Tuesday 25 October 2016

Quickie: First welds on the shell

After the epic progress of the last post, the pace has slowed slightly in the garage. Whilst the paint cures on the chassis and it is too cold and damp now to paint the associated ancillaries, I have turned my attention to sorting out the shell. However, my approach to this is going to be crucial to the ultimate success of the restoration. I have been researching the best strategy based on the experience of others and have been drafting a workflow diagram in an attempt to get my repairs in a logic order. I'd be lying if I said that it wasn't a daunting prospect of this phase of the project. Intimidated, but excited!

To ease myself back into the swing of things I started by making some very minor cosmetic repairs to the dash section. Thankfully the shell uses largely the same gauge steel throughout so this gave me the opportunity to fine-tune the settings on the welder, which will be a good starting point for everything that follows. As you can see, at the bottom of the aperture for the radio blanking plate there were two holes that had been drilled by the PO, presumably to accommodate additional switches; 



Repairing this was a simple case of cutting a small circles of steel to sit within the holes. Here is one of my tiny patches clamped into position;



I then welded all the way around. It is important to note that I added just one spot at a time and let the steel cool down completely before adding the next. This was to mitigate heat build up that could lead to warpage;



Carefully ground down and linished to form an invisible repair;



Once the other side received the same treatment I sprayed some primer over the area to give a little protection. As they say around these parts "Jobs a good'n!"


6 comments:

  1. Impressed as always. Your experience level must be improving by leaps and bounds! Keep it up. Love your blog, I am almost ready to start on my 73 standard bug and I am sure I will reference this blog many times. Thank you!

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    1. Good to hear that this blog is becoming a useful resource to my fellow VW enthusiasts :-) The experience I have accumulated so far has certainly had a big impact on my confidence level. This mammoth project actually feels achievable to me at last. Best of luck with your '73.

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  2. Keep on keepin' on. I don't comment much but always check in. Our progress is kind of moving in parallel as we started around the same time. Your task is alot more challenging as my Bug was a largely rust free California car. Also, your skills have grown quiet a bit.
    Chris in California

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    1. Always good to hear from you Chris! You have been with me for quite some time now on this journey :-) How is the '69 coming on? Do you happen to have a build thread online that I could check out?

      Yeah, I guess I am more comfortable with what I am doing now in general, particularly with welding. I really enjoy the bodywork/fabrication process and I think this is showing in my results. I have spent a lot of time recently analysing my rotten shell and forming a mental strategy for tackling this phase of the project. Kinda working through potential problems in my mind and then sequencing the order of repairs around what I think is going to be the most straight forward approach. The best is yet to come (...I hope these are not famous last words!)

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  3. I am not brave enough to throw my restoration out to wolves just yet. I have documented every step with copious pictures and some short vids. Will post a build thread(how antiquated does that sound) onto the Samba. At that point I will be firmly at the helm of the Chariot with whip in hand.

    regards
    Chris

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    1. Haha, I completely understand your reticence! Although I am sure you are more in control of your resto than you give yourself credit for. When the time comes to launch a Samba thread, be sure to let me know! Better get cracking that whip :-D

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