Bit more done this afternoon, just odds and ends really, installed the left rear light and popped some filler on, there was a tonne of lead in this corner though so welding was awkward...



The front was prepped ready last time by Fin as well but we ran out of time to paint it, so I mixed up some epoxy primer and whacked that on too...





And the tool-chest area too as I had some primer left in the gun...



Also order the panel between the engine hatch and rear hatch to replace it as its got a whopping dent and it bent up and in so thought its easier to replace than straighten.

More Wednesday hopefully!

Bit more done today, spent most of the time messing with Tig and aluminium to be honest, its nothing like stainless, so what I expected to take 20mins actually took 2 hours, its actually quite hard isnt it!!

Eventually got the hang of the set though, and with the foot pedal which seemed a lot more natural, managed to knock these up.



Not pretty but strong. These make up...



Which then do this!!



So the engine and box will have three mounting points, gearbox nosecone, bell-housing and engine bar, should help keep it in situ hopefully.



The rear axle stand is holding up the gear linkage bits we are fabricating at the moment, not the box.

Also did surgery on the rear as it was a little bent and very crusty... Scarey!!



Thank goodness for Autocraft!!

Did a little more today. Got the cage finished which is a huge hurdle. Am really pleased with the result too, couple of minor differences from one side to other but all in all not bad for an amateur. Im happy with it, and it is super duper strong!!







Then started on the removable engine hatch, notched the side rails to fit around the cage and also weld to it to support the floor...



Custard makes really good cutting fluid - NOT!! Hehe!

Fits like so...



Then t'other side...



Bought the wrong hatch closing panel, got the one off a proper 63 not a 62 cross over but this will be attached to the new hatch at the correct height etc and will allow me to remove the whole lot if required in one go, making for a super accessible super complicated engine!



Will be bolted in situ, along with a roll cage bar that bolts across the opening so should be strong and practical.

Thats all until weds, although with the holidays its pretty quiet in here!

Nice metal skills yet again Paul I wish I'd been brave enough to do the engine access as it will be really useful. Mind, you do have a lot more stuff going in there

I like the look of the little fella parked behind, what is it?

Steve

Awesome work again Wejjy. You are not shy of treading the unbeaten path are you!

I'm looking forward to the update when this thing goes to paint (maybe not as much as you tho)



And shame on you Steve You should know the whole VW family by now (It's a Karmann Ghia parked behind his bus)


Nige

nige1171 wrote:
And shame on you Steve You should know the whole VW family by now (It's a Karmann Ghia parked behind his bus)


Nige

I thought so but didn't want to appear any more stupid than I already am Just in case it was a Speedster or such like

"He who says nothing can't be wrong"

Sorry, I'm shamed

Steve

rusty1962 wrote:Nice metal skills yet again Paul I wish I'd been brave enough to do the engine access as it will be really useful. Mind, you do have a lot more stuff going in there

I like the look of the little fella parked behind, what is it?

Steve

Cheers Steve, as for the metal work, youve got the skills too pal, Ive read your thread dont forget!! Nowt special here!!
The hatch is purely for practicality, gives a humungous benefit in access which I just couldn't unjustify once I'd thought of it (if thats a word) Yep lots of stuff, ECU, Dry Sump tank, Swirl Pot, FI pump, wastegates, BOV's the list is growing each day!!

Yep Ghia is dads toy, quite quick 2332 on IDA's!

nige1171 wrote:Awesome work again Wejjy. You are not shy of treading the unbeaten path are you!

I'm looking forward to the update when this thing goes to paint (maybe not as much as you tho)



And shame on you Steve You should know the whole VW family by now (It's a Karmann Ghia parked behind his bus)


Nige

Cheers Nige, naa Im never going to be pure and will always be frowned upon in the scene, I don't do it on purpose though and understand peoples reservations, just cant help being the way I am, I blame my dad!!

I CANNOT wait until its paint day! Just a little nervous about the colour combo, it works in my head and on a screen, but real life is always worrying, we shall see, soon too hopefully.

Cheers for reprimanding Steve too, he will learn

Must say that you sir have got some serious skills!!

Top notch work and if it is unique that you want, you're on the right path!!

And love that Karmann,

James

jms007dbz wrote:Must say that you sir have got some serious skills!!

Top notch work and if it is unique that you want, you're on the right path!!

And love that Karmann,

James

Cheers pal! Kind words, too kind in fact!

Had a couple of hours after work today to get the hatch a bit further along. Made the frame first and squared it all up...



Then braced it up to add a bit of support



Made some fingers to locate it in the slots at the rear



Popped in place, looks exactly as planned



Since the rear closing panel is wrong I didn't weld any more of the frame up for it, the new one was at home when I got back so I will save that for next time. Put it in place to give an idea of how it will be though...



Did a bit of seam sealing inside next to get prepped for high build primer next time Im up there





Next time I will finish the hatch closing panel and seam seal the engine bay. Then its primer time on everything apart form the rear corners!!

Getting there

well done buddy

once that primer times done you will really feel you have made some massive steps



Again well done !!!!!!




Mark

Good stuff yet again

markp wrote:well done buddy

once that primer times done you will really feel you have made some massive steps



Again well done !!!!!!




Mark

Cheers pal, yeah cant wait to get it all in primer, it will be a good day! Hoping to get there before the weather turns permanently mingin!

rusty1962 wrote:Good stuff yet again

Cheers dude, will you be at Busfest this weekend?

DPR delivered this earlier in the week, its a work of art, wanted it on the side board in the lounge but Vicky was having none of it!!



Managed to get a couple of hours to finish off the rear hatch too. Started by tacking the rear brace in place...



Then slid the hatch in place to figure out how to get the closing panel will fit, cut 1mm off each end so it fits in nicely and clamped it in place



Welded inside along the back where the seal strip will hide it all and measured gaps. Then set about attaching it to the roll cage bar as it will come out with the bolts that hold this in place, popped a bit of 40mm box along the back and spot welded it to the seal edge and zipped along the back edge to the tube.





You cant tell from the rear at all



With hatch on...



To take it out simply undo 4 bolts on cage brackets slide forward 50mm and hey presto, access!!



Also popped an initial skim of filler on as I had 20 mins before hometime!!



I think I have officially finished welding now! Nothing left that I can think of, just perhaps a bracket for the oil cooler but thats minor and may not be necessary! Hooray!!!

I like the way you've done the rear hatch mod. Very neat