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My 61 panel (and a 66 panel digout)
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karl h
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PostPosted: Tue Nov 24, 2015 12:26 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

pinetops, i love your westy, hadn´t seen the thread yet.
Seriously now, if you want to see perfect work then check out Lyndons (vwhelmot) 64 project - pure perfection in metal work, awesome skills! just dont come back later and see my mediochre attempts..... thanx for chiming in, buddy

speaking of mediochre attempts:
after careful investigation i found out what kept the drivers door from fitting as it should, it sagged 1.5cm in the back (and thats A LOT). turns out it was my fault (again). look at the pic: i made the mistake to align the lower a pillar with the front crossmember and didnt align the fold, its too far to the front
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Last edited by karl h on Tue Nov 24, 2015 5:58 am; edited 3 times in total
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karl h
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PostPosted: Tue Nov 24, 2015 12:30 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

i will have to cut the pillar loose again, also from the front crossmember and rotate it a couple of degrees inward to get the lower hinge to fit properly. to try if this will work i wedged a strip of aluminum under the out side of the lower hinge to push it back about 8mm
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karl h
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PostPosted: Tue Nov 24, 2015 12:33 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

and voilá, a doorgap that is close to perfect, at least i will be able to adjust the door correctly when everything is welded properly, hurray Very Happy
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miracously the dogleg now fits a lot better....
Image may have been reduced in size. Click image to view fullscreen.

stay tuned
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Schwing
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PostPosted: Tue Nov 24, 2015 8:57 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

Great job on that door gap. This is the hard stuff that you are tackling right. Its difficult to be honest with yourself and admit you screwed up, I find myself there a lot haha.

Awesome work, I will pay close attention!
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karl h
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PostPosted: Wed Dec 02, 2015 2:47 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

thanx Schwing
i made some cuts and moved the lower a-pillar so the door now fits better. it dawned on me that i should better mount the windowframe too to not have any suprises later. the doorlock mechnism and inner releasehandle are also in to get an idea of the position of the door when closed.
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doglegparts (autocraft outer and brazilian inner) have been tacked together and i am trying to get a good fit and doorgap. i will attach the dogleg with sheetmetalscrews (havent got any clecos) to the seatpedestal and weld after i am happy with the fit
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karl h
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PostPosted: Thu Dec 03, 2015 12:25 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

some more welding to the dogleg (inner part to outer part) and some minor tweaking and the doorgap is very nice. i am pretty proud of myself Embarassed
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PostPosted: Thu Dec 03, 2015 9:07 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

Nice work Carl! I view you updates and smell welding and grinding disc's.. lol
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karl h
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PostPosted: Wed Dec 09, 2015 11:44 pm    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

yes it smells a lot like that, Bill Very Happy
some small repair to the b-pillar before the dogleg goes in consumed a lot of time. (sorry for the bad pic)
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and i finished welding the dogleg parts together. i was able to run a bead the whole length of it. i fear this might crack if just tacked and bondoed over
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karl h
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PostPosted: Fri Dec 11, 2015 12:38 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

and the dogleg is in....

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Stocknazi
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PostPosted: Fri Dec 11, 2015 8:29 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

What type of paint/primer are you using to cover your welder areas.

Looks like it's brushed on.
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PostPosted: Fri Dec 11, 2015 8:39 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

Great job looks perfect from where I sit.
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karl h
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PostPosted: Sat Dec 12, 2015 3:52 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

i use a weldthrough primer in all the areas that will be penetrated with a weld (spraycan, silver colour, no difference to not primed sheetmetal) and a red coloured metal primer on the inside of parts that i cant access after welding (brushed on). the whole car was coated after sandblasting with two part epoxy primer. when i am finished with the welding i will coat the rest of the outside surfaces with this epoxy too.
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karl h
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PostPosted: Mon Dec 14, 2015 1:06 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

getting bored with grinding down welds i started on the b-pillar on the passengers side. since i couldnt get a hold of gerson or his shipping department after multiple tries (maybe my mails end up in the spam filter) i decided to use the brazilian "repair" piece. first i drilled out all the spotwelds and made it three-piece
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the outer skin is fitted first, i will align it using the dogleg and the cargodoor next
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61 panel: http://www.thesamba.com/vw/forum/viewtopic.php?t=465022
68 ghia vert
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86 Caravelle
04 new beetle vert


Last edited by karl h on Wed Dec 23, 2015 3:26 am; edited 1 time in total
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karl h
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PostPosted: Wed Dec 16, 2015 11:56 pm    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

i tried to mount the cargodoor for alignment, but no go. the mounting point for the hinge is too far forward, so you cant fit the door by design of the "repair" piece
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so that POS ended up where it belongs, in the trash...
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fortunately i was at last able to get a hold of gersons shipping department through the contact page of his website (not his mailadresses) and just paypaled the money for a (hopefully) proper b-pillar
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karl h
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PostPosted: Wed Dec 16, 2015 11:57 pm    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

to keep me busy i decided to tackle the rest of the sidewall
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stay tuned
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karl h
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PostPosted: Mon Dec 21, 2015 12:52 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

but first i had to repair the inner lip where the fender is welded to the sidewall:
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PostPosted: Mon Dec 21, 2015 12:54 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

as well as the missing part of the fender that i cut out because of rustholes prviously:
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my b-pillar is close to being delivered. after i got an answer from klassicfab shipping is very fast!
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karl h
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PostPosted: Tue Dec 22, 2015 7:03 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

holding the WW sidepanel in place with all kinds of devices. the louver had to be spread apart too.
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karl h
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PostPosted: Fri Dec 25, 2015 10:24 am    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

mail from bogota arived and what a difference:
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fit is perfect!
gerson is the man...
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karl h
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PostPosted: Mon Jan 04, 2016 11:44 pm    Post subject: Re: My 61 panel (and a 66 panel digout) Reply with quote

the rubberchannel comes first:
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then the inner wheelwell. this looks a lot better than the other side - practice always helps Embarassed
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