The 'Ol 55

[tehillah1]

I made a small "anchor" patch off of a cardboard template to kind of get a feel for what this bucket will allow in terms of a repair.

Then made a larger template and started working sections from it...

Hammer form, tack, hammer, tack, tap, tap, tap, tack,

fit, hammer, tack, repeat...

I should be able to finalize this bucket this weekend after all the family shindiging.
I'm grateful for this community here on TheSamba...wishing all y'all a Happy Thanksgiving.

[VW_Jimbo]

Nice job! It is looking really good! Your welds look good! Keep track of that drain hole. And you might consider drilling another one further down into the bottom. There is a reason they rusted out on all of them! Up to you. I drilled a 1/4” hole as close to the tube as I could, without infringing on the tube welding.

Have a good turkey day. Enjoy those around you. As I am getting older, some of the people that were at the table a year ago, will never be there again. It makes for an odd set of feelings regarding the holiday. But, I am thankful they were in my life! Pretty cool to start seeing it from the midpoint. Can not even imagine what it will be like closer to the end.
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[markendee]

Kicking huge goals tehillah, great work.
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Member # 145244

[tehillah1]

There were three pieces to finishing up this pie in the left headlight bucket. So here's the final piece, fitted and welded in....

Since I'm in fender mode I pulled out the right front fender figuring I've got a fresh bead on what needs to happen with repairs to the front fenders.
This side is in better shape than the left front fender.

Headlight bucket is pretty clean, just surface rust, no rust through.

The bullet can is rusted through so that got replaced.

In stripping the fender down there's some ripple filling in the outside edge of the fender wheel arch that'll all level up and smooth out when I'm ready to start priming and filling. Other than that I've got two serviceable front fenders. This little car keeps surprising me with how well some parts have held up for 68 years.

[tehillah1]

I put together a new support head for dolly at the rear of the car allowing me to move the dolly into the engine bay and support at the car at the body mounts.

This will open up access to the rear apron which needs some major attention.

[Dan22]

Great work and progress T1!

I am curious how you configured the swivel part of your rotiserie at the engine compartment. Could you post some more shots of that detail? Of course the rotation amount is limited in the compartment but I like the mounting on the frame supports.

D22
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1-0900722 die langsame grüne Schildkröte
https://www.thesamba.com/vw/forum/viewtopic.php?t=765074

[tehillah1]

[Dan22]

Very nice having both of those options for pivot locations. Thank you for sharing.

I see you made the swivel adjustable for height. I will have to consider that when I make my rotisserie.
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1-0900722 die langsame grüne Schildkröte
https://www.thesamba.com/vw/forum/viewtopic.php?t=765074

[tehillah1]

I had one engine stand that was set up that way...it's the one attached to the front of the car. I had to do some ugly cutting and rough fabbing to make the one in back adjustable but now I can wheel the pan under the body while it on the rotisserie so it's pretty handy to be able to raise or lower it to the need...

[tehillah1]

Shout out to the community here on TheSamba.
Thanks for all the helpful insights, input and encouragement in 2023...and all of the incredible build threads that folks are willing to share.
Here's wishing all y'all a 2024 filled with peace and contentment.

[esde]

Happy New Years indeed, best of luck with it in this new year!
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that.

[VW_Jimbo]

[tehillah1]

This right rear quarter has been staring me down for 2 years now...

I've been avoiding it until I felt more confident in my ability to weld it up with minimum panel deformation.
So I got all the cancer cut back...

and a the patch panel shaped up and clamped in for welding

And welded in

I'm happier with these results than with the left side. Both will shape up with minimal fill and primer.

I'm gonna fix the two worst rusted weld nut fender mounts while I'm back here.

[esde]

Nice job, on what I feel is one of the always rotted out sections of every single old beetle. EVERY SINGLE ONE
Did you fab it all yourself, or start with someone else's panel?
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that.

[tehillah1]

[VW_Jimbo]

This is a grand update! I was wondering when you were going to venture out of your comfort zone and jump into the deep end! It looks like it turned out really well! You did well! It can only get easier with more practice! What spot are you picking next?
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[tehillah1]

Thanks for the encouragement Jimbo...I stalled this one as long as I could stand it...looking at the hole, moving the repair panel around the shop... but after working over the front fender headlight bucket I felt that my welding and panel fitting has improved to the point where I could tackle an exposed body panel.
Next up I'm gonna fix the couple of rot spots at the fender mounting nuts in this right rear corner and then move to the front A pillars. That'll leave the rear apron. Another project I stare at, scratch my head and wonder over. Hopefully I'll get this 'Ol 55 ready for primer in 2024 (no resolution intended...).
It is January and I'm still molasses.

Jim

[VW_Jimbo]

[tehillah1]

I cut out the worst spots in the right rear fender mounting area...I cut more than the lines would indicate

Shaped, fitted and welded in the patches

mounted the fender and running board to make sure everything is lining up right...

On to the right front quarter panel in front of the lower hinge.

Cut out the worst of the cancer

Shaped, fitted and tacked in the repair piece

And welded.

That went better than I expected and the repair is better than what I was last driving around with. I hope it shapes up decently with some primer and minimal fill...

[tehillah1]

Next up is the left front quarter panel in front of the lower hinge.

Exploratory surgery...items removed from the pit...spring washer, 10mm socket, fuse.

Patch panel shaped and fit

Welded

I put the fender on to make sure I got a fit.

I think that's the last of the pieces I have to cut and weld for rust replacement on this project. The rest of the spots I'll treat as best as I can, seal and level 'em up and get to epoxy prime.
Next up I'm gonna circle back to the rear apron. Adventure awaits.

I've gotta say that posting up my novice work can be a bit humbling in light of the work of the likes of Nancy, Jimbo, Esde, MarkenDee, Don, Dan, Scotty Timmerman...the list goes on... y'all know who I'm talking about...putting up stunning projects and high end work with phenomenal results...I read these threads all the time and admire the work and knowledge being shared here. Most of them are motivating showing what can be done...then I go out to the shop and stick some metal together to remediate rust-throughs and have to keep my focus on what it is I'm trying to and able to accomplish here.
Just trying to resuscitate this old bug for a final drive around and learning some new skill sets along the way. Half the time I forget to take pics of the processes or can't figure out how to get it out to the thread.
That said the community here on TS has been a gold mine of "how to" and a consistent nudge forward.