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Discussion Starter · #1 ·
well been busy in my "spare" time for over 18 months . Trouble is not enough spare time . So its an Oct 12th 67 built 68 model year UK spec VW panel van. Have been collecting as many NOS panels as I could find and "best quality" parts. Lets hope the pics post. will wright time line first. So when I got the panel it had windows cut in that rusted around the seals badly, as a quick make over (this is when I had my Garage business ) we welded in new sections and resprayed in original colour . Of course the skim of filler cracked due to body movement, this was as I found out down to some very bad repairs. Cut all the panels off, and ended up going back to chassis rails. New under floor sections fitted, crossmembers and sills, along the way twisted chassis realigned . Outriggers and jacking points ,rear arches repaired ,"good" cut front arches fitted,cab floor repaired. new load floor and kick up section done. Body side panels fitted using panel glue around rear arches . Polo steering rack with Renault master van 90 deg box fitted then new front panels welded in . Good used front beam fitted (one year only , its full of one year only bits!!) and a set of drop spindles modified to take a disc brake kit that "does not fit" (no such thing is there folks) Took 2 weeks hols to try and get paint on but still rubbing down filler, took me a day to get the tail gate to fit (good used) as it was tight top left to bottom right. Improvised body jack helped as well as shaving some from door to get shut line. Recon body must have moved ? fitting the new bits. The PIA has been getting the moulding correct on R/H side as had to cut it out of the old panel as the new section was for the N/S . Over the winter made some of the interior units as well
 

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Discussion Starter · #4 ·
a
, still lots to do but have a dead line for end of May next year. Then might get to work on my Austin Countryman -------------
 

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Discussion Starter · #5 ·
This one didn't transfer , inside of rear cupboard with spare wheel well tran
sferred from L/H to R/H side as bed covers the L/H side.
 

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Discussion Starter · #6 ·
Well its taken me ages to get filler right, bought a Velcro sanding block kit. OMG wish I had this before , it was easy to get body line right for side moulding and the curved block is spot on for front panel. More or less got the "rough " filling done today but need lots of putty to get pin holes and scratches out, seen a liquid glaze but not sure if that's the right stuff as last time (2 decades ago!!) I used some it was spray on. Not been well this last month so slowed me down a lot.
 

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Discussion Starter · #7 ·
Bit of progress , found I still had a pot of that liquid filler so brushed it on. Decided to fill a warp in side panel but run out of filler. AS said not been well with a "cold/sore throat" bug that then gave me 2 weeks of the squits, got so run down (lost 7lb) that the cold sore virus in my right eye has flared up so spent yesterday chasing around between docs, opticians, back to docs and then chemist to get ointment . Stuck in today waiting for it to work so hopefully can go down lockup tomorrow and do a bit to bus. Stripped n/s cab door to bare on Thurs and need to reinstate some filler on an old repair, will do same to o/s cab door carefully to get rid of the blue paint . Found 4 layers of paint in some places starting with the respray we did , the blue it was when I got it, white on top of blue for upper body plus some blue over blue repairs and the original green factory under that !!!!Still have sliding door, rear corners and engine lid to strip as well as around front screen when I get it out. o/s wheel tubs to clean with electric wire brush and then stone chip . BTW did I say I hate body work!!!!!!Much happier on mechanicals/electrics.
 

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Wow eh! Lol bodywork isn't for everyone but ya done good!!

Keep going chief :smoke:
 

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Discussion Starter · #9 ·
Well can of worms , striped drivers door and found a god awful repair. Repair section fitted without swaging the joint, its just pushed behind the door skin. The resulting large dip being filled with glass fibre and skimmed with nearly 1/2 ins of filler!!!!! ordered new door skin so if it turns up on time that will be my Thurs job. Ordered some panel adhesive as well so hopefully it wont need much filler on the join. You cant get a 68 door skin as handles different so will have to join below that, found some holes in door as well caused by sound deadening sheet folding over at top and trapping water. Next problem is finding room to work on door ------------
 

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Discussion Starter · #10 ·
Decided to fit the whole door skin and looks like only have to cut around rear handle fitting as front looks the same. Managed to get as far as a trial fit ,only had 3 hrs on it today. Will take photos next time!!
 

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Discussion Starter · #11 ·
Got fed up rubbing down filler so have been fitting servo and making up pedal linkage, will take some pics when finished.
 

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Discussion Starter · #12 ·
Well first day back on it this morning and more or less finished the linkage , will weld the arms on the shaft as I don't trust the circlips!! Will be fitting grease nipples to bearings. BTW the didn't fit servos to very early RHD yup its another one year only thing. First pic is pedal end and it took some working out so linkage missed pedal at full travel, had to extend pedal slightly. Next is servo end and last is looking from servo back to pedal end . Its all made from my parts bin except new servo and push rod , cross shaft is 2 beetle shafts joined , bearings are beetle pedals . Cant keep a hot rodder down!!!
 

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Discussion Starter · #13 ·
Fitted the new ATE master cylinder (rather than the one from Empi kit) and can now push pedal down . Next job is making up new brake lines , was going to start but way to cold and damp in my unit . Space heater just made it rain inside as it melted the frost on inside of roof!!!!!
 

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Discussion Starter · #14 ·
So on self isolation this week due to chest infection that been plaguing me from Feb , not sitting at home when I can self isolate in my unit . Got a lot sorted, painted brake parts and fitted. Had to brush paint as fumes affecting breathing still. Stripped down rear brakes and found one backplate fubbared , problem is its a one year only part Aug 67 to Mar ? 68 as rain lip on drum changed. Have ordered replacement 68 to 71 to see if I can mod , its a pattern part . Yes the fun of owning a very early bay, brake drums, bake plates and handbrake cables all unavailable . Rain lip same as Split bus but hub is different so that doesn't help.
 

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Discussion Starter · #16 ·
wanted to but unless I sell race car no funds, its running original 1600 single port with twin port heads that have been ported and twin ITC (single choke ) carbs so has a bit more go , used to tow the drag beetle on 4 wheel trailer no bother. Its just motor way speeds that are a bind , well the bits I ordered yester day morning came before 10am so have fitted both rear brake asy . Just need to make 2 new rear pipes due to unions being seized, no prob as have the tool (not a Mickey Mouse one either) to flair pipe . Next is to fit upper reservoir , need to bend hard plastic pipe to shape as this was the only one I could get.
 

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Discussion Starter · #17 ·
got stuck/ needed a rest so made this lamp from stuff lying around , range rover flex plate, some tube , old bike sprocket and VW crank gear, shade is old cutlery drain pot . Took ages to get the flex up tube !! needs a brass bulb holder .
 

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Discussion Starter · #18 ·
Found an old unopened can of stone chip, stirred it for ages and its still to thick to spray so might try some thinners . Had to mod lower steering column mounting (don't tell anyone but 90deg steering box was a bit out of alignment with hole in floor, woops) so added a strip of steel about 8 mm to lower edge. Drilled out one of the fixing bolts that sheared off , first drill I used was a tad small and tap wont start so took 5mm drill out of box . Teach me to not check its 6mm ,must have put it back in wrong hole so a rivnut will have to do-----------Need to drill heads of 10mm bolts in bumper mounts at rear , all 4 captive nuts broke free in blind box section and no room to get grinder in. Not sure how I will repair yet,2 ways to do it , open up end of box (there is a small cap at bottom already) weld some nuts to a plate and slide it in fixing it with plug welds or make same plate open up holes so nuts go in from outside and weld plate on. Both a pain in arse to do.
 

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thinners works fine to 'revitalise' old stonechip, done it a few times myself.
neil.
 

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Discussion Starter · #20 ·
Finished the stone chip , put wheels back on and dropped it off stand . Get to clean the 1/2 in of filler dust from roof now!! What a PIA to take handbrake mech out of dash , was a bit worn and jumped on teeth as bushing missing . Have another one , the frame was bent and so was the threaded eye that screws in rod. Must have come from one that had a major front smash, bush and ratchet bar was all I needed anyway but need to order a new handle before I can fit it .
 
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