| [ Total Views: 11415 | Total Replies: 193 | Thread Id: 83581 ] |
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 baghall
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Ben Hal Outlaw Bushranger
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| posted on September 20th, 2012 at 09:03 PM |
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and the beginingsof a repair.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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Smiley
A.k.a.: Daniel Stephens
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| posted on September 20th, 2012 at 10:14 PM |
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Wow dude!
No wonder you were having issues with the body cracking in that area. I'd say that the rust has weakened the body a little.
Smiley 
If you said I was a Volkswagen man, you'd be right.
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baghall
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Ben Hal Outlaw Bushranger
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| posted on September 20th, 2012 at 10:17 PM |
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Yeah I am a little scared of when I start cutting up further on the pillar.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on September 21st, 2012 at 10:33 PM |
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Finished the repair today.
First photo shows me using a vice clamp to press the folded edge for the gutter. Came out ok but need a bit of dressing up before painting.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on September 22nd, 2012 at 06:49 PM |
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Tentativley attacked some more rust today. Here is the saga in photos.
Photo 1 shows just how much filler was usedlast time it was repaired, even used fibreglass as filler with surface rust underneath.
Photo 2 and heres the rust.
Photo 3 rear wheel arch passenger side.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on September 22nd, 2012 at 06:54 PM |
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Photo 1 shows previous repair
Photo 2 even past repairs are rusting away
Photo 3 started gutting it all out
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on September 22nd, 2012 at 07:00 PM |
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Photo 1 cutting out rust continues.
Photo 2 and began repairing the rust again
My welding is getting better too.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on September 24th, 2012 at 04:56 PM |
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Well more rust repaired today, and I realised thatI only have 3 areas of rust left. Bottom of A pillar, down passenger side of rear window and next to
the heater inlets at rear. 'A' pillar will definitely be the worst to repair. Finally feel like I am getting somewhere. Tomorrow I'm having a day
off from repairing rust and going to begin work on preparing rear guards to make moulds off them.
Also realised electricity bill will be huge for this quarter with all the welding etc.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 1st, 2012 at 09:40 PM |
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Been working on Al again but have now burnt out a 5" and 4" grinder and a 18V drill. Bloody getting expensive this exercise.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 5th, 2012 at 11:49 PM |
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Well found a bit more rust at the begining of the week, but had enough of cutting and welding atm so decided to do some work on the rear guards,
spoiler & bonnet.
This set shows progress on the guards.
Photo 1 - gringing glass to prepare for glassing up holes. Need to grind so new glass can key to old material.
Photo 2 - 3 layers of glass were used so I could build a larger flange. Most of the holes are broken or cracked. Going to try to use a slightly larger
flange for mounting in the hope of stopping this happening.
Photo 3 - first layer of putty for shaping. In total I used 3 layers of putty finishing up with stop putty for the small pin holes etc.
These are going to be used as a plug to build some moulds. This way I can make as many as I brake 
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 5th, 2012 at 11:57 PM |
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While putty was drying I began working on positioning the whale tail Igot at Valla onto the rear spoiler. This is shown in photo 1. Stuck this down
temporarily using heavy duty putty.
Photo 2 is the second attempt at getting the whale tail fixed. First attempt was skewed approx 9 mm and looked crap.
Photo 3 shows the enlarged hole in the front bonnet for my fresh air duct.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 6th, 2012 at 12:14 AM |
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Photo 1 - shows the fresh air scoop for the cabin.
Photo 2- shows the rear whale tail now fixed down in the correct position
Photo 3 - Shows the guards ready for painting, however, they need the slots cut in for the planned recessed LED tail lights.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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Anthiron
A.k.a.: Nicko McKay
Compulsive Aussie Vee Dubber
The Baja Rejuvenation Begins
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| posted on October 6th, 2012 at 02:08 PM |
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Nice work on those rear guards! Coming together
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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Smiley
A.k.a.: Daniel Stephens
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| posted on October 6th, 2012 at 02:44 PM |
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Looking great!! Now can you make me some that are 3 inches wider? In carbon? Pretty please 
Smiley
If you said I was a Volkswagen man, you'd be right.
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 6th, 2012 at 06:33 PM |
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Thanks Anthiron, Smiley they aren't finished yet still gotta cut out for the custom lights and these are only the plugs. Planning to make moulds from
them in case I break them. Did cut oul holes for lights but still
got to make plugs and lay up than more putty and sanding. have to get these done so I can make the guards as the resin I will be using has a shelf and
will need to be thrown out soon. Problem is I gotta go back to work on monday.Work really does interfere with what you are doing sometimes.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 7th, 2012 at 02:23 PM |
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More work on guards yesterday
Photo 1 - mock up ready to mark out for lights
Photo 2 - lights cut out (there goes all the hard work)
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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Smiley
A.k.a.: Daniel Stephens
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| posted on October 7th, 2012 at 03:05 PM |
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I still need them widened too, about 3 inches should do it. Thanks! 
Smiley
If you said I was a Volkswagen man, you'd be right.
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 7th, 2012 at 07:09 PM |
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| Quote: | Originally
posted by Smiley
I still need them widened too, about 3 inches should do it. Thanks!
Smiley
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 14th, 2012 at 04:07 PM |
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Not a lot done during last week (back at work buggar it). However started glassing up for recessed lights this weekend.
Photo 1 - shows pugs glued in.
Photo 2 - shows start of glassing in plugs hopefully finish glassing them in on monday arvo.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 15th, 2012 at 07:35 PM |
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Well went round to collect and finish the glassing of the guards from a mates place and his wife had finished glassing the light sockets (& nicely
done). So I ust had to take them home and begin filling and sanding to final shape.
Photo 1 - completion of glassing
Photo 2 - Dog wanted a photo
Photo 3 - Putty started but shows the holes for the lights
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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Smiley
A.k.a.: Daniel Stephens
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| posted on October 15th, 2012 at 10:15 PM |
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Looking great! Keep it up.
Smiley
If you said I was a Volkswagen man, you'd be right.
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 15th, 2012 at 10:44 PM |
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Thanks Smiley but won't be some updates for a couple of weeks. Gonna take a little while to get shape completed & I got my folks 50th anniversary
this weekend. Mum wants me to bake the cake. SCAREY that one!
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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Bone
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| posted on October 16th, 2012 at 08:18 AM |
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If you can maintain a baja, you can make a cake ! Keep those photos coming of the rear guards coming as I'm keen to possibly copy your idea. (New
rear guards) Nice work mate.
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baghall
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Ben Hal Outlaw Bushranger
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| posted on October 17th, 2012 at 08:16 PM |
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Thanks Bones, don't mind you copying them but you gotta wait till I have been driving mine first!
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on March 29th, 2013 at 09:52 AM |
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Well it's now good friday so hopefully get some more work done on Al. Nothing done since last post as had a shit end to 2012 and shit start to 2013.
Mum diagnosed with cancer early November and passed away Australia day. Spent all of school break helping family nurse her, was difficult but well
worth it.
Anyway plan on working on light holes in guards over weekend as well as doing more work on the body have several rust areas to be done still, and will
work on them to have a break from working on the guards. I clearly have no patience for the filling and shaping in order to get 4 holes looking the
same! Have also bee working on the rear spoiler and will get that close to glassing up just need to sand the filler and shape it a little better.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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Craig Torrens
A.k.a.: Craig Torrens
Scirocco Rare
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| posted on March 29th, 2013 at 10:07 AM |
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Sorry to hear about your mum.
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baghall
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Ben Hal Outlaw Bushranger
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| posted on April 5th, 2013 at 06:07 PM |
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Thanks Craig.
Been doing bits on car after work but not got a lot done, too damn tired. Looking forward to weekend to get some work done and begin holidays in a
week so hope to get some work done then.
BTW don't know if I mentioned it but I dislike shaping, ready to make mould in fibreglass.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on July 8th, 2013 at 08:57 PM |
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Finally getting some work done Al again. Completed pulling down the floor pan and started work on it.
Pictures show preparation of rear forks for clearancing for CV joints of new gearbox.
1) Cleaning up for cutting and welding
2) Holes cut out
3) Holes ground to suit pipe sections for welding in. (bottom right dog wanted to get in the photo)
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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baghall
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Ben Hal Outlaw Bushranger
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| posted on July 8th, 2013 at 09:10 PM |
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this set of photos show
1) Pipe section welded in. Had to do this twice as MiG was not welding them properly and had to grind them back and reweld using stick welder. This
caused me to blow in some holes fortunately I have had lots of practice at this.
2) Painted for temporary protection
3) Oh, and this fits with room for CVs.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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OberonViking
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| posted on July 9th, 2013 at 06:35 AM |
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Good to see some progress (I should really get on with mine).
1970 Baja - waiting in the paddock for some TLC.
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