Yesterday afternoon found some spare time to work on my car (2 hours). At first I drilled the holes for the welding a second time. (The first time I drilled them 2mm too small with my sleeping head :roll: ). After that there was some grinding, bending and again some grinding needed to fit the plate good.

Soon it will be welded on.

Wiebrand

more more more!

Hahaha here is some more.

It's time for another update:

Today worked 13 hours at my car.. so it will be ready hopefully ever :D.

At first an pic of the last time. All the holes are drilled for welding the underplate to the chassishead.
http://www.keversite.nl/fotoalbum/fotos/23629.jpg

This morning first brushed clean the places where the welds will come.
http://www.keversite.nl/fotoalbum/fotos/23630.jpg

Then the fuellines "covered" with some gardenhose to avoid "making noise".
http://www.keversite.nl/fotoalbum/fotos/23631.jpg

And finally the plate is ON!!!!
http://www.keversite.nl/fotoalbum/fotos/23632.jpg
The holes are welded with an open hole between every two welds. These "open" holes will be welded with some heavier welder.

Some grinding.
http://www.keversite.nl/fotoalbum/fotos/23633.jpg
http://www.keversite.nl/fotoalbum/fotos/23634.jpg

The restmaterial after replacing the napoleonhut and the underplate.
http://www.keversite.nl/fotoalbum/fotos/23635.jpg

Final result viewed from the top. http://www.keversite.nl/fotoalbum/fotos/23636.jpg

Because I had to cut something of the floorpans to replace the napoleonhut, I maked them to the right size today.
http://www.keversite.nl/fotoalbum/fotos/23637.jpg

The chassis would be ready today for the "doorlassen" and after that painting, wasn't it that I cut out another piece of ****. :rolleyes: This piece of $hit was some welded in plate that I did my first time I ever welded. Totally ugly, so I cut it out again and make it soon nice.

Grt Wiebrand

haha, very nice. i wish i had the room to keep in my frame inside to work at one it at the same time as working on the body

great work, keep it up!
James

Hi Wiebrand,

I went through your post and found it very interresting. I was wondering about the side scoop installation:
From your pics, i do not understand how you made the recessed part arround the shape on the body before putting the scoop on. Do you have more pics of that procedure?
Also, i was wondering how that the scoop interfere with the interior sides (pics?).
Finally, how does it connects with the engine compartment? (pics also?)

From your experience with these scoop, how complicated a job is it to install? Is the remmele kit comes complete, with the proper mounting instructions?

Thank you for your answers and keep on with the good work.
Louis

Hey Louis..

Here is the proces to make them fit in the car..

At first an mold is maked from wood for the "Remelle" air-intake.
http://www.keversite.nl/fotoalbum/fo...2004230237.jpg

The mold. So the gabs for the intake are the same size and on the same hight on both sides.
http://www.keversite.nl/fotoalbum/fo...2004230055.jpg

From the mold drawed on the body.
http://www.keversite.nl/fotoalbum/fo...2004225627.jpg

set-of
http://www.keversite.nl/fotoalbum/fo...2004205905.jpg

He's in
http://www.keversite.nl/fotoalbum/fo...2004210117.jpg

Some other pics, that may be useful
http://www.keversite.nl/fotoalbum/fo...2004225627.jpg

http://www.keversite.nl/fotoalbum/fo...2004205742.jpg

http://www.keversite.nl/fotoalbum/fo...2004205818.jpg

http://www.keversite.nl/fotoalbum/fo...2004205950.jpg

http://www.keversite.nl/fotoalbum/fo...2004210027.jpg

Grt Wiebrand

I maked it with an "verzettang". (I don't know the word of it in English)
Just like the left thing on this pic
http://www.rustbuster.nl/Aanbiedinge...rzettangen.jpg
It works like this.
http://www.rustbuster.nl/Lassen_en_l...p/Proplas5.jpg

On the link below you see all the pics I have of making them fit.
http://www.keversite.nl/fotoalbum/my_photos.php?id=2005

The last corner of the sidepanels have to be "cut" out. You can see in the above link 1 picture of the place were the scoop will be in the inside. On the inside the scoop goes an bit to the backside. So an gab have to be cut out of the sidepanels. Sorry no other pics of that, because I'm not that far right now.

It will be connected to the enginebay with an hose of aluminium or RVS of 70/80mm in diameter. At the engine bay I wil mount at each side one plate (with an cut out hole) with an "tube" welded on that plate. This completed plate will be screwed to the firewall (were also is drilled two large holes). And also sorry to say, but no pics yet. But when the chassis comes more to the end I will be going further on the body. I will post pics as soon as I can. :D

At first I want to say that I don't have an Remmele set but an Remmele-look-a-like set bought by www.kevertuning.nl. You buy them without any instructions! But if you have questions you always can call Frank (verry nice guy who always want to help you).

Till now the installation is not quite complicated or so. Rustrepair is more complicated than this ;)

Thanks Louis!!!

So yesterday worked an couple of hours on the bug. I had bad luck with the heater so I had to work in the cold .. but hell yeah. 8-[

Yesterday I cut out an earlier reparation. I was to bad welded in (one of my first weldings ever).

He's out.
http://www.keversite.nl/fotoalbum/fotos/23846.jpg

Then "knocked" some sheet metal, welded it in and grinded it smooth. Just like of factory Smile
http://www.keversite.nl/fotoalbum/fotos/23847.jpg

The side will be welded of soon (with an heavier welder).

After that I brushed all the weldings clear so I can seam weld them soon.

Wiebrand

it looks like a pretty good job

by the way, what are you planning on putting in the car concerning the engine?

Thank you very much for the great answer Wiebrand.
Louis

Because of less on money the first year(s) it will be an original 1600 (with spagetti-header and bigger "sproeiers" (don't know english work for it). When I have some money, I will buy another 1600 and built that up with an turbo. After that (if I ever come to this point :rolleyes: ) there will be some kind of 2 Liter with Bi-Turbo or with G60 and turbo.

But that's all in the future.

Wiebrand

AWESOME car weibrand, looks brilliant, yours seems to be going down the similar road to me, inspirational, im guessing the word you were looking for may have been valves? um, love the car, top work, im doing mine to the same extent, like inside the tunnel etc, so it will be 100% rust free, but the main difference is...

Im going water cooled subaru!!! hot damn its going to have some HUGE balls! keep the updates coming aswell :agree:

Thanks mate!

So, tonight my brother wanted to help me, so we made some good progress.

At first we grinded some seams blank, so we can seam weld it the next time.
http://www.keversite.nl/fotoalbum/fotos/24015.jpg
http://www.keversite.nl/fotoalbum/fotos/24017.jpg

Also better welded a couple of holes and old weldings and grinded a hole lot of old weldings. The chassis is now ready for seamwelding and after that for some paint.

Then also drilled some small holes for better drainage in the future.
http://www.keversite.nl/fotoalbum/fotos/24018.jpg
http://www.keversite.nl/fotoalbum/fotos/24019.jpg

Then welded better the bracket for the Sparco fuel-inlet.
http://www.keversite.nl/fotoalbum/fotos/24021.jpg

After that we grinded some welds on the sidepanel, and beat out some dents in the door and near the fuel-inlet. This is the totalpicture till now.
http://www.keversite.nl/fotoalbum/fotos/24022.jpg

Bye

Wiebrand

Today it was the plan to work several hours on my car, but after all I could only find 2 hours that I could work on my car.

Tonight seam welded my chassis. It was the plan to seamweld hole the chassis, so the napoleonhut, the chassishead, along the chassistunnel and at the back the gearboxforks. But only the chassishead and the napoleonhead could be seam welded. The gearboxforks were too much corrode by rust and the floorpans are too tin so we could not weld nicely on that places.

Some pics.

http://www.keversite.nl/fotoalbum/fotos/24808.jpg

http://www.keversite.nl/fotoalbum/fotos/24809.jpg

http://www.keversite.nl/fotoalbum/fotos/24810.jpg

Wiebrand

hi !

you are not frightened by the futur weight of your superbeetle ?? :confused: :eek:



Ben

I am asuming he will have a strong enough engine to overcome the added weight from all the additions and strengthening .

Tonight from 8 till half past 11 worked on my car.

At first welded 4 nuts on the chassishead for mounting an skidplate.
http://www.keversite.nl/fotoalbum/fotos/25036.jpg

After that maked an schedule for the bolts and other things that have to be bought or be immersed.

Wiebrand

Tonight founded two hours were I could work om my car. Brushed with the grinder an spindel, steeringaxle and an brake clean. Also I almost made the list of bolts/nuts/etc compleet for my car.

WIebrand

Looks great Wiebrand!

To bad you don't live in Sweden, if so I would have made you a great deal on bolts ;)

That would indeed be nice... :laugh: .. But it al comes together.

Yesterday worked from 3pm till half past 11pm.

Had an verry good party saturdaynight, so after an heavy revalidation it was time to get back to work. Just bruised my pink and had also 2 stealbrushhairs standing in my forhead. Put hell yeah, that's life :rolleyes: .

Brushed several things 'clear'.
http://www.keversite.nl/fotoalbum/fotos/25209.jpg

And also finished the list of bolts and things that has to be bought or zincked.

Wiebrand

So tonight found some time (2,5 hours) that I spend on my car.

ANd again it was time to brush several things of the chassis clear.

The result:
http://www.keversite.nl/fotoalbum/fotos/25399.jpg

http://www.keversite.nl/fotoalbum/fotos/25400.jpg

See ya next time
Wiebrand

Time for some pics of yesterday. Had an short day on school, so I could work some hours on my car.

At first the, on wednesdayevening ordered, products came in yesterday morning. Everything good packed and good quality. NICE :D
http://www.keversite.nl/fotoalbum/fotos/25428.jpg

http://www.keversite.nl/fotoalbum/fotos/25429.jpg

Then it was time to again brush some things clear. See the pic underneath.
http://www.keversite.nl/fotoalbum/fotos/25427.jpg

Greetings

Wiebrand

After all you've done, are you really going to use drum brakes?

Jason

Iwas thinking the same thing!

If I had the money I was already going for BMW-disks..... :o (student)

But yeah.. since this things are bolted on.. I can update them later. Maybe this new plates will be on for a couple of months.. but who will say.

SO after four days of party-ing (carnaval in the Netherlands), it was again time today to work on my bug.

And AGAIN brushed clean several things.
http://www.keversite.nl/fotoalbum/fotos/25645.jpg

http://www.keversite.nl/fotoalbum/fotos/25646.jpg

Also grinded several weldings and completed the handbrake-bracket.

WIebrand

I´m also a bit disappointed about rear drum-brakes, but these are very easily updated later if you want!

How much you´re going to lower your car? I was thinking if you can move your front control-arms upwards enough if your car is going to be very low? I meen it´s not good having inner end of control-arm lower than the wheel-end of it when car is fully loaded with driver etc...

I think it is good idea to make some reinforcements into 03´s chassis front as it´s usually very rusted and weak... Nice job and patience for this kind of things!

Car is very nice! (altough I don´t like the curved windscreen so much) I´m waiting when we can see it painted...?! :cool:

Great project. looks like it's coming along nicely. :D

On my brakes, I went from drums to Ghia disk, now I'm putting 993 4-pots on all corners.

I am also a student, so I understand where Wirbrand is coming from. That's 1 reason I decided to go Subaru. From the way I looked at it.... Subaru - A lot of work. Vs Type 4 - A lot of money. I'd rather work hard and spend less. Then the other way around. Since I saved a bunch on the engine. I can afford to upgrade everything else.

Good Luck Wiebrand. Keep up the great work.

Thanks for the nice words guys!! :D

Always good for the motivation :laugh:

Past thursday grinded some weldings at the chassishead.
http://www.keversite.nl/fotoalbum/fotos/25686.jpg

After that started with "blocking" with P180.
http://www.keversite.nl/fotoalbum/fotos/25684.jpg

Saterdayevening (after work) spend another 4,5 hours (till midight) with cleaning the barn and masking it with plastic.

So today another hour or 10 worked on the car.

As first the underside of the chassis cleaned with "silicone-remover".
http://www.keversite.nl/fotoalbum/fotos/26289.jpg

And then the painting could start.
First good heating, with an air-canon.
http://www.keversite.nl/fotoalbum/fotos/26293.jpg

"Throw-away-cup" made
http://www.keversite.nl/fotoalbum/fotos/26294.jpg

Underside of the chassis painted in Epoxy Primer. Onderzijde
http://www.keversite.nl/fotoalbum/fotos/26295.jpg

Upside of the chassis painted in EP.
http://www.keversite.nl/fotoalbum/fotos/26298.jpg
http://www.keversite.nl/fotoalbum/fotos/26296.jpg

And some lose pieces of the chassis in the EP.
http://www.keversite.nl/fotoalbum/fotos/26299.jpg
http://www.keversite.nl/fotoalbum/fotos/26300.jpg

That's it.

Wiebrand

Sweet!... so what paint(s) are you using for the chassis and mechanical parts?

Lookin good.... those air/heat cannons are cool eh? wish i had one!


Jonathan

Thanks Jonathan.
I'm using 2 layers of EP (Epoxy Primer), the tunnel will be "plamuren", then all the seams of the chassis will be sealed with "strijkkit", then all the underside of the chassis and trailingarms will be set in "Bodyschutz", then most things will be painted in red or black 2K-paints, and as finish everything will be shot in clear.

For all the paint I use 2K.

p.s. for the thing in the " .. " I don't know the English translation of it.

Yesterdayevening I worked from 7 till 11.30p.m. on my car. Checked several lose pieces of the chassis, brushed some things clear and stored them warm and dry.
After that I got further with the list of bolts and to buy thing till 1.00 a.m.

Wiebrand

Very nice. Im not sure what brand your using for the under coating of the chassis, but i would recomend using a product from Wurth thats called SKS Black.... or if you wanted to paint it body color with stone protection (EXACTLY LIKE PORSCHE UESED) you could use the SKS Grey. the only down side to the Wurth product is that you must use the Wurth Multi sprayer for there products to look correct (looks like the fatory porsche under coat).
We use it a lot on restorations at work... it's the only way to make it look factory porsche. but it would be nice on a beetle to!

Jonathan

The brand I use for undercoating is Teroson. And I use the grey one.. for an faster and les use of the red paint.

Wurth is also verry good stuff.

Some little update off yesterday.
Bought myself an threatmeasurementtool and checked every lose thing of my car. Measured everything again. And now my list is for 97% completed.

TIME TO BUY SOME NEW STUFF next week.

Wiebrand

I planon using Por15 on my chasis. What do you guy's think.

I heared several good things of them.

I stay with EP because then I can also bondo right on it (because there is not going any interior in).

Wiebrand

Sooooooooooooooooooooooooooooooooooooooooooooooooo oooooooooooooooooooooooooooooooo what an day was yesterday. This project will be my dead once ;)

Yesterday I maked an 13 hours day at my car.
At 11 o'clock I was in the cold barn. Begun to brush the gearbox clear. What an piece of $h!TT to do... but yeaahhhhhh.
http://www.keversite.nl/fotoalbum/fotos/27116.jpg

Then brushed some other lose things clear. Blew the tunnel clean. Masked some holes. Also hanged several things and ungreased them.
http://www.keversite.nl/fotoalbum/fotos/27114.jpg

Then mixed the paint. So I could shot the layers of EP around midnight.
At first the inside of the tunnel.
http://www.keversite.nl/fotoalbum/fotos/27113.jpg

Then the lose things.
http://www.keversite.nl/fotoalbum/fotos/27115.jpg

I could be some nice end of an long day. But I was forgotten that my brother had cleaned the paintinggun and that I haddend to thinner the paint soo much :(

Wiebrand