Bad Juju, the roof chopped turbocharged Volksrod - Page 2
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  1. #11
    Rods 'n' Sods Junkie
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    Big-bern is offline
    Really enjoying this build

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  3. #12
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    Quote Originally Posted by issigone View Post
    hi,
    wow amazing work there, liking that.
    i recognize them first pics, my home town.

    cheers chris.
    Hartlepool?

  4. #13
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    fall-apart-dave is offline
    I've been welding again. Suppose I best put some photos up. So where was I?

    Oh yeah, framehead was about cock on as far as I could measure it without a special jiggery-thing. So next up was to repair all the bits of metal I cut out and find any more that needed it.

    This framehead bolt sleeve had all the structural integrity of lightly glued corn flake.



    Drilled the swine out.



    Forgot to take pics of the repairs to the crusty holes on the face plate but they are all done now.

    Long had look at the rest of it... Christ there's a lot of weld gone into this thing



    Make a panel, line it up...





    NOTE THE CAREFUL ATTENTION TO THE SHAPE AND NOT OVERLAPPING THE PANELS!

    Buzzbuzz weldweld...

    Tada! That'll do.







    Right, on with the Napoleon's hat (bulkhead support panel). Measure mueasure, tickle tickle...






    Buzzbuzz weldweld...





    Lining up the tunnel bottom plate...



    Tacked it in place after drilling holes for plug welds before I remembered I'm meant to e moving the handbrake forward to allow for the bench seat. curse word. So left i there for now until the New Year when I can also run a 10mm kunifer fuel line in the tunnel (might as well, while I'm in there). Anywhere sell that stuff by the meter? Can't find it for reasonable money anywhere and I don't need even close to the amount it's available in!

    I very carefully thought about flatting the welds off to make the repairs invisible, but I opted against it and decided to keep it "honest" so that anyone looking can see where the repairs have been. This is not a concourse resto, this car is and always will be a junkyard dog, made out of whatever I found lying around. So in the spirit of that, the welds are staying proud as a mark of the history of the car.
    Last edited by fall-apart-dave; 30-12-2016 at 11:22.

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  6. #14
    Rods 'n' Sods Junkie
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    mcmental is offline
    liking this

  7. #15
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    fall-apart-dave is offline
    Well... A bit more done and almost ready for the floors.

    Needed a second handbrake bracket so I can fit a bench seat.. Chopped one out of my donor chassis.

    Chopchopbuzzbuzzyweldyweldyweldy...







    That'll do.

    Best extend the boden tubes and bend them around the gearshift...

    Measuremeasurechopchopweldweld...





    That'll do.

    Best get that bottom plate tacked back on and the framehead bottom plate offered up...



    Bunch of BS repair panels...






    Had me thinking I'd warped the chassis... Measured it more times than I've interfered with myself this week, all bob on level and straight. Measured the repair panel... 7mm longer one side than the other, and twisted.

    Out with the hammers then... The last time I pounded something this hard I was paying her...



    There, that'll do.

    Stitch welded it all together...





    That'll do. But ugly, bit messy, but I was against the clock, running out of gas and had other things on my mind.

    Next up is the rear crossmembers, and then I can weld the floors in... Starting to look like a chassis again!

  8. #16
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    fall-apart-dave is offline
    So rear cross members and floors in...

    Plug welded the floors after making a million flippin' holes all round the floor pans to weld into...







    Flatted the welds off on the crossmembers so the body will still go on (I hope).







    No that's not a cracked weld in the last pic, that's a shadow.

    That'll do.


    Just the new gearbox nose mount to do not so that it will accept a Splitty nosecone I put on my gearbox (which will raise the trans by about 2.5"). Then paint.


    Crapping myself about fitting the body up now... Will it fit or not? Place bets now...

  9. #17
    Official RnS Addict mygasser's Avatar
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    I've not done that extensive a repair to beetles before but if I had to I'd bolt it all together then fit it to the shell. Once bolted to the shell weld as much as I could then pop the body off for finish welding. But then I hate doing things twice so.........
    need a job done on your project? i may be able to help.

  10. #18
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    german8rcoupe is offline
    Converting to left hand drive?

  11. #19
    Official RnS Addict Magman's Avatar
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    Quote Originally Posted by german8rcoupe View Post
    Converting to left hand drive?
    The napoleons hat bit? I was just going to ask the same question.
    Or the picture is flipped....
    http://www.enigmaracing.co.uk

    A work in progress....

  12. #20
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    Quote Originally Posted by Magman View Post
    The napoleons hat bit? I was just going to ask the same question.
    Or the picture is flipped....
    Think pics are fine...pedal holes check out ok.

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