What to do this weekend - one piece front end

[pploco]

So I finally got up the courage to hack away. I have had the once-piece front end now for a couple of months. I scored a HUGE fuel cell out of the junk yard that I am tempted to put into the front.

http://www.thesamba.com/vw/forum/album_page.php?pic_id=215432
http://www.thesamba.com/vw/forum/album_page.php?pic_id=215431
http://www.thesamba.com/vw/forum/album_page.php?pic_id=215430
http://www.thesamba.com/vw/forum/album_page.php?pic_id=215429

Should I bother with the monster fuel tank? I have a sender and plenty of room with the front clip removed. I hope to have the front piece mocked in tomorrow so I can make the final cuts.

So far the install has been pretty simple. I have a type 4 front end with disk brakes to install on this project. I did have to break a couple of tack welds to remove the old torsion beam. When I put the new one in, should I tack it?

[Nicksan]

Sounds good. If you could fit it in the extra fuel is always good to have, but do you need a gauge? Make sure to post some pics of the one piece install. Type 4 front end on a bug, how is that going to work?

[pploco]

My mistake - type 3 NOT type 4.

[pploco]

Ok day 2 and here is a little more. I must admit that this install is not for the faint of heart. The whole time I wished I had a mini shmo sitting on my shoulder coaching me through this .

I started today cleaning and painting the front beam and pan front with a rubberized coating. I then mounted the new ghia front end.

http://thesamba.com/vw/forum/album_page.php?pic_id=215802

I had a buddy make a front swivel bumper to mount the front piece on. When I figure how to clone and miniaturize shmo I will tackle a front cage. For now, this will do.

http://thesamba.com/vw/forum/album_page.php?pic_id=215803

When I trimmed the front apron, I left quite a bit of metal to build to. I especially wanted to leave a lot of the inner fender to protect wiring etc. under the hood. I made a template:

http://www.thesamba.com/vw/forum/album_page.php?pic_id=215804

The end cuts.

http://www.thesamba.com/vw/forum/album_page.php?pic_id=215816

I fought and fought the alignment and finally decided it looked better to overlap the original hood jam by about an inch. I cheated and temporarily mounted the one-piece with a self tapping screw. I can fix it before paint.

http://www.thesamba.com/vw/forum/album_page.php?pic_id=215812

The alignment at the door seam looked so much better this way.

http://www.thesamba.com/vw/forum/album_page.php?pic_id=215805

I still have to figure a way to get the fiberglass to suck up to the bottom against the body seam. I may weld a small channel against the body seam - any thoughts would be helpful. I plan on welding a seam on the top of the left over inner-well as sort of a splash guard.

Having the piece overlapped a little let me put some body clips on the top under the sides of the windshield.

http://www.thesamba.com/vw/forum/album_page.php?pic_id=215806

Looks pretty good so far. I hope to procure a welder (still trying to convince the wife - if not I'll borrow one) and make a headlight bucket mount.

[baja5]

You will probably have to trim the 1 piece front end on the cowl area to get it to all line up, and mine doesn't really hug the body all the way down. it is fastened with dzus fasteners, they seem to suck it in pretty tight and hold it solid though. looks good.

[Jowlz]

If you right click your picture in the gallery and choose properties, then cut and paste the url you will get pictures in your post instead of links. Looks good
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The honey-do list put my project on hold.......

[pploco]

Hey baja5 what did you use for a fuel filler assembly? Do you just flip the 1 piece or do you have some flush fuel door?

[baja5]

The whole front of my car was cut off and my fuel cell is mounted behind the front seats, the fill neck is a recesses unit that uses a regular cap.