The DUNGBTL Build

[bruceo98]

[DUNGBTL]

Drillurium!

I’m converting the front bonnet hinge springs to hydraulic struts. I also wanted to drill out the hinges for weight savings and because…race car.

Let’s get on with it then.

Warning: the hinge spring supports are riveted to the hinges and the springs are compressed. There’s a lot of stored energy in the springs, so be mindful of that when you remove the rivets!

I used a cutoff wheel to grind the rivet head down enough to punch it out with a drift.

I stood in front of the vise as I punched out the rivet and watched as the spring support shot across the garage hitting the garage door! So, for the other hinge, I decided to do a little target practice…READY, AIM,

FIRE!

…way off to the left of the target!

The projectile!

Anyway, please be careful if you’re going to do this!

Enough nonsense…on with the weight savings!

4 oz…1/4 lbs of weight savings! At least they look cool!

Cheers,
J.

[H2OSB]

They do look cool!

H2OSB
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[SnowDaySyncro]

I do love the drillium look!
I have an idea for some bracing on my Syncro that will cross part of a window, so I thought it would be fun to add holes for a modicum of visibility but mostly because I like such details and because I think I could end up with something that is a wee bit stronger and lighter than the original part.

Like your hinges, each structure consists of two stamped pieces of steel. The edges are flat pinchwelds with a hollow center, 20 or so mm deep. My idea is to cut a few round holes, around 60mm in diameter, then dimple them inwards and TIG the rims of the holes together. It looks really cool in my head, but that doesn't always translate to real world results. Time will tell.

[vamram]

Laughed out loud at your target practice. Looks cool, but won't the holes compromise the strength of the brackets?
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'74 Super 9/16 - present, in refurb process.
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[DUNGBTL]

[bruceo98]

Looks cool. I like it .
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I may not be the best, but when the top 10 get together, they all talk about me.

[bruceo98]

What size bits did you use to drill them out? I was looking at some aluminum billet ones but they want like 500 bucks for them . I might just make some out of aluminum plate .
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I may not be the best, but when the top 10 get together, they all talk about me.

[DUNGBTL]

[bruceo98]

Ok I’m blind. I now see the sizes written on the hinges . Anyhow , looking at the hinges they seem to be a pretty straight shot from where they bolt up to where they bolt up to the hood . I think some aluminum plate might be able to make that work . I’m going to have to try that and see how it works out . Polished with some holesshould look killer. Another idea you’ve given me . One day I might just stop adding things and get this finished before I die .
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I may not be the best, but when the top 10 get together, they all talk about me.

[DUNGBTL]

1302R Rear Apron

Another inspired idea from Rome brought to life!

The inspiration…early 60’s 356 Carrera…

…the DUNGBTL’s tribute version…

I plan on making a custom exhaust to mimic the early 911 sport peashooter exhaust so I left the cutouts alone…something like this:

How’d I do it you ask? I got the idea of using a slotted front apron from looking at my own….

$100 later I had a Dutch repo one on my workbench ready for the chop-shop. I cut out slotted sections and after using my fine English metal working planishing hammer and some ancient forest hardwood, removed some of the curvature to match the rear apron.

Then it was a matter of cutting out ‘windows’ in the apron and butt welding in the slotted sections. Followed by hours of carefully grinding down the welds…followed by hours of body work…the aprons residual stresses, created during forming, relaxed when I cutout the ‘windows’…who knew! So, some oil canning spots were created. Several heat/shrink sessions and hammer/dolly work was required. Followed by days of primming and blocking and sanding, blocking, priming, blocking, sanding…ad nauseam

Thanks a lot Rome!

RESULT!

Thanks again Rome for the idea. I’m really happy with how it turned out!

Cheers,
J.

[Rome]

Suggestions and even recommendations from among theSamba can be either ignored, accepted, or rejected. Some of them can be envisioned by the car owner as feasible. And some even considered favorable. I'm glad that you have the ability to transform a favorable idea into reality. The vents really do look good, especially since they are not visually hidden by your rear bumper!

[Rome]

Looking back a ways in your thread, I just realized that your spare engine lid is from a '70/'71 Beetle Karmann Cabrio. It has the 2 center pairs of vents with 2 additional louvers at the bottom to line up with those on the outer 2 pairs. This style will work well with your plan to paint the vents satin/flat black.

Sedan lids with the 4 sets of vents ('72 on) had the center pairs with 1 less row at the bottom probably just like your '72's original lid. All 3 of these have the factory-style sedan lids- vamram's '73, Jorge's red 2003 Mexi Beetle, my '77 with fiberglass fenders and '68 "tombstone" taillamps.

[H2OSB]

J, you're damn good at making your mods appear like something the factory might have done.

H2OSB
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(o\_i_/o) I'm not a vegetarian because I love animals, I'm a vegetarian because I hate plants.

[DUNGBTL]

[DUNGBTL]

[agramer1966]

I believe that's one of the best subtle mods I have ever seen.
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[bsairhead]

Are you going to do weep holes on the left and right sides?

[DUNGBTL]

[bruceo98]

That turned out nice . I see you had your hand in body work sometime in your life . Looks like it belongs there . Well done .
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I may not be the best, but when the top 10 get together, they all talk about me.