Jump to content

1963 VW Beetle:Ragtop Resto.


63Ragtop

Recommended Posts

been bustin my ass on this thing this last week, sleep when you're dead bitches!

004_zps5b8f1d32.jpg

005_zps2bee69b0.jpg

I think I blew a hole in every single one of these, I think when I drilled the spot welds out all that time ago, I had drilled though about half the bottom layer as well, making the metal very thin, very well stuck together now.

004_zps3384031d.jpg

the frankenfender is taking shape

006_zpsfe4f31b2.jpg

this is the difference between the two fenders.

001_zpse439d966.jpg

this is me trying to hold things together, in the correct place.

006_zps3d91874f.jpg

it's alive! it's alive! might just pull this off icon_eek.gif 

go everything ground down on sunday, gave the fender some hammering, starting to look good.

chur

  • Like 3
Link to comment
Share on other sites

  • 1 month later...
  • Replies 254
  • Created
  • Last Reply

Top Posters In This Topic

Top Posters In This Topic

So I scanned some old pics of the rag the other day, the first 2 where just after I first got it.
The front was wound right up, with very old zx whereveryoucallem michelins,fucked shocks, stock seats(drivers side also shagged) nasty old 1200cc something something, one windscreen wiper icon_lol.gif 

2871d18a-78a8-477a-8f5d-aaf90ff49225_zps

But it was shiney, red and had mags!

24f22232-d97f-4119-a9c0-0b926c862154_zps

and this is the new engine being installed by my brother and myself at the VW shoppe in Hamilton.

342b8ef9-3d43-4668-9d20-3d1977a79248_zps

8514b563-b35b-4990-9eb6-22c71ae0c8f1_zps

  • Like 4
Link to comment
Share on other sites

got the fender looking like a fender

 

010_zps6e797162.jpg

 

needs a good smashing with the hammers and dollys

 

008_zps43018cd4.jpg

 

lit this so you can see the wonkyness, i have since spent some time time hammering it, and it looks much better.

( no pic of that yet)

 

009_zps5aeddd9b.jpg

 

happy with the overall shape

 

002_zps48b29c01.jpg

 

also plugged up some rust pin holes, thought this might be better than patching, dunno now? still lots of work/fuckingabout.

  • Like 1
Link to comment
Share on other sites

bit more of a update, 

 

015_zps1ed35679.jpg

patched the last two holes in the left rear fender bolting on side of car area thing(?)

014_zpsc25fb72e.jpg

so except of the huge holes at the very bottom, those are sorted. icon_redface.gif icon_rolleyes.gif icon_lol.gif

Also did this the other night to check everything was where it should be, all seemed to work okay.


002_zpsec60d759.jpg

the main reason was to check the bonnet release tube was working/in the right place etc.

005_zps3c39920c.jpg

so I could weld thing back together, seemed to crack at some point.

006_zps0f04b2f8.jpg

welded

007_zpsf69c5bd5.jpg

while I was at it I mocked the rest of the front up, had to adjust the bumper mount holes so the rubber seals would fit.

004_zps6307f87a.jpg

005_zps4dc86b03.jpg

looks like a car!

0f1fc324-6280-4832-b57a-089a3037e6ab_zps

nearly made it out the shed.

001_zps571cbd0b.jpg

 

I've pulled it all apart again, took about 5mins, and nearly finished welding the valance back on.

 

more news at 11!

 

talk here - //oldschool.co.nz/index.php?/topic/33947-63ragtops-63ragtop/page-2

  • Like 3
Link to comment
Share on other sites

  • 4 weeks later...

Still chopping guys!
Had a bit of a break on the bug, had to do housework/lawns/go away for the weekend and the kids where kind enough to give me both of their colds one after the next icon_confused.gif ah well.
Right where was I?

Spent a little time hammering the weld on the fender, bloody happy as, will need feck all bog!

003_zps5a76c3df.jpg

kinda hard to show, so just take my word it's awesome. icon_lol.gif 

005_zps3096fd1a.jpg

better than massive rust holes!

Got the valance all welded up

001_zps76d43def.jpg

002_zpsa6c7fb3e.jpg

003_zps8e7f4f63.jpg

just look at all those holes! not going to show the welding here, welding upsidedown sucks, looked like little metal stalactites, took ages laying on my back grinding that shit down!

001_zpsb74978fe.jpg

002_zps93ac5030.jpg

003_zps28f6ef2a.jpg

005_zps27c81e37.jpg

001_zpsff45ecc3.jpg

Started on the drivers side fender

003_zps9e099265.jpg

opened it up to fit the oval fender like the other side.

005_zps164a7b29.jpg

weldy weldy

001_zpsd4e983f6.jpg

And then I broke the welder! well sort of. I got the wire stuck in the torch, really stuck, Turns out the liner is worn out and it needs a couple other things sorted, should have it sorted soon.

So onto the next thing!

006_zps3c000585.jpg

icon_eek.gif

  • Like 3
Link to comment
Share on other sites

  • 3 weeks later...

Right, re-learnt how to use the MIG, turns out it was missing all sorts of things a welder should have to make it actually work, so much better now. some of the welding I did on the driver side fender is a bit shit because of this.

IMG_0256_zps9f90c74b.jpg

several pinholes still, so I'll have to go over it again. It's a real bitch cuz the more you weld and grind the thinner the metal can get making welding harder, which leads to more blow outs and more pinholes icon_evil.gif 

The front patch has came up well though, the doner needed some work. has had a hard life.


007_zpsacad7834.jpg

welded it all back together

IMG_0222_zps91cd2263.jpg

and stuck it here

IMG_0241_zps9e7b6ef7.jpg

tacked

IMG_0242_zpsf8857a45.jpg

more tacks

IMG_0245_zpsfbe1a1b1.jpg

and after more tacking I ground it down on the weekend and hammered it flat.

IMG_0254_zps1877cdbb.jpg

both fenders looking good

IMG_0244_zpsa5a11c84.jpg

heres a better shot of the other side, after it's beating. Shouldn't need too much bog.

IMG_0250_zps9c419dca.jpg

While I've been working on the front fenders, I've also been thinking about the rear fenders. The left one I had is a awful pattern panel that was about an inch to long where it matches the valance, was a stupid shape and the tail light (both actually) were on a angle. So I got this lovely old thing off the veedub shoppe in hamilton, Solid OG fender, Me happy.

IMG_0234_zpsfce45863.jpg

someone had painted over the factory paint with this lovely BLUE!
Just two cracks in the bottom edge, which should weld up sweet.


IMG_0229_zps7abb4c7a.jpg

i though this was cool, check out the tracks.
only problem now is it makes my other good fender look shittyicon_rolleyes.gif icon_lol.gif

Also found this while looking at my pan


IMG_0216_zpsa5cdb2ed.jpg

wonder if that's why the electic's sucked on this thing?

okay, time to build a spit.

  • Like 2
Link to comment
Share on other sites

  • 4 weeks later...
  • 3 weeks later...

Well this thing is useful!

IMG_0375_zpsca3d6a4a.jpg

after moving everything around I can even fit the honda inside, It was out in the pissing rain and I felt sorry for the old thing, had it for ten years now, so reliable.

IMG_0393_zps646d9e70.jpg

broke out the wire wheel to see whats what.

IMG_0348_zps0744e15a.jpg

IMG_0351_zps7738d6a3.jpg

IMG_0344_zps3e1db2be.jpg

IMG_0382_zpsa910e009.jpg

rust is what it is!
rusted from the inside out.

this is what's left of the heater fitting that takes the heat up to the windscreen

IMG_0381_zps8eea82cd.jpg

cut the bottom of the quarter panels off

IMG_0383_zps17d69473.jpg

a bit of dirt and crap, mainly just surface rust.

IMG_0385_zps20da0c66.jpg

I'll make a new panel up to replace this

IMG_0387_zpsae4131c9.jpg

most of these holes are old rust from before the shell was dipped, so all these areas you can't reach with a spray gun where bare steel.

IMG_0386_zpse865082e.jpg

luck for me everything was caked in fish oil, so is pretty solid.

IMG_0391_zps9f4ff6d2.jpg

I scrapped some of it off, it's like wax, but it has done it's job well.
 

  • Like 1
Link to comment
Share on other sites

I cut a bit more of the quarter panel off, should have done it this way to start with.

001_zps8c243954.jpg

so i could unravel the many layers of steel that vw stuck in here.

002_zps0e3571d9.jpg

much like the rear body mounts, I didn't really want to do this, but am now glad I did.

003_zps5b086a67.jpg

004_zpsc966c680.jpg

krusty rusty stuff

gave it a quick going over with the wire wheel

005_zps86b037a9.jpg

006_zpscfa0481a.jpg

first real good look inside the channel

007_zps550e1294.jpg

this is the state of the metal on the inside of that part i cut out

005_zps29638ecb.jpg

and now for the rest of the bottom plate.

Link to comment
Share on other sites

Sorry about the boat loads of pictures, got a bit carried away with it!
This must be the trickiest area to fix, I took HEAPS of photos so hopefully I can put everything back in the right place.
Carrying on from the last post, spotwelds! what fun! meters and meters of fun, stuck together every 10=5mm apart. holy shit thats alot of spotwelds!
These ones where not so bad, this is the outside edge of the channel, where the running board attaches.


002_zps536f3527.jpg

the inside edge however!

004_zpscd5eb6bc.jpg

was a fucking bastard of a thing, I don't think there was enough room to get the spotwelder in like the other side, it was really stuck.

003_zps85366d58.jpg

and some where invisible, and then someone had double tapped these ones.

Like I said such fun! The trick I found that worked good for me, was to drink quite heavily while doing this mind numbing work and listen to very loud heavy metal or punk, Motorhead, bad religon etc...
And before you know it the week is finished and victory is yours!

002_zpsa59f3eb1.jpg

004_zps7fb5f917.jpg

this is going to take some thunking.

007_zps17a5effa.jpg

another double layer for strength/rust. There was also a scoop that attaches to the hole, it pretty much fell out.

008_zpsf3d98c88.jpg

rear end of the channel,

Ones I've seen overseas/online have a second pipe running inside the sill, you will notice the lack of any kind of heater pipe inside this channel, wonder if this an aussie car thing?

009_zpsab487402.jpg

trimmed abit more from the front wheelwell to get a better look, hmmmmmmm.

I think I'll start at the back and work forwards, give myself some time to think what to do next, any help would be greatly appreciated, I have no idea right now/suss it as I go.

 

Any sane person would replace the whole thing, but to be honest that scares the crap outta me!

  • Like 3
Link to comment
Share on other sites

  • 2 weeks later...

Got some more done last week.

001_zps65d6b956.jpg

chopped the last of the rusty areas out and then sandblasted everything.

001_zpsf86c675b.jpg

got this blasted across the road, saving me about a days work, hopefully I can repair it.

002_zpsa8fdfbeb.jpg

did this one night, once it was in I realised it was not quite right, I had made the corner a right angle, but it's more acute that on the inside of the channel, nothing a grinder and a welder can't fix though.

001_zpsaecd2a13.jpg

this little piece took me about 3 hours of my life.

003_zps356fddfa.jpg

seems to fit good

004_zpsa11aecf4.jpg

I even made the little dent detail ( geek!) using a chunk of metal I had left over from building the spit, which I filed a groove in and smashed with a hammer.

002_zpsa442e3d3.jpg

ground it all down yesterday and fixed the inside edge. I like to grind the inside as well, not because you can see it, but I hope a smooth finish gives rust less places to get a foot hold.

010_zpse7d4714f.jpg

just like a fucking new one!

009_zps906339f4.jpg

there where also a couple small rust holes on the top edge of the outside face that i was able to fill with just weld.
Hopefully I remember to weld in a new nut for the running board before I close everything up.

  • Like 8
Link to comment
Share on other sites

  • 2 weeks later...

Another week, another patch.

005_zps1c94f560.jpg

or two. A couple 5cm sections all fixed up.

002_zps777a1f0a.jpg

made this to close the end of the channel

0041_zpsec6d3796.jpg

slots in here.

007_zps189f4397.jpg

welded

006_zps878e991f.jpg

grinered

004_zps34856674.jpg

this was a pig to smooth out, the grinder wouldn't fit, so was done with the dremmel, a less than perfect finish, but no rust any more is the main thing!
I needed another panel hammed to do some of the above work, I had a pointy one, a domed one, but I needed a flat pointy one, like a pick shape(very technically I know) took a wee trip down to the second hand tools shops in beautiful Henderson, I love rummaging around these tiny old shops that are packed to the roof with shit, Dude wanted $39 for the old hammed with a lose head, then I spotted this panel slapper file thing, which should be useful in the near future, He wanted 30 something for that, ended up getting both for $45, I'm sure he still made on the deal, gotta love the barter system!

001_zpsb2008a67.jpg

I cut a wedge of steel and hammered it into the top of the handle so the head is nice and tight good as new.
I like old tools.

  • Like 2
Link to comment
Share on other sites

Another tiny update guys, don't mean to sound like a wanker, but I'm pretty flippin pleased with this wee thing!

remember this?

001_zpsf86c675b.jpg

even though I had it sandblasted so all the rust was gone, this left the metal pretty thin in places. And as this is a strengthening panel I thought it best to put it right.
So I cut it back to were it was solid and had a go at metal origami.

001_zpsd24f4612.jpg

test fitting the rear fender so I get the stud in the right spot, also checking the quarter panel would fit back on top of it, so many layers of metal in this bloody spot.

011_zps4f6fd501.jpg

like so

013_zps69035f36.jpg

and welding it together, there is also a wee patch at the top, were it was damaged when I removed(ripped) it.

005_zps8a0d79e0.jpg

tidied up

001_zpsd65af07d.jpg

very happy with the fit, took alot of bending and hammering to get this back were it should, I made a bit of a mess of the shape when I pulled it off.

003_zpsd7b79307.jpg

yeah icon_cool.gif 

007_zpsd0f5dec9.jpg

the stud I used is just a old bolt I welded to the back of the panel and then ground the head down as it was to big.

hope you like?

  • Like 6
Link to comment
Share on other sites

  • 1 month later...

So another bite of the ellefant.

IMG_0590_zpsad2c00fc.jpg

welded the outer panel back in place and smoothed it all out.

IMG_0626_zps6acccac7.jpg

I think I might leave the quarter panel off till I've finished with the sandblasting, so much crap gets down the inside of the panel and once it's closed up I'll never get it out, maybe, I'll get bored one night and start welding it up knowing me.

  • Like 1
Link to comment
Share on other sites

So i made this thing, which is the end of the channel its self.

IMG_0581_zps143f4baa.jpg

goes here

IMG_0580_zps54bf2bb1.jpg

that took a lot of work to get right, pretty happy with it.
After chopping a bit more rust and badly pitted metal out of the very bottom of the firewall, I sandblasted and primed.

IMG_0611_zpsf03d9644.jpg

made another patch to replace the bottom of the firewall

IMG_0615_zps1d0c0b9f.jpg

hot glue gunned it in here.

IMG_0619_zps1c186c6e.jpg

IMG_0624_zpse1fe4960.jpg

had to make that tiny patch on the flange thing

welded up the pie cuts I made to shape the metal

IMG_0642_zpsa36f694a.jpg

and smoothed that out

IMG_0643_zps258e56e3.jpg

and finally welded it back in

IMG_0649_zps6522c7da.jpg

just tacked in here

IMG_0652_zpsdad405de.jpg

the inside view, welded together and to the firewall.

IMG_0655_zps7c7e4388.jpg

Now. The more perceptive of you will have noticed in that last pic that the channel seems to be missing some metal.

IMG_0562_zps08530733.jpg

well thats coz i chopped it off.

IMG_0585_zps339e5591.jpg

yes yes, I should have just bought new channels icon_rolleyes.gif icon_lol.gif 

IMG_0674_zps112a5a79.jpg

IMG_0675_zpsdfdd1821.jpg

ah well, in for a penny, in for a pound, or some such rubbish!

I still have to finish welding it all up, but its looking like I might pull this shit off!

IMG_0665_zps33f5db64.jpg

this me checking the bottom plate still fits.

IMG_0667_zps19f80098.jpg

these bottom plates are actually pretty good, the pressing are not exactly the same as the old stuff, but the main thing it that the bolt holes are in the right place and line up with the pan perfectly, I will fill in the big drain holes that are in them, and they will need a wee bit of trimming but thats okay.
Next up will be the A pillar and the rusted channel that it joins to, so with that in mind, I made this.

IMG_0629_zps50e6b179.jpg

  • Like 3
Link to comment
Share on other sites

  • 4 weeks later...

Did some more stuff.

IMG_0706_zpsf71ac126.jpg

IMG_0710_zps4d9f280f.jpg

IMG_0708_zpsda23eb6e.jpg

was in a bit of a rush when i chopped this out, used a thicker cutting disc than the usual 1mm one, so now I have a whacking great gap to fill, as I'm going to try and repair this mess. I had a look at the cheap repair panels that you can get for the A pillar, they were terrible. And as I'm to tight to spring for the good ones I'll give it a go at fixing the old one.

Then I cut some more!

IMG_0717_zps30651a86.jpg

I thought long and hard about the best way to go about this, as this bit was ok, but this bit was fucked, anyway seemed to make sense at the time. icon_rolleyes.gif icon_razz.gif

This is the inner rust trap, part #12679666 icon_evil.gif 

IMG_0724_zps5a17d609.jpg

what was left of the sill

IMG_0723_zpsa52c2401.jpg

like i said "fucked'

IMG_0733_zpsc963781a.jpg

replacement makering

IMG_0736_zpsa80c7743.jpg

IMG_0737_zpsdf20c9e2.jpg

this lot of metal I got, does not have the zinc coating like the other stuff, at first I thought, sweet now i don't have to sand/wire brush all that stuff off but man, as soon as you touch it it starts rusting!

IMG_0743_zpsc50260d9.jpg

so i had to sand it all down anyway.

IMG_0755_zps5e15e4a0.jpg

still a little unfinished as I need to close that wee hole once I make the heater pipe hole, and then i guess i should make a new rust trap?

IMG_0757_zpscf7c012f.jpg

I also sandblasted the inside and outside, managed to get the thread plate thing that the door bolt to, out without breaking the strap the holds it in, icon_biggrin.gif . But then I forgot to sandblast said bolt plate thing icon_mad.gif
oh and i repaired the inner A pillar, just the corner was rusted out, did the whole thing, fab,weld,grind, paint, in record time, before the kids movie finished!

  • Like 4
Link to comment
Share on other sites

  • 2 weeks later...

 Not been able to do much work the last week or so, between writing off family cars and working long hours plus the whole family having the pox, this is all I managed last week.

IMG_0758_zps5d162a99.jpg

I'll hopefully start welding the main patch in soon, after I suss the heater pipe thing out.

chur.

  • Like 3
Link to comment
Share on other sites

  • 4 weeks later...
  • 1 month later...

Well here we are, the start of another year and my car is still not anywhere near being finished icon_mad.gif 

Must keep pushing!

This Fab work does eat up the time loVol, I just want to do the best job I can, and I can't afford top shelf parts, so it's hammer time!

Didn't really get much done over the holidays, so hot in the shed, swimming is better.
I did wire wheeled/blasted these parts up.

IMG_0798_zps9b83e41d.jpg

don't think I will be able to save the hinge cover though, just to tricky with my limited skills and tools.

Also wirewheeled my arm icon_eek.gif icon_redface.gif 

IMG_0797_zps6e689ff1.jpg

Glued the scoop to the new inner panel thing(there is a hole on the other side icon_wink.gif )

IMG_0817_zps6106aa7a.jpg

and welded it in here.

IMG_0813_zps4bc3edbf.jpg

I hoping to get the heat working when she back on the road.

I have been spending a lot of time messing around with bottom plate, I think the best thing is to finish all the other repairs to the channels on both sides, then test fit the shell to the pan before welding the bottom plates on for good.
I don't know, I've never don this before!
The plates seem to fit the pan perfect, but when I stick them on the shell they seem 5-10mm short?
So a test fit seems prudent.

I had to dig the pan out to get to all the camping stuff for the hoilday so I took a couple snaps.

IMG_0793_zps441be3f8.jpg

A little pitting, but so solid icon_biggrin.gif 

IMG_0796_zps59263150.jpg

So that's it for now, I've been working on the patches for the front and rear quarters this week, but can't actually weld anything yet until the A pillar in back in place and I can fit the door, so till then i'll keep hammering.

  • Like 3
Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

×
×
  • Create New...