Back to the pan

So much of my time lately has been absorbed in researching, thinking and planning the next stages of the resto. However, I think it has been necessary for me to take a back step, reassess the priority areas and unblock some issues that were preventing me progressing. Ultimately I concluded that I needed to refocus my attention on the chassis and crack on with maximum vigor! Firstly, I had a brain dump and wrote out a check list (in no particular order) of all the odd jobs that need doing before the chassis would be ready for paint: 

I have now set myself up with a decent supply of Argon/C02 welding gas: 

  

With a new regulator fitted and plumbed into the MIG welder. It works like a dream:

The WW floor pan halves that I bought a while back were designed for a LHD car and I needed to consider how I would go about converting them to RHD and make it correct for for a '65 pedal assembly setup. Through my research it became apparent that there should be a small strengthening/reinforcement plate which supports the pedals. Some bugs appear to have this strengthening plate visible on the top side of the floor pan, but there was no trace of this when I dismantled the components from the old pan. Strange I thought... then I recalled cutting through what I thought was an old scabby repair patch last year and realised that it was actually the reinforcement plate (the layers of rusted crud were masking its true identity!). An intensive search on Google images and various VW forums confirmed that the plate sits underneath the pan on the '65 model. Luckily I have been retaining all the old scrap cut from the car to use for welding practice. This was this old chunk that I was looking for: 

I chiseled off all of the rust flakes and it all became obvious:

The plate itself is basic enough, so I will be making a new one out of 5mm flat bar. The long edge is basically seam welded to the point where the edge of the Naps hat and bottom plate meet. The short edge is seam welded to the lip of the chassis tunnel and there are also a series of spot welds that fasten the floor pan to the strengthening bar. The two (threaded) holes in the middle are for the mounting brackets, which sit on top of the pan – which is fortunate as it means that I will just needed to drill 2 holes in the new drivers side floor pan in order to adapt it to RHD.

The only minor problem was that I had not cut this piece of flush when I separated it from the tunnel. This obviously meant that the plate was now slightly shorter than it should be, but I did not know by how much exactly. After a thorough rummage through the scrapped pan offcuts I reconstructed the front edge of the old pan. I then clamped the plate to the old floor pan scrap being sure to line up the bolt holes: 

I then clamped the reconstructed mess to the chassis tunnel in its original position for assessment. This enabled me to ascertain how much of the original reinforcement plate had been trimmed off: 

and here is the view from the underside:

Turned out that the plate was between 8-9mm short:

Armed with this new knowledge I created a reference drawing to act as a pattern (see the red outline) for when I make the replica part. I probably spent far too long producing this in Photoshop, but if it's worth doing then it is worth doing right:

News from the garage

My apologies for the small break in blog posts lately, I have been doing many little odd jobs in the garage and thought it would be most efficient to deliver a round-up post when I had enough news. So, here is a brief overview of the past month of activity....

My glamorous assistant has been dropping by occasionally to continue stripping the shell. Starting to make some real headway at the front end now:

Meanwhile I set about cutting out chunks of rusty bad metal from old repairs that I could no longer stand the sight of:

However, it has recently come to my attention that the front of the car has had a shunt in the past, as there is some buckling and creases along front quarter panels that were not part of the original factory pressings (hard to see from this photo, but it is quite blatant in real life):

I have a feeling that I will end up replacing the front quarter panels entirely, but as my experience and confidence in making these judgement calls is still lacking I shall make this decision at a later date. Even so, I decided to press on and began stripping the passengers side:

As the eagle-eyed of you may gather from the semi-outdoors shots of the shell above, I finally got the rear of the car up on casters! Again, I significantly shortened the width of it to maximise the overall space in the garage:

This one turned out to be more unstable than the front one with a quite a bit of lateral play, so I added some additional support for peace of mind. The shell can now be maneuvered in the garage by one person, however taking in it onto the often muddy terrain outside still requires the assistance of an extra willing person. I am happy though because, with the summer months approaching, I can simply roll the shell outside whenever I need to liberate a bit of workshop space! 

Oh, something I forgot to mention in my previous post; when I was inspecting the state of spare wheel well area I found evidence of an improvised repair using fibre-glass that I was able to pick off in small pieces using my fingers! I am now starting to desensitise to the all the lurking horrors and have accepted that it is all part of the fun of restoring an old car:

Introducing...

My glamorous garage assistant:

So, I was delighted to got some much needed assistance last weekend in the form of my girlfriend, who turned out to be an absolute demon with the angle grinder and drill-mounted wire brush. Whoooop! Plus, she later confessed that she enjoyed working on the car – so I have a feeling that she is likely to become a regular fixture in this ongoing resto story...

Started with the inside of the rear quarter panels and got them primed up:

Then we began stripping the driver’s side front quarter:

A close-up of a couple of really crusty areas that made me shiver:

As usual there was a lot of filler slapped all over the place and a lot of tatty old repair patches slowly emerged from beneath the underseal:

Whilst my girlfriend battled on with the dirty work I decided to upgrade my front saw horse. Basically narrowed it to about a third of the original width and added some heavy duty braked casters to the bottom:

I actually ended up removing the top angled cross-brace sections as it was preventing the car from sitting back down on it correctly (forgot to factor-in the obvious!). Even without these sections it felt suitably sturdy and as the shell is now almost completely stripped of components I was not too concerned about the weight issue compromising the integrity of the structure.

It feels great to have a bit more working space around the front of the car now. I will get the rear saw horse sorted out next and then the shell should be fully maneuverable at last!

The Reddening!

Pushed on with cleaning the inside of the shell this week. Finished stripping the crud off of all the fiddly areas in and around the boot section and gave it all the usual lick of primer:

Then moved onto the rear quarters. Made quite a mess when the grinder/wirebrush combo came into contact with the insulation material that was attached to the inner side of the outer skin:

The mashed-up residue got everywhere and because it is sticky by its own nature it had a habit of bonding itself to everything it landed on - including my head! Was quite a satisfying task though in a strange way. Once again, all the bare-metaled areas received a liberal coat of primer: 

Having grown sick of the sight of the awful patched-up area on the drivers side rear crossmember, I decided to action.... of the angle grinder kind:

I know it doesn't look like much of an improvement, but at least I have revealed what is left of the original metal and most significantly I have some good reference points to work off when I come to fabricating new patches. So, here's how things are currently looking in the back:

Still procrastinating on the shell

Finished cleaning up the rear valance and removed the remains of the tatty old seal lip: 

As always I gave the area a lick of primer:

Then I turned my attention and arsenal of wire brushes to the rear interior area. I did not know what I was going to find under all the rust, horsehair, glue residue and seal sealer:

There are the typical areas that will need patching such as the outer corners that curve around the wheel arches: 

And just below the rear window the was some corrosion that will need rectifying - I always remember the window seal being cracked, brittle and generally past its prime. I just wish that I would have had the sense to replace it before the bloody spongy moss started growing on top of it!

...but in all I was relatively relieved to discover that the whole boot section was in a fairly good state:

So, lots of fiddly sanding (which is still ongoing), but I am enjoying myself just plodding along on the shell. It is just a task that seems to fit my mood lately. Away from the garage I am on the lookout for a shot-blast cabinet so that I can strip some of the trickier parts (and there is far more of them than I first imagined!) - but to find anything that can contain parts of substantial bulk within the rather meager budget I have allocated is proving tough. So, I am weighing up my options and considering building one from scratch out of reclaimed wood. So, watch this space for a possible project tangent in the near future!

Gretchen, aged 5

Happy New Year! I thought it would be great to start 2014 with a bit of a treat that I have been holding back for a special occasion ....a glimpse of Gretchen as she looked back in 1970!

 

Although I cannot disclose too many details for confidentiality reasons (hence the crop), I can tell you all that I managed to make contact with one of the original owners of the car at the tail end of last year. We talked at length about his many years of ownership and we swapped a few stories about her past adventures. Later that same month he forwarded a lovely letter from his daughter (who also owned the car for a while), which included a family group photo with Gretchen (yes - it has now been officially confirmed that this was always her name!) peeking through in the background. I am so grateful to them for sending this photo and for taking the time to inform me about the cars history. It completely blew my mind! The picture provides me with so much motivation every time I look at it. 

Oh, and I just love those vintage VW logo mudflaps - another item for my wishlist.

What began a little distraction...

In between my welding practice I have been tending to a few rusty areas on the shell that have been distracting me from out of the corner of my eye. However, what began as a few minor areas has sort of snowballed (excuse the festive pun). Here is a quick run-down of the past couple of weeks of activity...

Crusty deck lid area:

The lip that holds the rubber seal was in pretty bad shape, so I decided to remove it and grind the area flat. I will most likely use the later type of engine seal - the one that fits directly onto the deck lid.

Drivers side rear quarter:

This was an area that had become really bad soon after I bought the car and I remember it failing its MOT one year because of the state of it. I had no choice but to take it to my local garage who advertised themselves as being specialist in vw restorations. Well, it turns out that what for years I assumed was just a 'skim' of filler to smooth out any imperfections turned out to be a dense layer that was hiding lazy repair work:

Once I had removed all the filler and turned my garage into a winter wonderland (the dust got everywhere despite using an extraction system) I could assess what had be done. Basically they had taken a flat section of sheet steel and made no effort to shape it to the contour of the car. They have then appear to have tack welded it into position and hastily ground the welds flat(ish) leaving unsightly abrasions all over the place. This was finished up by slapping copious amounts of filler (3-4mm thick in some places) over the top and sanding a fake profile. What a lazy bunch of cowboys!

I marked up the panel and cut out the abomination without delay. I found that the 'pros' hadn't even made an effort to treat the back of the repair patch and had just left it as bare metal, which had obviously rusted up nicely over the years. Oh well, the offending section is out now:

I then moved on to the inner arch area and figured I would strip it so that I could see what was going on beneath the underseal.

As expected there was quite a few old repairs and other repairs over the top (like patchwork in some places!) but there were vast areas of good condition original steel which was a welcome sight. I treated the whole area with a rust inhibitor before keying it up with the electric sander:

Then added a liberal coat of primer to keep the panel fresh until I get around to making the repairs. It funny - I hadn't intended to touch touch the shell until I had finished and rebuilt the chassis, but I must admit that it feels like a good to see some advancement whilst i'm mastering my welding technique!