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Sorry for the lack of posts recently, the biggest job has been stripping the underneath of the whole body to get it all painted in epoxy mastic. Bloody horrible job!
I took a gamble on a 996/boxster spacesaver wheel fitting and it does with loads of space to spare in a variety of positions! For interest, the tyre size is 105/95R17. http://www.ricola.co.uk/images/cabri...spacesaver.jpg I cleaned up the rear of the front valance and welded on some bolts for the intake mesh, all edges prepped for plug welding on. http://www.ricola.co.uk/images/cabri...lance_prep.jpg 50x3mm strip with captive nuts welded on to the bottom between the inner wings to give a rigid mounting face for the air dam. http://www.ricola.co.uk/images/cabrio/spoiler_strip.jpg Front valance plug welded back on along the sides and bottom and then painted up in the epoxy. It's made the whole front end incredibly rigid!You can see I also painted the whole underside of the body in epoxy. http://www.ricola.co.uk/images/cabri...nt_valance.jpg Carpet strip plug welded back on to the top of the heater channel and painted. http://www.ricola.co.uk/images/cabri...rpet_strip.jpg rear interior modified bodywork given a good epoxy coating http://www.ricola.co.uk/images/cabri...nside_rear.jpg Rear end also got the epoxy treatment. Just about ready to start on the external paint prep now! http://www.ricola.co.uk/images/cabrio/epoxy_rear.jpg |
Wow! you built yourself one sexy car, nice job!
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She's gunna be a beaut!!!
Jason |
Keep going Ricola!!!
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Bit of an update...
I have done some work recently but not overly exciting for pictures as it's all paint prepwork. http://www.ricola.co.uk/images/cabri...arter_fill.jpg Rear quarter panel skimmed and smoothed... http://www.ricola.co.uk/images/cabrio/wiper_weld.jpg I welded up the LHD wiper holes http://www.ricola.co.uk/images/cabrio/bonnet_repair.jpg Bonnet needed a few sections replaced due to poor previous repairs rusting http://www.ricola.co.uk/images/cabrio/kamei.jpg Kamei mocked up again, luckily there is a suitable double bend on the bottom of the front wings to mount to. I plan to make a mould out of the cut down Kamei piece and a metal strip that will be bolted up on to the body, I'll then make up a fibreglass part. http://www.ricola.co.uk/images/cabrio/kamei_mock.jpg All mocked up to see the final effect. I don't think I'll get away with running the numberplate there unfortunately! http://www.ricola.co.uk/images/cabri...wings_fill.jpg Bodyworking the rear wings now... I'm changing jobs and have a couple of weeks holiday to use up over the next month so hopefully I might even get it in paint by the end of August! Rich |
The cut-down Kamai looks really good mounted like that Rich! (but you already knew that I guess ;) )
Prep work is the most labour involved, but time spend now will determine the outcome, so very well done you take your time. |
Great work so far Ricola! (as always) :goodjob:
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I'm still out there working...
http://www.ricola.co.uk/images/cabrio/door_rust.jpg More rust found on the bottom of the door... http://www.ricola.co.uk/images/cabrio/door_repaired.jpg and repaired... http://www.ricola.co.uk/images/cabri...ngs_fill_2.jpg More sanding! I have to give praise to the How to guides on www.mig-welding.co.uk for bodywork, especially the ruler trick and also a tip I found elsewhere of adding a bit of fibreglass resin to the filler to make it thinner. http://www.ricola.co.uk/images/cabrio/kamei_flange.jpg I cut a metal flange piece which was bolted to the body, the remains of the Kamei was then bolted in place and the two bonded together with fibreglass filler. The ends will be reshaped and the whole thing smoothed before I use it as a master to create a mould for a new fibreglass part. |
Another good day:
http://www.ricola.co.uk/images/cabrio/wings_etch.jpg All 4 wings in etch... http://www.ricola.co.uk/images/cabri...high_build.jpg and two coats of high build primer... |
First colour coats! I'll do the final coats and clear with them loosely attached to the body, this is more to just cover the primer so I can put them out of the way while I do the rest of the prep work...
http://www.ricola.co.uk/images/cabri...irst_paint.jpg |
http://www.ricola.co.uk/images/cabrio/wings_clear.jpg
I decided to just finish the wings, the metallic particles are so small I can't see them being painted separately from the body making any difference. I put on some wetter coats of the cellulose metallic and finished off with 3 coats of 1K acrylic clear. http://www.ricola.co.uk/images/cabrio/wings_clear_2.jpg For information, I used a cheapo spray gun for the etch and primer coats, then an Iwata AZ3 HTE2 spray gun with a 1.3mm tip for the colour and clear coats. This was all running from my 3hp 150l compressor that I made up a short copper section with water drain. It has actually given a really nice finish out of the gun with not a single run! A couple of small bits of dirt got in one wing but should easily polish out when it has fully cured. I had to paint the wings in two lots under my workshop porch bit as it was threatening to rain... |
OK, small update:
http://www.ricola.co.uk/images/cabri...id_painted.jpg Decklid painted, no real problems, although I did sandblast the slats as they were too fiddly to sand nicely. http://www.ricola.co.uk/images/cabri...et_painted.jpg Bonnet finally painted. I've done this 3 times now! First time there was some striping visible in the colour coat as the passes weren't wet enough to flow into each other nicely. Then I got a really good second colour/clear coat and left it in the sun for a few hours to dry before putting it on some cushions in the conservatory just to have it out of the way but they left imprints all over the bonnet! I had to wet sand it all back and paint for a third time, I'm not doing it again!! I'm working on the doors now and I've found out why somebody had put a gold pinstripe under the normal sidetrim. They had drilled one of the doors in the wrong place and the stripe was to cover it up! So, filler removed and the extra trim clip holes were welded up. Another useful tip: hold a piece of copper against the back of the panel and the weld won't blow through. I also had to repair a few local bits of the door bottom and the copper strip trick also worked well to stop the weld melting away the metal at the edges. I'm definitely on track for finishing all the paint by the end of the month! |
Sooooooo sexy ;);)
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looks good!!! keep up the good work cant wait to see the finished project.:goodjob:
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Doors painted...
http://www.ricola.co.uk/images/cabrio/doors_painted.jpg More rust uncovered! This is the drain tube from the scuttle area by the wipers, it's a well known rust trap in 1303s so I wasn't too surprised. Repair from the inside of the car was the easiest way to go. Here I have opened out the rusty areas ready to weld new sections in. http://www.ricola.co.uk/images/cabri...drain_rust.jpg To repair the tube I decided to use another trick I saw, bend some copper strip around the part and weld straight onto the strip creating the new section. http://www.ricola.co.uk/images/cabri...n_repair_1.jpg The outside surface is smooth (as it went straight on to the copper surface) but the inside needed some work with the die grinder . All good in the end though! http://www.ricola.co.uk/images/cabri...n_repair_2.jpg I've been busy doing minor bodywork too getting the main shell ready for paint, nearly there! |
Very good! This thing will be made mostly of welding wire when you are done!!
Jason |
Looking good. Love the color.
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Another good day today!
Body now etch primed.. http://www.ricola.co.uk/images/cabrio/body_etch_1.jpg http://www.ricola.co.uk/images/cabrio/body_etch_2.jpg and two coats of high build primer! http://www.ricola.co.uk/images/cabri...gh_build_1.jpg http://www.ricola.co.uk/images/cabri...gh_build_2.jpg next job to wet sand this back ready for colour... |
You are moving right along! But, I think you need a step ladder to reach the top of the windscreen frame... :D
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I can't wait to see it finished!!
Well done! |
I thought somebody might comment on the top bit, lol! It is in very good condition and only needed a bit of a rough up, no point covering it in primer again as it only needs colour..
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Just finished reading this build post and I must say that looks awsome mate!:cool: I really look forward to some day seeing it in the flesh!!!!!:)
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Got the shell in paint today! :D
http://www.ricola.co.uk/images/cabri..._painted_1.jpg http://www.ricola.co.uk/images/cabri..._painted_2.jpg Now I just have to restrain myself for a while to let it fully cure... |
Last concentrated burst of activity before I start my new job tomorrow.
I made up a couple of aluminium plates to stop the torsion bars sliding inside, also a small bracket for the 2 new fuel pipes (5/16" kinifer) which ended up clashing with the body so I'll have to redo that! http://www.ricola.co.uk/images/cabrio/torsion_stops.jpg You can just make out the chargecooler pipes coming out through a new plate at the front of the chassis, I also ran new front and rear brake lines. Instead of the usual cheap rubber body gaskets, I bought a long length of foam gasket and made my own VW style one, didn't take too long, hole punching it as I went to line up with the body mount holes and then glued any ends together with sikaflex. http://www.ricola.co.uk/images/cabri...sis_gasket.jpg Body on! I also mounted the bonnet as it was taking up far too much space in my workshop. http://www.ricola.co.uk/images/cabri..._chassis_1.jpg The rear frame will get stripped/painted, but that's for another time. it makes a very good carry handle when lifting the body about... http://www.ricola.co.uk/images/cabri..._chassis_2.jpg |
I cant tell and I hope you dont need to go backwards, but I really hope that foam is closed cell, open cell will be a nice sponge for h20 and you'll end up with a super rust situation again!
Jason |
Ricola,
Man that is coming out nice.. Just wanted to recognize all the very hard work and time put into that project.. When your free, come work on mine ;) Alex |
Cheers guys. Yup, don't worry Jason that's closed cell on there...
Rich |
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Jason |
love the work you did on the pan this thing is going to be awsome when its done keep up the good work!!!!! :goodjob:
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Rear valance panel needed extending at the top to meet what was left of the body neatly. It bolts in place at the top and is then clamped between the body and wings down each side.
http://www.ricola.co.uk/images/cabri..._valance_2.jpg Plenty of ground clearance! http://www.ricola.co.uk/images/cabrio/rear_view.jpg Body panels all 'thrown' on for the moment as my wife was sick of them spread out everywhere, lol! http://www.ricola.co.uk/images/cabri..._painted_4.jpg I'm happy with how it's all sitting... http://www.ricola.co.uk/images/cabri..._painted_3.jpg |
Very nice! :)
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i demand to start a club, something like my dub rolls on 18x10s & it looks ****in tough! - just gotta find some .5" wider for me cos 9.5's dont cut the mustard :P
that said can ya go lower than that? will be a shame to ruin the nice lines with the soft top folded back. when your done, take me up on the offer of coming to aus! mine needs some attention & i have a spare room :D |
We'll be in different clubs as I roll on 19s! I'm sure it will end up a bit lower, maybe so there is a small amount of air between the tyres and wings but not much, I certainly don't want to compromise the drivability for a few mm ride height...
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Ricola where did you get the rear valance i desperately need one.
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Just my local VW parts place: www.gsfcarparts.com
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If anybody else had a feeling that the doors didn't look quite right in the previous pictures I was having the same thoughts! In the end after repainting and then re-clearing they have come out right. I also wet-sanded and machine polished the whole car so I can start refitting brightwork and other fittings...
http://www.ricola.co.uk/images/cabri...polished_2.jpg Much better! http://www.ricola.co.uk/images/cabri...polished_1.jpg Door windows in, it was like doing a 3D jigsaw puzzle that would only go together in a particular sequence! http://www.ricola.co.uk/images/cabrio/doors_windows.jpg I've put in all the door hinge screw not too and am really please with how the doors line up with the rear quarter panels, the swage line is perfect. I just need to pack up the rear body spacer a small amount to get the door gap parallel. |
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The plan is to go with a tan sonnenland one... It came with a tan vinyl one in very good condition but that has shrunk around the side windows... It needs to come off anyway as I need to replace the wooden bow above the rear screen.
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looks great keep up the good work :)
cheers andy |
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