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Old August 20th, 2010, 11:16 AM   #1
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 18
Default Moler Inc

Hi from the UK

I'm Ady, I live Lincolnshire, and love old VW's, and I'll take anything on!!

This is my current daily driver, a '64 UK RHD splitscreen panelvan, bought like this...




...did some of this...






...added some of these...


...and ended up with this...




...yes I am mental, and yes it's staying in red oxide

See all 1000+ pics HERE

Have a nice day now

Last edited by moler; Today at 09:14 AM.
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Old Today, 09:25 AM   #2
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

I did start one of these threads, quite a while ago too by the look of it!

To update you, the van has gone, and I've had a few old VW's since, non of any note really except my '67 Beetle...


...my current dub was imported into the UK from Australia, and is awaiting registration...


...but the one I'm building now is my favourite, and it's got a long way to go, but here's a teaser pic...


...if you bear with me I'll update this thread with all the posts from the UK Volksrod forum, so nearly 600 pictures of the project so far
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Old Today, 09:31 AM   #3
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

15-Oct-13

I know I have the oval to do, but the plans for that have got out of hand (expensive ideas!) So I've decided to build something closer to my original brief 'to build a Volksrod for as close to a grand as possible' :)

I bought this '72 1200 for 320 + 50 for delivery (less than the oval shell :o )...


...it has a cracking little 1200 engine that's in very good order, the gearbox is good too. The brakes all work as they should, and the electrics (for now) all work.

The body is poorly, but as I rod it most of the crap will go, especially as it's going to be a pick up ;)

So the plan in brief is to move the body back by 9" (no frame extender), 4.5" chop, and 4.5" channel. I had planned to just blank the back of the cab off with what effectively would be a flat sheet with a window, but having looked at a few pick ups have decided to go the extra mile and create a rear roof gutter and compound curved roof and a wide'n'low rear window. Long bonnet, wooden load bed, wood crate engine cover, evil sunvisor, banded GT's steels, General Grabbers, matt black and red......let's see how all that goes :lol:

This one is Moler Inc, I've had this logo for a while...


...and it'll adorn the doors when finished :)

This is an outside project, as the split has the garage, so fine days only on this :rolleyes:
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Old Today, 09:32 AM   #4
moler
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Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

17-Oct-13

Started on the strip out, and it truly is a basket case, just like I wanted!

Body welded to the pan...




...scored a long bonnet for this, and a '54 bonnet for the oval for only 150 :D ...


...marked for the first cut, hopefully leaving plenty of meat to play with...


...I'm off for a few days next week, if the weather's fine I'll hopefully get this sucker cut up :)

The running total is 470
This is after selling parts from the Beetle, and selling a few odd bits that have been lying around for while.
And buying, 2nd hand heater channels, 235/60x15 General Grabbers for the back, and wheels inc having the rears banded.
I have pan halves and A post bottoms to buy, but the biggest future cost will be having the wheels powder coated.
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Old Today, 09:33 AM   #5
moler
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Location: Lincolnshire, UK
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Default Re: Jet Rocket!!

18-Oct-13

I had a few hours today, so started by cutting out the body to get at the loom, no point sacrificing the loom for a body that gonna be cut up...


...then I started on cutting the back off...


...I had to get creative on the inside as everything was welded to each other with patches...


...and off it came...


...I really should finish tidying it out!...


...bit grotty under here, but most of it has to come off for the plans I have, so will get a good clean...


...quick tidy, and then continued with the strip out. I was on my own so cracked out the 10 ton body ram to help with the windscreen, only really interested in saving the seal as it's ok...


...I had been wondering what to do with the back off the pans once the body has been moved back, be looking at this they'll need to be standard, bonus...


...with the last few minutes I decided to cut the front valance off for no offer reason then to see the volksrod beneath :P


Garden art???


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Old Today, 09:35 AM   #6
moler
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Default Re: Jet Rocket!!

[b]24-Oct-13[b]

Ok, so I did go out to chop the roof off, honest, but got delayed by my newest toy, a blast cabinet. So after assembling it and having a play, as you do, I did turn my attention to the rod...


...incidentally, if anyone is the market for one these, this is the cheap one off ebay, and I can highly recommend it :D

Back to the rod then.
Simply chopping 4.75" (couldn't make my mind up between a 4.5" or 5" chop :rolleyes: ) out the front pillar isn't quite as easy measuring 4.75" along the pillar and cutting it out, oh no. To drop it 4.75 vertical inches you need to work out the long side of the triangle, the hypotenuse. Remember that from school? SIN CoSIN Tangent? no me neither, so I measured the angle and went and found a triangle calculator 'ont tinterweb', little over 5" as it turns out...






...managed to get both sides cut...


...then turned my attention to the B pillar. I don't want to cut straight through this, I plan to cut it in such a way that the inner section will reach the roof and outer section will reach down over the top. The theory at least is that I won't have to pie cut it, as, being a pick-up, the window surround doesn't require much attention...


...hopefully got this worked out and cut tomorrow :)
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Old Today, 09:37 AM   #7
moler
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Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

27-Oct-14

Hopefully these pictures will show what I'm trying to achieve, the red line highlighting the cut marks...




...it should line up nicely, layered for strength, and the seat belt mount is saved too...


...too late if it's wrong now...




While the chop I'm doing doesn't need a cross ways chop of the roof, it still needs to be chopped length ways, I want to retain the rearview mirror bracket so chopped that bit out...


...and then cut the roof in half, and used the bracket to hold things together...


...nearly got the A pillar spot on, no pie cuts here, ok maybe one small one...


...next up is remove the B pillars from the car and get them to line up to the roof cuts!!

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Old Today, 09:38 AM   #8
moler
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Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

30-Oct-14

Little update, but all progress is progress right ;)

Got the B pillars removed and started the desection...


...stripped everything from the front half so I can cracked on with it removal...


...lovely uncut dash :lol: ...


...hacked the pans off, they were in a bad state...


...easy access for the pedals, shame they've been welded in.


T'was dark then, so I turned my attention to another new toy, my freshly blasted (in my blast cabinet) Myford lathe bed...


...other bits have been blasted, time for paint...


...got to get the lathe refurbishment done so I can drop the spindles on the split
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Old Today, 09:39 AM   #9
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

13-Nov-14

I MUST BE MAD!!!!

Right I'll start with purchases, I have now got a pair of pans and a naps hat courtesy of VWH's 10% off on halloween. I've also got a pair of buggy cannons (jury's still out on whether they'll get used!!) and a pair of headlights.

I've got the front off finally, despite previous owners attempts to make them 'as one'...


...I haven't looked closely at the this yet, but already know it needs a lot of work, hopefully the cross panel is salvageable??...


...with the front out the way, and more of the floor gone, the spine reveals it ugly secrets...






...the framehead, as you'd expect, has seen lots of work too. The recent closing plate is coming off as I'll require something a little longer once things are moved back.

So this is what I have today, quite excited really, always wanted to do a bug floorpan :lol:


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Old Today, 09:41 AM   #10
moler
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Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

14-Nov-14

I started today by removing the steering and traction...


...then had a switch around so I can get closer to the garage...




...the framehead is even less clever than I thought...






...cleaning up the spine was the main job for today. The rear most section of floor was original, so came off easily after a little spot weld drilling and grinding...




...in fact there was quite a large section of original floor...


...shame it quickly turns nasty...


...other side done too, then a light coat of weld through primer to help keep the rust at bay...


...the front is much the same as the other side...


...time top look at the underside. The rear again is good...


...while the front is in need of help...


...I've removed the dodgy repair, and a large section of the good spine closing plate as I need to get in there for some jiggery pokery ;) ...


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Old Today, 09:42 AM   #11
moler
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Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

10-Dec-14

Been a while, lack of motivation due to the weather being crap the mainly culprit!

So, if the framehead wasn't looking too good from the top, it looked even worse from the bottom...


...an aftermarket repair section is 80, and I'd be able to save 20% of the OG framehead

Now even I'm not that mad :eek: I was offered a full pan for 75, 100 if I wanted it delivering, that was solid in all the right places, no brainer really :D

So, today I started dissecting this one, it's like deja vu all over again :lol: ...


...the all important framehead, in very good condition...


...TOP TIP if you have to drill loads of spot welds out, it's sometimes hard to see them from over the top, marker pen dots help no end...


...marvellous...


...even the naps hat is mostly solid...


...only the end needs attention, I intend to repair, reuse, and reposition the naps hat...


...the framehead closing plate is pretty unreal too...


...with some careful dissection I've removed the naps hat closing plate, what's left behind will stay put. This shows the naps head closing plate in what will be it's new position, the red line show how it will be filled in...


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Old Today, 09:43 AM   #12
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

11-Dec-14

Grabbed an hour or so when I got home from work today.

Quick reference pic, this'll be + 9"...


...I spent the whole of my time this evening removing in one piece the naps hat ready to reuse...


...the damage to the spine (oh the irony!) isn't a problem due to the modifications required...


...more tomorrow hopefully
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Old Today, 09:43 AM   #13
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

2-Jan-14

Managed half a day today, so just a small update.

Part of my plan for everything moving back 9", is to delete the handbrake and create something a little different. So today I set about moving the gear stick back while deleting said handbrake mounting point...


...it was a great feeling to finally break the welder out on this project...


...it's shame the spine doesn't stick to one profile along it's entire length...


...this is the old spine being harvested for some infill sections...


...it was dark by the time I'd got all lined up and tacked together...




...hopefully more tomorrow (but I said that last time!!)
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Old Today, 09:44 AM   #14
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

3-Jan-14

Wahoo, I actually managed 2 days in a row!

Started today by fully welding up yesterday days work, one small section I can't do as it needs pushing out from the inside to line up, so I'll do this bit later...




...then a grind back and smooth...




...not bad considering I didn't go mad with the blending in. Next up was to move the accelerator tube and adjacent pressing, here the salvaged piece from the other pan fleshly blasted...


...area cut out and tube shortened...


...welded in...


...and smoothed...


...attention then turned to covering the old one...


...to make the cover plate first you need some masking tape laid together to make a sheet...


...place it over the top of the concaved pressing...


...without a wax crayon to hand I had to improvise, first I highlighted the high points with a straight edge, and then highlighted that with a marker pen...


...transfer that to my filler piece...


...then cut out, get carried away! weld in and smooth without taking any inbetween pictures :lol: because of the nature of the joint, there's quite a bit of undercut, it didn't bother me at the time, but looking at this picture now makes me want to fill the rest in with weld, even though it's gonna be stonechipped!!


I now needed to move the pedal assembly mounting points, unfortunately there's a bracket inside the tunnel for holding the clutch cable conduit on the passenger side one, so I had to remove the spine closing plate earlier than I really wanted too. First you need to remove that pesky OG underseal, I used my preferred method of a slightly blunt chisel to chip it off...


...this took me less than 10 minutes...


...it took significantly longer to drill the spot welds out!...


...I got carried away again, but remembered just in time...


...this is the bracket, the clutch cable conduit still insitu, the other part of the bracket is for the fuel pipe...


...at this point it started to rain, so I had a clear up and retreated to the blasting cabinet to prepare the naps hat.

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Old Today, 09:46 AM   #15
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

8-Jan-14

I had a few hours this afternoon on the spine. I moved and welded in the pedal mount, then started to look at repairing the hole left behind using my favourite source of repair metal, VW ;) ...


...I ended up chopping a lump off that was already curved, but the flange edge was toast so needed removing...


...my sheet metal bender isn't strong enough to bend this, so I had to improvise...


...bent, trimmed and welded in...




...I was going to chop this out and weld in a repair piece, but after looking at it, I decided it could be straightened and welded up...


...it was beginning to get dark, you can tell from the fuzzy picture!...


...welded and ground back...


...and the other side...


...as it was now too dark to continue outside, I finished blasting the salvaged naps hat and got some paint on it ready for next time...


...it's in great condition considering it's OG, just this to contend with...




...
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Old Today, 09:46 AM   #16
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

11-Jan-14

So the last bit on the spine itself is the relocation of the passenger side pedal mounting hole, nothing special about it so I'm cutting a new mount and filling in the old one...


...I love these stepped drill bits, very easy to use, and do a good job...


...then to create the elongated circular hole I used a hole saw, using it tilted over means I can cut only one side...




...and then the other without losing the pilot hole, and the stability it provides...




...a little filing finished the hole...


...centre piece is straight forward...


...I filled the holes with a little stud like this. First I cut most of the way through the stud...


...when wound it in flush (sorry for the shit pictures!!)...


...then snapped it off leaving the filling piece ready for welding...




...welded in some mounting nuts too...


...ground back and blended.


I then welded up the piece that I couldn't get flush from the outside...


...used a piece of an old strut brace to line it up...


Naps hat time...


...after much measuring tacking, cutting the tacks, measuring, adjusting, tacking again, it's in place...


...next time I'll be repairing the end of the naps hat and it's OG closing plate, and making a new framehead closing plate.

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Old Today, 09:48 AM   #17
moler
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Location: Lincolnshire, UK
Posts: 18
Default Re: Jet Rocket!!

20-Feb-14

It's been a while since my last update, but I haven't been completely idle.

I invested in a gazebo to work under, and attached to the end of the garage. Unfortunately the wind had other ideas, and it didn't even last long enough to be able to take a picture of it :lol:

So the decision was made to repair the windscreen edges in the split, replace the screens and move it outside.
So I turned this...


...into this...


...then to this.


She was then moved outside and the hotrod moved in.

The only work on the Volksrod though has been on it's rear wheels. The original plan was to make a set of 7.5" wide GT steelies using some 5.5" wide GT's and some odd 5.5" wide bug wheels I have...


...but while re-rimming a pair of 6.5" wide Merc steelies for a friend I ended up with this as an offcut...


...so, circumcise the GT wheel...


...get a freshly machined up Merc rim (thanks Sean)...


...and add together...


...one 7.5" GT steelie, still need to blast the 2 sections before heating up the rim and shrinking it on
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