixed each hinge to the body
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Jon
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Che Castro
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| posted on January 8th, 2005 at 05:54 PM |
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so I basically pulled it apart and drilled another hole in the outside skin where the fourth hole should be, beat it into a spark plug socket with the
rounded end of a broom handle :P to make it curve inwards slightly to match the other holes.
This was a Danish Steel replacement, the steel was soft and very easy to bend... A bit too easy. I guess its better than rusty steel though :blush
here it is fitted up over the existing A Pillar. Excuse the crappy welds on the cross members. Still trying to get the hang of the MIG doing
Vertical fillets :P
[Edited on 8-1-2005 by Che Castro]
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Jon
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Che Castro
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| posted on January 8th, 2005 at 06:00 PM |
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I was originally planning on just replaceing the heater channel floor. and the more and more I got through the A pillar and other parts, I just
decided I would jump into the deep end and do the whole heater channel :blush
Managed to get one for $80 from a friend (they are usually about $270 cheapest) the only problem being that it was a Late model one and had the heater
outlet between the A and B Pillars. Here's a pic of it. Kind of difficult to understand as you cant see all of it, but near the drill is where the
heater outlet is. The front of it is to the right of the photo. Had to drill out the spotwelds holding the carpet clip bit too as it was late style
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Jon
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VDUBXTC
A.k.a.: Jace
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| posted on January 8th, 2005 at 06:03 PM |
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Looks like your at the same stage as us with the oval. 
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Che Castro
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| posted on January 8th, 2005 at 06:04 PM |
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nothing a day and a night of cutting welding and breathing burning paint fumes can fix! 
Had to cut off the late outlet and graft a flat piece over it. Also got the dremel out and cut out the early style heater outlet from scratch  was a lot easier than I thought it would be! It's not exactly the same as
the RHS vent, as the forward 3 louvres on the vent have a slight curve to them... but dont tell anyone!
Sprayed the inside and poured Rust kill paint inside so it ran into the flanges on the sides. Should keep rust at bay for a while to come *fingers
crossed*
[Edited on 8-1-2005 by Che Castro]
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VDUBXTC
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| posted on January 8th, 2005 at 06:07 PM |
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Also, mick motors sells the heater chanels for $120 delivered.
But they have no vents at all
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Che Castro
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| posted on January 8th, 2005 at 06:07 PM |
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made an outside A pillar section and the front wheel well panel bit as well. Excuse the crappy fabrication as I dont have an anvil or a dolly or
even a proper panelbeating hammer! Really need to get one...
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Che Castro
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| posted on January 8th, 2005 at 06:09 PM |
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after an afternoon of drilling out spotwelds and breaking them with a chisel I managed to rip out the rear section of the heater channel
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Jon
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Che Castro
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| posted on January 8th, 2005 at 06:15 PM |
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Before I cut out the rear heater channel bit I also triangulated the other members so the B-pillar wouldnt move around without the heater channel. I
also welded some strap to member above the heater channel and bolted it through where the running boards usually mount. This is so I could just bolt
in the replacement to get the alignment right and hold it in place to weld it.
[Edited on 8-1-2005 by Che Castro]
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Che Castro
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| posted on January 8th, 2005 at 06:20 PM |
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heater channel there one day...
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Che Castro
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| posted on January 8th, 2005 at 06:22 PM |
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gone the next! muhahaha... to be continuted.
p.s quickly bolted up the replacement one and it fitted like a glove
phew!
[Edited on 8-1-2005 by Che Castro]
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Che Castro
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| posted on January 8th, 2005 at 06:27 PM |
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hehe manx. Its not too much more to go *fingers crossed* Pan is waiting to be mated with the body...
I was considering doing a quick ish respray though. All the panels are dead straight, just that the paint job was done poorly, a few runs that make
ripples (isnt black paint great for spotting these things ) bit too
orange peely in some areas for my liking.
haha I had a look at the first post I made. and I called it a mini project I thought I would have it finished and running by december with a few thousand $$$ when i first got it.
Hehe... love how projects almost always blow out
[Edited on 8-1-2005 by Che Castro]
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VDUBXTC
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| posted on January 8th, 2005 at 06:32 PM |
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Shit now i am starting to wonder if we will have the pacience for this type of job.
You don't want to do another one do ya?
[Edited on 13-1-2005 by manx_xtc]
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Che Castro
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| posted on January 8th, 2005 at 06:52 PM |
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hehehe its not as I hard as I thought it might be. Although its not exactly the most fun work! Although ripping out the whole heater channel was
very satisfying. I was thinking "eat that rusty scumbag!"
forgot to post the pic of the old A pillar bit and the old heater channel. Very glad I decided to rip it out. The previous repair just lapped some
very thin steel (0.7mm) over the existing rust hole and bogged over it
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Jeza
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| posted on January 13th, 2005 at 12:37 PM |
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Jon
I am truly impressed, this really is excellent work and a fantastic photo diary to boot!
I think I'll send some of the NZ guys this way to check out the heater channel replacement- many are busy looking for a better shell... and that just
ain't gonna happen with the years they've got (early 70's, thin steel VW's)
What are you gooing to power it with?
Cheers
Jeremy
......random gibberish for today.......
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