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Old March 22nd, 2015, 12:42 PM   #1
moler
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Default Volksrod pickup 'Moler Inc'

Moving the build thread into here to elicit feedback ;)

It all begins here...
http://volksrods.com/forum/showthread.php?t=31589


Sold the mock up gearbox last week, it's was a 1300 in good order, but why do they always have to do this?


Anyways, welded up the headbrake cover and smoothed it out...


...what are these for?


I had nice surprise from a mate, replacing these...


...with these :D ...




...designed with extra opening for his drag bug, really helps here too, you might recognise his work, if not...
https://www.facebook.com/SMJ.Performance?ref=br_rs

...before I start on the front body work I want to install the latch assembly for the bonnet, both for access, and positioning. Type 3 (and Porsche 944 apparently) better than the bug one as it has the second safety latch too...


...and it's going in here somehow...


...due to it's size I needed to mod the front structure...








...pesky hole to full in...




...done (or so I thought!)


...push bike brake cable...


...I needed a shorter bolt, thought I had an m4 grub screw somewhere (this is when the trouble started)...


...found these lovely countersunk set screws while looking, so countersunk the plate...


...cable entry point...




...S***, F***, AND B*******!!!!...


...the set screws bottomed put before tightening onto the plate, the shallow thread in the box section meant clearancing the screws didn't work either :(
Attempt one...


... :angry: and the one opposite this one was in the way of the latch mech, which I only noticed when I'd welded it in, it looked awful too...


...attempt two...




... :D but it took 2-3 hours to get back to this point!...


...finally...


...now to attach the top part to the bonnet...






...I'll start with one of these...


...this should give me enough adjustment...








...tentatively does it...


...I'll leave the rest of the welding till the bonnets off and turned over...


...with the bonnet now firmly planted, on with the bodywork. Salvaged bits to lengthen the quarter panels...




...I still have the seal edge to sort on this side, I need a cunning plan!...


...the other side is much nicer.




Thoughts on this please? maybe the fact that I can't make my mind up, has already answered the question :lol:


:)

Last edited by moler; December 19th, 2016 at 07:40 AM. Reason: New pic url's
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Old March 22nd, 2015, 12:53 PM   #2
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Default Re: Volksrod pickup 'Moler Inc'

Rock solid and clean ! Really like the hinge arms.
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Old March 22nd, 2015, 02:05 PM   #3
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Default Re: Volksrod pickup 'Moler Inc'

When in doubt, leave it out.

Quote:
Originally Posted by moler View Post
Thoughts on this please? maybe the fact that I can't make my mind up, has already answered the question :lol:


:)
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Old March 22nd, 2015, 07:32 PM   #4
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Default Re: Volksrod pickup 'Moler Inc'

Nice work. If you can 'blend' in the VW emblem (and from the skills you've shown, it's possible), I think it would look pretty cool.
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Old March 22nd, 2015, 09:40 PM   #5
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Default Re: Volksrod pickup 'Moler Inc'

I'd save the emblem for the bed of the tailgate of the truck.
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Old March 24th, 2015, 10:34 AM   #6
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Default Re: Volksrod pickup 'Moler Inc'

Hey Moler

I was reading your progress on your other thread...tried to reply and kept getting an error message...glad you moved it over here...

I love your thought process for sure....you are the man...I love your workmanship..

MikeC
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Old March 28th, 2015, 08:13 PM   #7
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Default Re: Volksrod pickup 'Moler Inc'

Awesome documentation of the hood latch! I am about to do a similar setup and this helped a bunch!
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Old March 29th, 2015, 01:47 AM   #8
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Default Re: Volksrod pickup 'Moler Inc'

hi moler
Been following your build since the start and its just an inspiration for me ....you got some mad skills and i just love the picture documentation ...i cant speak for anyone else but it is deffo helping me .....keep the pics comming glad you moved the thread to here im sure im gonna have a question or two, hope ya dont mind.
cheers
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Old March 29th, 2015, 11:08 AM   #9
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Default Re: Volksrod pickup 'Moler Inc'

Thanks chaps, always nice to know it's providing inspiration and guidance

Short update as I haven't been out there this weekend, went to the Resto show instead

I next wanted some structure to stop the sides flapping about, I started with this...




...then some uprights...






...I had an eyeball with the tank, I'd like it this far forward, but doubt it'll fit...


...the bit I've been getting excited about inner fender well time, sorry about the dust...


...I was bare metalling the other side...


...the front quarter isn't very straight, so to help me line it up I used a headlining spar...


...tacked up across the top...


...even got it fairly straight thanks to the spar...


...I'd like the infill to go along side the framehead structure, then curve the upper section in, a bit like the standard inner wing...


...so more structure required, I'm using bits of old bed frame for this, even using the original fixings...


...this time bolted from the bottom...


...this will hopefully help me get it all straight...


...and a little triangulation for good measure...


...and that's it for this week! I've ordered the metal for that should see the body shell finished.

I did try some arty shots with different lighting













Last edited by moler; December 19th, 2016 at 07:41 AM. Reason: New pic url's
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Old March 29th, 2015, 11:41 AM   #10
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Default Re: Volksrod pickup 'Moler Inc'

Looking fantastic! I especially like the third photo from last with the artsy lighting and the angled view.
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Old March 30th, 2015, 02:16 PM   #11
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Default Re: Volksrod pickup 'Moler Inc'

But, what about the emblem?
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Old April 12th, 2015, 11:29 AM   #12
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Default Re: Volksrod pickup 'Moler Inc'

Very little progress to report, but here you go

I had to invest in a complete new stretcher/shrinker to replace the shrinker I had as the new jaws don't fit the old bodies, it does mean I can get on with the offside front quarter panel top edge...






...tacked in, carefully!...


...looking much better already, there's hope for this side yet...


...my metal store order arrived too so I can get on with more of the front bodywork...




...bit of fettling to match the rear edge, this is looking good, but it was touch and go for a while!...




...very steadily welding all this up trying to prevent any more panel warp...






...then there was an interlude as my parents bus, Poppy, needed some love in the form of an engine reseal, t'was like tea bag ...


...and then I decided to have a tidy up and have a swap around in the garage to create more space, and the ability to section of the front for blasting and painting, this meant getting him back on his wheels, which was nice...


...scored this tool trolley from Ikea of all places, this will hopefully prevent me from losing tools, and keep things tidier...


....I finally got back to working on him today, and that started with me getting a couple of old worn out 195/45x15's put on the 7.5J wheels to see what wide front wheels look like? I likey, I likey alot ...






...back to some real work. The shape of the bottom of the front inner fender well was all wrong, so it needs cutting out and a rework...




...everything is steadily getting welded up...




...bit more structure to square off the under bonnet access panel...


...and that's how I left it tonight, normal service will resume this next week

Last edited by moler; December 19th, 2016 at 07:42 AM. Reason: New pic url's
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Old April 12th, 2015, 10:13 PM   #13
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Default Re: Volksrod pickup 'Moler Inc'

Brilliant workmanship! I love the wheel choice. This is just a very cool build.
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Old April 19th, 2015, 12:46 PM   #14
moler
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Default Re: Volksrod pickup 'Moler Inc'

Many thanks, I love them too

Structure finished, just the hole in the inner wing to fill in...


...it requires a tapered curve section, so in the bender one is fixed while the other end moves by 1/4" at a time...






...one tapered curve section...


...good fit first time (for once!) hole drilled for the bonnet release cable...




...trimmed to fit...


...holes drilled for plug welding...


...tacked...




...plug welds done and ground back, seam almost there...


...I want to make the front closing plate next, so I can have a matched curve at the end of the other side. A cross member is required for this...




...the closing plate needs to match the curves at the end of the inner wing, for this I need a former so out comes my trusty 6mm plate...


...cut to match the curve...


...on to the closing plate itself...




...clamped for bending...












...ends marked for flanging...


...cut with enough to bend over...


...former clamped in place...


...this much can be done cold...


...but the corner needs heat...


...once trimmed this'll be perfect...






...loving it ...




...using the same former I flanged to other end too...


...I've wanted to bead roll something on the rod so here's my chance, so a little practise piece...


...Finished the blind ends off using a spanner and hammer...


...rolling the beads into the closing plate...


...clamped in to mark for trimming down...




...trimmed and welding in progressing...




...I made a section of sealing edge to match the original and tacked it in, I'll show you how I made it next time...


...

Last edited by moler; December 19th, 2016 at 07:42 AM. Reason: New pic url's
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Old April 21st, 2015, 04:49 PM   #15
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Default Re: Volksrod pickup 'Moler Inc'

How does the spanner and hammer thing work? Do you have any before/during/after pics?
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Old May 3rd, 2015, 07:15 AM   #16
moler
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Default Re: Volksrod pickup 'Moler Inc'

Quote:
Originally Posted by Flipper_1938 View Post
How does the spanner and hammer thing work? Do you have any before/during/after pics?
I don't sorry, but it is simple, the roller only creases either side of the bead, so you have to finish off the ends, the spanner has the right shape

No update last week due to trying to sort the garage out, Nathan gave me 'tidy garage envy'

There's still a bit to do, but it's getting there. Blasting cabinet and some of the boxes are behind the partition, I've even found my bench!...


...onto how I made the seal edge then. I started by bending the metal round a piece of steel rod of suitable diameter clamped in my bender...


...note the newly rediscovered bench in the background ...




...this as far as I can get in the bender...


...on to the vice to finish the bend off...


...I then used a piece of angle iron to hammer against to straighten the edges out...




...then trimmed to length...


...so that's both sides on...


...weld ground off across the top, coming together nicely...


...onto the nearside inner wing/fender, it's construction will be the same as the other side...


...light weight structure going in...






...quick offer up of the rear wing...


...then it was time to turn everything orange ...


...tacked on...


...I had the same problem on this side as the other, the bottom of the rear edge was the wrong shape, or rather, not suitably matched to the wing ...


...I took a template off the other side so they'll match...










...I do like that slight flick forward at the bottom...


...in between getting it all welded up, I removed the underseal. It's horrible stuff but if you don't mind losing the paint, then a bent piece of metal with a nice sharp edge works well...


...this took about 15 minutes to do...


...I finished the cleaning up with a clean and strip disc.


The tool trolley is working very well, no more tools on the floor in the dirt, made this little addition, grinding disc storage...



There would have more today after I decided not to go to the Stanford Hall VW show, but I managed to give myself a welding flash yesterday So I'm sat here with my shades on trying to do this update, it's taken me twice as long as normal

Last edited by moler; December 19th, 2016 at 07:45 AM. Reason: New pic url's
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Old May 10th, 2015, 12:58 PM   #17
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Default Re: Volksrod pickup 'Moler Inc'

The welding flashed turned out to be metal in my eye again, so I went off to A&E on Monday night. And because yesterday I went to help a mate who'd just retrieved his camper from a restorer that basically taken him for a ride, and today I've been doing bits to the Squareback, there's very little to report I'm afraid.

I blame the eye incident on my new visor, it doesn't go all the way down due my ear defenders sticking out too far, I even vaguely recollect something doing in my eye too Anyway I've invested in a pair of slimline ear defenders so now the visor goes all the way down, result, hopefully this won't happen again


I hope the ponytail is required to make them work

The work I have done is just a continuation of the nearside inner wing/fender...














...that's all folks!

Last edited by moler; December 19th, 2016 at 09:06 AM. Reason: New pic url's
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Old May 17th, 2015, 11:38 AM   #18
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Default Re: Volksrod pickup 'Moler Inc'

I got all that weld ground back...


...and then turned my attention to this...


...I've never been happy with the look of the front, so decided to change it, off with the beam...


...off with the structural supports, there's now plenty of other structure to compensate...


...my plan for this means I need to make the studs for mounting the steering rack captive...




...my plan is to box the front in...








...the last of the box section...


...for the joint between body and pan...


...next the closing plate on the front, the top of the framehead needs a mod...






...closing plate template...


...not the prettiest, but much better, I'll finish the rest of the inner bit when the body comes off...


...the final bit is a removable section to go around the steering rack, but that can wait...


...possible locations for the battery?...






...though that last one quickly got ditched as I wanted the tank to be at the front, here it's sat on the inner arches/fenders...




...time for some tank mods, so I started marking out the required clearance...


...this needs to come off...


...so off it came...


...sat 10mm off the body...


...and it clears the inner arches/fenders nicely...


...I decided to move the filler to the end so removed it...


...and I'll use a baywindow fuel level sender in that hole...


...it's a little short, but I have some spares so I can lengthen it...


...new filler location...


...I've a mate who welds aluminium, so he can can make all this good again, including a boss for the sender...


...the tank needs some brackets to sit on...






...curving the top around the argon cylinder...






...a pair of trusty rivnuts, and the brackets drilled to mount...




...a strip of 3mm rubber to sit the tank on, allowance was made for this...




...more room than there appears to be...


...another possible location for the battery...


...anyone know of any problems with mounting so far from the starter?


Last edited by moler; December 19th, 2016 at 09:07 AM. Reason: New pic url's
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Old May 25th, 2015, 10:42 AM   #19
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Default Re: Volksrod pickup 'Moler Inc'

Not a huge update, as I've started removing the last of the paint and surface rust with the blasting pot....


...it's slow going, I get 10 minutes blasting, then it's 50 minutes clean up and pot recharge...








...I'm about 60% done, so more of the same next week!!

I also changed out the less than ideal 009 on my parents camper, replacing it with an SVDA item. While it was stripped down for inspection I thought it'd be rude not to polish it...




...did a rear wheel bearing on the camper too, what a PITA that was!!

Told you it wasn't huge

Last edited by moler; December 19th, 2016 at 09:08 AM. Reason: New pic url's
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Old May 30th, 2015, 06:02 AM   #20
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Default Re: Volksrod pickup 'Moler Inc'

Very nice sheet metal work!
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Old June 3rd, 2015, 04:29 AM   #21
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Man your work is so clean and you make it look so easy! Awesome work!
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Old June 8th, 2015, 10:56 AM   #22
moler
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Default Re: Volksrod pickup 'Moler Inc'

Thanks gents

A mixture of blasting, working on other peoples dubs, and doing summery family stuff has meant there's little to update you guys on.

The blasting is all but complete for now, there'll be more once the body is off of the pan, so I decided to tackle the roof.

Hopefully you remember the roof pulled like hell when I welded it, and subsequent discussion found the cause, other than me, was likely to be joggle I used on the infill piece, so I decide to cut it out and do it again...




...what I didn't factor in was how much the roof has shrinker along the weld seam...


...so I quick message to the mate with yellow bug that I've cuts off before and was on my way round with a grinder to harvest some VW metal...


...it's quite as good as I'd hoped but it was 5 miles away and a tenner so It'll do, rust removal...


...I'm using a big a piece as I possible bring the seam tio the edge and away from the centre, I would have liked it to wrap around the brow but it damaged so it's about 2"-3" off...


...I have this to contend with too...


...primed so I don't have stand on my head...


...and that's it, garage night tomorrow though

Last edited by moler; December 19th, 2016 at 09:08 AM. Reason: New pic url's
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Old June 14th, 2015, 11:13 AM   #23
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I discovered this the other day while measuring up for a hinge, I'd grabbed my 1 metre steel rule as I was the closet thing to hand and I'm glad I did...


...can you see the dip? maybe this will help...


...SHIT!!!

As it happens I'm in the best position to resolve this with the rework of the roof, so a slit here...


...apply my body ram here...




...straightness ...




...this is the resulting opened up slit...


...so now I can cut the rest of the roof out, this wasn't the final cut mark, but you get the idea ...


...as I cut round it I left a few tabs to support the roof while I begin tacking it...


...I started with a tack at the back...


...then offered up the skin...






...to help with the tacking I created a long reach Franken'clamp...


...added a bit copper with a little added heat dispersion...


...it stops the weld pool dropping out...


...and a bit of added cooling prevents the roof distorting from over heating...


...well happy with how this is going...




...just the over hang to sort...


...this is so much better than before...





Last edited by moler; December 19th, 2016 at 09:09 AM. Reason: New pic url's
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Old June 16th, 2015, 10:17 PM   #24
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Default Re: Volksrod pickup 'Moler Inc'

Just fantastic! You're inspiring me to make a few more mods than I'd planned on for my Single Cab.
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Old June 22nd, 2015, 09:44 AM   #25
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Nice to hear, happy to help

It's been a week of welding and grinding...




...all done. It still needs filler but the thickest will only be about 3mm, which is a vast improvement over the 15mm it needed before...


...next I initially turned my attention to the inner fender/wheel arch areas...








...but after a lose of containment ...


...I decided that these areas were best tackled from underneath. That area is hard to get into and still needs blasting, so I'll do them once the body is off the pan.

The doors and seat are pretty much the last jobs to do before the body comes off, so while the doors are off I'll do the seat first, being logical and that Quick clean and tidy up...


...you may remember this is how far I got with the bench seat base frame...


...and that I'm going to use this beetle rear bench frame...


...and with this baywindow 2/3rd seat frame, I have a plan


In other news, I fitted this Flat 4 GT steering wheel in the Square too, not as straight forward as it should have been, but worth the effort...



Last edited by moler; December 19th, 2016 at 09:10 AM. Reason: New pic url's
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