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  #46  
Old June 18th 2018, 18:13
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I've actually got a set of 944 Alloy arms, so I wouldn't need yours in trade. We can definitely work out something for my steel ones.
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  #47  
Old June 20th 2018, 08:36
H2OSB H2OSB is offline
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Errg! I really just wanted to get rid of those alloy trailing arms. Ok, when you get to the point where your steel arms have become free (of the car), let me know.
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'74 1303, Outlaw sedan (with a GL flavor)
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  #48  
Old June 20th 2018, 16:30
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So I pulled the car out onto the driveway to blast and grind any areas where I suspect there would be rust I need to deal with. At this stage I’ve only done the outside bits, and at times I’m quite excited about not finding a horror story, and other times I’m like “ugh, not as good as I hoped”. Don’t get me wrong, this is much better than the other cars I’ve looked at, but not as good as I initially thought. On the plus side, the C-Pillars are no surprise. I bought the car knowing that they were going to be a problem.


Easy fix, no welding required…






Couldn’t blast in here with my quick setup, but I also have a whole second replacement section so the rust isn’t a problem.








This area was a bit of a surprise. It looked very minor with the black paint over it, but once I started blasting the glass went right through it.


I knew about the bits above the trim line…but the rot continues down below.


I see major surgery in my future :P


In general, I haven’t seen late model cars rot so close to the rain gutter, without showing rot higher up. I’m not sure how deep into this C pillar I need, or want, to cut into …but I think after fixing the passenger side I’ll have a good handle on how much to open it up.


This will be an easy fix.


I think this heater channel will end up being a patch job, not a full channel.

Doesn’t look like I took photos of the rear apron, but it’s a 50/50 mix of cheer and disappointment. The apron is straight and sold, but the area covered by the deck lid has some very rough surface rust pitting. I will see what can be done to fix it, but I might be looking for a new apron to graft in. Haven’t touched any of the interior rust, which is mostly in the C-Pillar or luggage tray. Will fix the outside first, and then worry about the inside of the car. Also haven’t looked too hard at the usual rust in front of the dash, as I’m not sure how much of the factory dash I’m keeping.

-Dave
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  #49  
Old June 24th 2018, 11:52
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Amazingly, I found a parts car in my tiny town that I could cut solid sheet metal from...





-Dave
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  #50  
Old June 24th 2018, 18:20
H2OSB H2OSB is offline
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Moss does NOT grow on you sir.
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  #51  
Old June 25th 2018, 14:58
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Hahaha, well I gotta work on projects when I'm home and not traveling for work. Once mid-summer hits, I won't get any time until winter.

Got a few hours in the shop yesterday, and managed to rough-cut most of my repair panels. Turns out the inside wall of my parts piece was rotten, so I won't be able to fix the inside panels I cut with metal from this car. Hmmmm...that was a mis-calculation on my part.





Hopefully tonight I'll start shaping the pieces, and maybe start tacking them into the car. At this stage I also need to decide if I'm going to run trim on the car, or weld up the holes. My gut reaction is to weld up the holes, and run vinyl trim if I want the look. But the front quarter panel has that seam and an indent under the trim that I would then need to deal with. The easy way out is to of course keep the trim...
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  #52  
Old July 19th 2018, 14:10
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Just in case anyone is wondering...the car hasn't fallen on me in the shop.

Rally Bug lost a valve seat, and I had to do a quick engine teardown to get the parts list before I headed off on some travels. First stop was American Rallycross at Circuit of the Americas, followed by four days of route planning in Texas for a Hagerty event. Now I'm in California for four days of route planning and some VW shop visits, then I'm off to Nebraska to find the twistiest roads I can find. Apparently after Nebraska I get to go home, for a full three days before flying off again for American Rally Cross and World Rally Cross in Quebec. Whew!

...I did say it was going to be a long-term project, right?
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  #53  
Old December 15th 2018, 04:18
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I did say I'd be pretty busy with work, right? Geesh. I'll admit, I've been avoiding the project for a while, as putting panels back into the car is basically a make or break it item on the shell of the car. I've done a bunch of work to the '58, and started prepping for an engine build for it this winter. I have started ordering a bunch of parts for the German Look, figuring if I can't get stoked on doing the body work, I'll start on some of the mechanicals...but, none of the parts have arrived so....

I'm going to have to make some new patches, as the donor car was rotten in the same area...but I figure I might as well make patterns that are as close as possible.


I'm probably going to have to make this one out of fresh steel. I cut it too small, and the surface rust was more than surface. Of course, it's all curves...great.


Oh hey! I got one right! :P


Well...#%&@. We're out of gas.


Won't be able to get back to it until after Christmas.

-Dave
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  #54  
Old December 16th 2018, 23:15
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Hi

Nice work. I'm not sure how to explain this but on all my cars I cut the very bottom of the section where A pillar and front 1/4 meet, VW put a small hole in there but it can easily block up. The section I'm talking about is where you describe the photo as "I think this heater channel will end up being a patch job, not a full channel."

Steve
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  #55  
Old December 22nd 2018, 12:06
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Digging this project!

FWIW, there are plenty in Europe that would LOVE to have so little rust to deal with..

One thing that happened to my car again and again was little surprise pinholes popping up repeatedly.
Any undiscovered little rusty spots can pop back up through your new paint after a couple of years.
It became quite frustrating to keep finding them.
Not until I got the entire car blasted did it give me a chance to properly strategize WRT patch pieces and where.

It's also nice to skip the dusty step of removing paint to prep for weld.


Not sure it's an option in your area, but,
Nowadays there are a lot of these mobile wet blasting rigs,
They come to your place, and do the entire shell in your driveway in one day.
Since it's wet, there's no dust or mess, no panel warping, and no neighbor complaints.
(OK, some neighbors will complain about anything..)

You want to have most of the heavy undercoat and seam-seal out of their way first.
My favorite for that stuff is a 'twisted knot' wheel on an angle grinder, FWIW.


It would have saved me basically an entire summer of miserable blasting work in my own home-made white-trash tarp-garage blasting "booth".

I'm still coughing up little bits of lung in the morning...
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  #56  
Old December 22nd 2018, 22:18
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Thanks! I wish I could spend more time on it, but making money to pay for the project is a good idea as well :P

I moved to an island three years ago, and while its a very large island...I don't have the contacts and people I did in my old town. I haven't actually looked to see if there is blasting available in the area, but I'm sure there is. I know there is a C02 blasting guy in my town, which is super cool, but haven't looked into the pricing. The big problem is I live in a very wet town, a rainforest actually. And even though I have a heated garage, it's not great to leave things in their bare state. Not to mention it rains from October through to May...so I can't take the car for blasting unless I rent an enclosed truck, or wait till summer. But yeah, I should probably consider just getting it done.

I did laugh at your UK comment. I know I'm complaining about a "rusty car", but man it could be so much worse. My '75 is a perfect example of that!

-Dave
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