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Old June 17th, 2011, 01:24 PM   #1
BrownBUGUK
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Default UK VW Rusto-ROD epic
Re:: Check my progress......   

Hi all, A while back, Dec2010 I decided to give my old '72 bug a bit of lovin', nothing too involved, just a quick patch n go project to make a slam door driver out of her, shouldn't take a coupl'a months tops!!

Well, so much for that plan.......here's how it went:

This is NOTHING compared to the RODical work elsewhere on this site but I thought you might like to see what we're doing over here.

This is how she looked



Just before I stripped the wings:



Only to find the usual tinworm:



At this stage I was still relaxed, ya gotta find some sh*t eh?

Meanwhile, I had been dicking around with the horn grills and rear number plate light:



.

Then I found this

Front n/s heater channels




Next.....

Last edited by BrownBUGUK; June 18th, 2011 at 12:32 AM.
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Old June 17th, 2011, 01:30 PM   #2
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Default Re: UK VW Rusto-ROD epic

Also, this





Ultimately .....this:













Basically, the whole bottom 15cm of the body had to be renewed as well as the floorpan edges.

Remember, this was supposed to be a quick patch n go !!
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Old June 17th, 2011, 01:39 PM   #3
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Default Re: UK VW Rusto-ROD epic

Anyhows, I pressed on regardless, many would've bailed at this point I'm told (most of my friends) but me being me, I didn't:

Instead I did this , Jimmy did a lot of this so it ended up like this:















All still a 'work in progress' but looking much better
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Old June 17th, 2011, 01:52 PM   #4
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Default Re: UK VW Rusto-ROD epic

You can multiply by x2 all of the welding in the previous post as both side were just as fooked as each other.

This was a girl with a 'past' to say the least, remember that C pillar shot :



Well, the entire roof had been nailed on by an ape with a glue gun, alignment issues were coming to the fore:

I always knew something wasn't quite right! This B pillar shot shows how bent it was:



Check out the lump of bondo in the top corner of the window apperture:



A little fettling was required:





You can also see the roof cut across the C pillar.

Pillar cuts as they were uncovered:







Broke this joint free with a nail file



Now all safely welded:


Here's the bit I like, while cutting out rust on the rear gutter we did this:



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Old June 17th, 2011, 01:57 PM   #5
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Default Re: UK VW Rusto-ROD epic

Inspiration







Oh yes, if mine looks even half as good as these I'd be a happy guy. Notice how they're all brown? That's because I'm going brown, satin dark chocolate brown to be exact, already got the tank done:



Pleased with that
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Old June 17th, 2011, 02:08 PM   #6
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Default Re: UK VW Rusto-ROD epic

We're now into May 2011, so 5 months have elapsed since I started, optimistically, with a view to ending by end of Feb'11 sooo a little longer than planned

All the time I've been doing stuff, almost every day:

Setting up how I want the lights:



Fixin' the hood



Painting stuff:



Buying stuff:





Patchin stuff:









Restorin stuff:











Generally working my way through a tick list as long as my arm
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Old June 17th, 2011, 06:48 PM   #7
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Default Re: UK VW Rusto-ROD epic

Keep up the good work ! Your eather a very brave man for working with so much rust or just plain crazy.
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Old June 18th, 2011, 12:29 AM   #8
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Default Re: UK VW Rusto-ROD epic

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Originally Posted by Daddy o's 67 View Post
Keep up the good work ! Your eather a very brave man for working with so much rust or just plain crazy.
Why thank you DaddyO, I have to admit it was a LOT more rust than I expected and I have to thank Scotty (using his workshop/equipment) and Jimmy (welding/metalwork) if it wasn't for my buddies I wouldn't be where I am with it.

Can't wait for paint
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Old June 18th, 2011, 10:28 PM   #9
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Default Re: UK VW Rusto-ROD epic

Amazing!
that's allot of work!!
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Old June 19th, 2011, 02:00 AM   #10
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Default Re: UK VW Rusto-ROD epic

Dude that must suck to find that much rust in what looked like a perfectly good car... still, good on ya for perservering!!

Love that color too!!
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Old June 19th, 2011, 04:25 AM   #11
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Default Re: UK VW Rusto-ROD epic

love it, love it, love it!!!!!!!!!!!!!!!!!!!!!!
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Old June 19th, 2011, 09:41 AM   #12
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Default Re: UK VW Rusto-ROD epic

I want those body jacks Dammit ...

Coming long nicely too ... lots of hard work but always a good result ...
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Old June 21st, 2011, 04:00 AM   #13
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Default Re: UK VW Rusto-ROD epic

wow.........thats was some severe cancer, you have grave patience man! kudos!! keep it up, i wanna see the brown shine! :)
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Old October 9th, 2011, 01:25 AM   #14
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Default Re: UK VW Rusto-ROD epic

Hi all, Thank you all for your comments, well a long time has passed since June but a lot has been achieved:

All that pushin n shovin, fillin n rubbin resulted in a body ready to paint





Much, much flatting ensued!

Then colour.......



Here it is fresh out of the oven

a particular favourite photo

Tidied under the hood:


Couldn't decide on Porsche or Rossi??





Went with Rossi:



Rear end with modified plate housing and reworked gutters...giving it a wider, fuller back end view I think:





Well, that's where it is folks......hope to have it on the road within 3-4 weeks. Thanks for watching
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Old October 9th, 2011, 03:04 AM   #15
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Default Re: UK VW Rusto-ROD epic

This is the interior:







I think it'll contrast well with the dark brown, got some ideas of how to detail the dashboard and make it look a bit more like a 50's rod



Loving my Moto-Lita wheel. Looking to fix the same outer trim along the middle of the dash from speedo outwards on both sides. Along with the pinstriping (inside and out, classic red, cream & grey) I have planned it could look cool.
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Old October 9th, 2011, 05:37 AM   #16
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Default Re: UK VW Rusto-ROD epic

Can't believe anyone would spend that much time, on a worthless rust bucket!













LOL
Sure glad you did!
Anyone would be very proud, to own your car!
You all did an excellent job -- any plans for the next one?
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Old October 9th, 2011, 07:15 AM   #17
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Default Re: UK VW Rusto-ROD epic

Quote:
Originally Posted by dt113 View Post
Can't believe anyone would spend that much time, on a worthless rust bucket!













LOL
Sure glad you did!
Anyone would be very proud, to own your car!
You all did an excellent job -- any plans for the next one?

Haha.....If I knew then, what I know now maybe I wouldn't have started this whole project. I'm more than pleased with how it's turning out..... believe it or not there's more to come, this is only phase1.

Phase2 included removal of engine and some tarting up in certain areas

Thank you DT, very kind of you to say.
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Old October 11th, 2011, 01:39 PM   #18
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Default Re: UK VW Rusto-ROD epic

Quote:
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Can't believe anyone would spend that much time, on a worthless rust bucket!
Over here on our heavily salted little island, that car was in 'good condition for its age'.
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Old October 9th, 2011, 07:33 AM   #19
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Default Re: UK VW Rusto-ROD epic

Beautiful work on such a 'patina ridden' bug. Until your rod I wasn't a real fan of brown...but WOW!
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Old October 9th, 2011, 09:01 AM   #20
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Default Re: UK VW Rusto-ROD epic

looks great. good job. someone did a good job hiding all that mess. glad you sorted it out right
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Old October 9th, 2011, 10:34 AM   #21
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Default Re: UK VW Rusto-ROD epic

Quote:
Originally Posted by crack monkey View Post
looks great. good job. someone did a good job hiding all that mess. glad you sorted it out right
None of the rust (mess) was hidden, all was cut out and replaced with, mostly, genuine VW metal (T4 van side panels) or repair sections. Mind you there is a lot of welding under the bondo, can't be helped when the complete panel isn't replaced, I know what's there, but hell, it 'll be OK

Quote:
Originally Posted by V8Transporter View Post
Beautiful work on such a 'patina ridden' bug. Until your rod I wasn't a real fan of brown...but WOW!
Why thank you V8, you're not alone in coming around to brown....most of my friends in the VW world didn't like the sound of it either, but gradually as they see it for the first time they have to admit to liking it. It's actually turned out a little shinier than I had first planned...too much hardener in the 2xpack paint made it that way, next time I'd go to 30% matting agent rather than 20%.

As I add the shiny stuff the contrast becomes more apparent which is what I was looking for

Thanx both of you for your replies.
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Old October 9th, 2011, 10:42 AM   #22
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Default Re: UK VW Rusto-ROD epic

Dicking about with the small jobs.......that take forever to do

Like sorting a bad contact coupled with seized spindles on the wipers, round and round wondering why they don't spin up. Finally traced a bad contact in the loom/earth and the seized spindles meant all out again, then in then out as I had to set the 'rest' position....that took a bit of thinking to sort out

Now I like the positioning at rest:

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Old October 9th, 2011, 10:48 AM   #23
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Default Re: UK VW Rusto-ROD epic

I went for Rossi headlights cos I love the lights on this 40's Ford and I think they look like them. I'm aware of the irony though - Late bug with early slopey wings (wrong 'un) going for an after-market upgrade to uprights, fuck it





Even the blade bumper (fender) look alike and the general roundy shape, like the curves on a woman
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Old October 11th, 2011, 02:28 PM   #24
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Default Re: UK VW Rusto-ROD epic

Quote:
Originally Posted by BrownBUGUK View Post
None of the rust (mess) was hidden, all was cut out and replaced with, mostly, genuine VW metal (T4 van side panels) or repair sections. Mind you there is a lot of welding under the bondo, can't be helped when the complete panel isn't replaced, I know what's there, but hell, it 'll be OK
.
i ment before you tore into it. the car looked nice and solid with your begining pics. i would never have guessed it was that rusted.

you have done a steller job
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Old October 11th, 2011, 11:19 PM   #25
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Default Re: UK VW Rusto-ROD epic

Ahhh, now I get what you mean CM, thanx for the compliment , I enjoyed it although it was hard work at times, so what started out a a quick fix n go turned into a full on proper job - check the resto here: http://www.volkszone.com/VZi/showthread.php?t=682286

Should be pretty soon.
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