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Old June 22nd, 2015, 12:16 PM   #26
BrownBUGUK
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Default Re: Volksrod pickup 'Moler Inc'

Class work as usual.
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Old June 28th, 2015, 11:56 AM   #27
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I started by removing the base rail of the Beetle seat, and losing the outer springs as these are too short once reshaped...


...to mount the springs to the new base I was going to carve the base rail up and weld it to the new one, but after an internet browse I found a better way, too the lathe for some batch work ...




...and weld on like so...


...the sharp eyed will have noticed that these are a little shorter now! I steamed into making them paying much attention to the springs, unfortunately the spring need lightly shorter tube for them to sit straight, so they all got cut down afetr I'd welded them on


...I reshaped the outer springs to create the centre springs, this still left me one short as one was broken. After much fettling it sits about right...




...I tried to join the top rail like this...


...but I only managed to get one full hole drilled into this hardened spring steel before the cobalt drill bit went blunt, so only one rivet! Bits of wire were added to keep things together while I come up with a plan...


...this is the original joint from later beetle seat frame, sections are layered...


...and this is the one form the Baywindow seat frame, the sections are butted up, I'll probably end up making one of these...


...how the end pieces look before shortening...


...except for two springs and the joint the base is done...


...happy with that...


...lick of primer, some might recognise the colour ...


...and a lick of paint...


...I sourced another base, cheers Mr B for that...


....so all the long springs are now in...


...however, I've had to stretch all the cone springs (one was already broken) and they're still not quite right, so I've ordered all new ones that should hopefully be longer...


...onto the back then, this the bay window one that needs widening, and I'm going to re-spring it almost completely...


...the bits I need...


...these had already snapped off due the original construction method for the seat making them weak. They press spikes into them for retaining the cover, you can just see one at the left end of the bottom bracket leaving very little metal for strength...


...welded into the a section of Beetle base rail...




...so here it is with the original Baywindow end sections, and another piece of Beetle rail for the top...


...fits nicely...


...the second Beetle seat base allowed me to double up on the lower rail for added strength, just need to section it to get over the spine of the floorpan...






...all looked to be going well...


...until...


...DOH!! Back to the drawing board. Amongst the off cuts I found two pieces with bits of the original curves on, these worked brilliantly, and looked a whole lot better...


...that's better...


...fully welded up and ready for some springs...


...option one and two...


...I went with two, square at the top and over hanging the bottom...


...only it was too low...


...so went with option three, square top and bottom...




...I'm now half way across with the springs, each one is modified from original, first it's straightened, then re-bent, I'll try and capture the process for the next update...



Last edited by moler; December 19th, 2016 at 09:10 AM. Reason: New pic url's
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Old July 6th, 2015, 12:02 PM   #28
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Default Re: Volksrod pickup 'Moler Inc'

So the process of making the springs, this is what you start with...


...it's too long by this much...


...that leaves the end like this...


...using a shifter I bent it back so it'll fit properly...


...next you have to straighten the other end out...










...leaving you with this...


...then you just need to reshape it...






...finished spring...




...this the original fastening...






...and repeat nine times ...


...now to resize the top frame...


...because it's now in a number of bits, and it's very hard so difficult to drill, I need to make some joining pieces like these originals...














...I've made mine for a lapped joint as opposed to a butt joint...


...I had to make six of those to complete the frame...




...reusing the clips to attach the frame to the springs...




...I used one of those original butt joining piece for the joint I failed to complete on the seat base.


The J section frame on the back rest doesn't look that good, so I decided to use up some the J section off cuts to box it in...




...bit better...


...the new springs arrived for the seat base...


...cut in half and suitably manipulated, all were installed...




...bit more black paint and it's coming together nicely...


...next I need to hold the thing down. I'm copying another of VW's ideas for this...


...take one piece of rusty angle iron and...




...the hole to the left is so I can test the slot cut...






...happy with that


...you may recognise this cut...


...this is for the base frame that'll be welded to the floor of the rod...




...while the idea is for the seat to be adjustable back and forth, it's being tailored to look it's best when positioned for me ...


...tacked into position, I can drill for mounting the brackets...


...the ever reliable rivnuts...


...took this pic to show you how the base frames aren't at 90 but that the brackets are...


...ready for a test fit...


... ...


...this position wasn't a guess as I'd already trial fitted it. The position is perfect, I know because I sat there for a good 15 minutes and even made brum brum noises

In other news, I sorted a few issues out with this blue late bay in between the showers...




Last edited by moler; December 19th, 2016 at 09:11 AM. Reason: New pic url's
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Old July 12th, 2015, 04:00 AM   #29
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Default Re: Volksrod pickup 'Moler Inc'

amazing work as usual!
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Old July 12th, 2015, 11:53 AM   #30
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Default Re: Volksrod pickup 'Moler Inc'

Thank you Psychopork

These are the hold down brackets in use...


...they hold the seat down very well, but it was difficult to get in and out, so I've changed them to be more like the original ones, still holds the seat down very well, but eases getting the seat in and out no end...


...I put the padding in from the bug rear seat, and added a steering wheel is see what access was like, I might need a flat bottom wheel by the time it's on the floor...


...anyone know what this wheel is? it needs repairing but I love it...


...for the MOT the rear of the seat has to be secure, so after much deliberation I decided to go back to basics. As you lift the front of the base the rear drops enough to be located into slots, this how VW did it, though I'll be using slots located at either end. I liberated this tube from an old bunk bed...


...to pass though the gap between the B pillars it ends up this short...


...so I need to stand the slots off from the side a bit...


...angle of the dangle ...


...for angling the slots...


...radius'd to make 'em priddy...






...nice...




...except I couldn't get the f****r out!!...


...slight mod took care of that ...




...it feels very solid, even the missus had a try...


...time for a tidy up, this is all that's left from 2 rear seat bases from a bug, and 1 baywindow 2/3 front bench.


On to the latest door...


...the door I'd already done was cut in the wrong place really, and was rotten along the bottom. I got this one off a mate, cheers Col, and save for the handle delete it was in good condition. I didn't want to make a load of noise and dust, so started with the paint stripper...














...I did finish it off with a clean and strip disc, but this took very little time, and created very little dust ...


...I thought who ever had done the handle delete (not my mate) had just filled it with filler...


...but no...


...so on to the chopping, I used the old door for dimensions as it fit well...


...this is one of the incorrect cuts on the other door, staggering the cut means as you cut into the skin, it's in the right place for where the hinge moves up, and keeps the inner frame lined up nicely...


...lock side chopped and tacked back together...


...this is another change. There's an inner strengthener for the hinge, I cut through the last one, this time I saved it...


...frame tacked and the door spun over, this is where it all comes together as I'll have an almost complete skin edge to edge, with no filler in the middle of the door at all...


...joining the skin edges here should prevent distortion...


...I've cut the handle finger recess out as I'll be making my own handles ...


...needs a little fettling, but not bad for a first pass...


In other news, I had a quick timing and emissions check to do on the lovely Poppy, Ma & Pa's '71 Devon Sunlander...



Last edited by moler; December 19th, 2016 at 09:12 AM. Reason: New pic url's
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Old July 13th, 2015, 01:43 AM   #31
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Default Re: Volksrod pickup 'Moler Inc'

Really nice work on the seat
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Old July 13th, 2015, 05:34 PM   #32
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Default Re: Volksrod pickup 'Moler Inc'

WOW! Just WOW! What an awesome job you are doing! Thanks for sharing and inspiring us world wide!
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Old July 19th, 2015, 11:27 AM   #33
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Default Re: Volksrod pickup 'Moler Inc'

Thanks peeps

Door handles then, I wanted something low profile but obviously handles, this some of the 1/2" box section I bought for the safari's...


...I used some of the box section left over from doing the rear body structure to create a housing for the handle...






...I used an old thick filler gauge to create a little room for paint ...


...this is the pivot point, and I chamfered the end for ease of operation...


...creating said pivot point...


...I must have got excited as there are a couple of pics missing here, mainly adding a section to the rear of the handle...




...offered up ...


...I need to anchor the handle housing to the frame...






...works really well, but I will need to think about drainage...


...the old door gave up a section to finish the door skin off...




...all tacked up, I'll do all the welding in a oner when the door coming off the car again...


...need to create an access hole to get to the back of the handle...


...although it seems I got distracted with door top frame ...


...misjudged the cut at the front!!


That's all I got done this week as, in other news, I fitted a TQR chassis notch kit to this...


...my mate Andy's cracking Split

Last edited by moler; December 19th, 2016 at 09:13 AM. Reason: New pic url's
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Old July 20th, 2015, 05:25 AM   #34
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Default Re: Volksrod pickup 'Moler Inc'

Truly amazing work!!! And I thought I was good with metal, well I clearly DON'T have sheet metal working skills, yeah I can do a tiny bit of sheet metal work, but it doesn't even come close to yours & a bunch of others here

This is just an amazing project


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Old August 2nd, 2015, 12:01 PM   #35
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Epic praise, I'm unworthy, truly :

Missed last week as I didn't have a great deal to update y'all on, this week I have enough, hopefully

So after misjudging the forward cut on the door top I thought I'd try another one...


...as you can see, with rear edge lined up the top gap runs wide, just another of those anomalies where the same part doesn't fit or line up! So I went back to the first door top and used a small infill to bridge the gap...


...this is an idea I've had for a while now, radiusing the rear corner of the door top...


...I removed the paint for a better look...


...then went for it...


...I cut section off the other door top to blend the step in on the back of the frame...




...I then needed a section with a flange for the inside frame radius, I started with this...


...stretched it bit...


...and got this...


...but the fit wasn't great...




...so I started again with a tapered flange...


...and that fit perfectly...








...I decided to make the top edge in one thickness not two, 2mm thick plate in this case. This tin of stopper made a useful former...














...using this piece of original VW metal...


...I created the beginnings of an outer skin for the corner...






...it was at this point that the door tops vertical frame being narrower than the top began to bug me!...


...so I took decisive action...


...and using the other top frame...


...bastardised it...


...yet another bit the other frame...


...it began to look like a proper hack job!...


...obviously appalled I forgot the intermediate pictures ...


...the top curve was a little fat so I fixed that using the bit I originally cut out...


...and then this needed a pie cut...


...it got even uglier...




...and just as I thought I'd cracked it...


...I noticed the taper. I added a little primer the see it better. To give you an idea the top frame is 35mm wide, the side was meant to be 33mm wide, and it is at the bottom, but it tapers to only 31.5mm wide at the top ...


...more decisive action...






...the outer frame is probably more weld than plate now, but at least it's done...


August is going to be a lean month for garage time, my wife has a week of training in her new job, and there's a holiday to have, so I'll apologise now for the lack updates

Last edited by moler; December 19th, 2016 at 09:14 AM. Reason: New pic url's
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Old August 3rd, 2015, 04:35 AM   #36
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Default Re: Volksrod pickup 'Moler Inc'

Wow

Amazing work...you are setting the bar pretty high for sure...

thanks for sharing...

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Old August 4th, 2015, 10:39 AM   #37
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Default Re: Volksrod pickup 'Moler Inc'

I agree, amazing work and dedication to detail!!
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Old August 4th, 2015, 12:20 PM   #38
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Default Re: Volksrod pickup 'Moler Inc'

Nice work... Really enjoying this build... Nice to see some over-engineering on the other side of the Pond.
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Old August 15th, 2015, 12:51 AM   #39
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Default Re: Volksrod pickup 'Moler Inc'

Anyone else pissed off jealous over this guy's sick skills?
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Old September 6th, 2015, 09:56 AM   #40
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Default Re: Volksrod pickup 'Moler Inc'

Very kind words, thank you

It's been a while, but I haven't been idle, I've done work on three bays and my Squareback. But now it's time to get back to the Volksrod.

First job was to have a tidy up as the garage had imploded some what...


...better.


Next job back on the rod was to sort the door gaps out. I already had some skims between the hinges and A pillar as, for whatever reason, the front gap on a Beetle always seems too tight to me...


...after fitting 3mm in the top and 4mm in the bottom the gaps were improved to the point of happiness...




...I then fettled the infill around the door top corner to get an equal gap...




...and so onto creating the rounded door jam. I'll start the curve off on the new door top ...


...I welded the corner piece in fully, both internally across the top, and external down the joint, I then tacked the next bit of the jam in...




...happy I was going the right direction, I welded it in fully...


...then shaped the top in situ...


...and welded it...


...I got a little carried away with the next two pieces...




...then a simple piece to fill in...




...a bit of smoothing back...




...although this picture doesn't really show it, it looks loads better having something behind the door gap.




Sorry it's a short update, I was getting worried I'd lost my enthusiasm for the project, but these 5 short hours have reinvigorated me

Hoping to get a few hours in the garage in the week next week, but I'm in London over the weekend so next weeks update will be short too, normal service should resume thereafter

Last edited by moler; December 19th, 2016 at 09:14 AM. Reason: New pic url's
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Old September 20th, 2015, 11:11 AM   #41
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Default Re: Volksrod pickup 'Moler Inc'

Last bit of the outer frame then, and the gap needs sorting here too...


...quite a bit of slitting and manoeuvring...


...it wasn't pretty...


...until it was ground back....




...for the rest of the welding on the door it came off. I decided to make the shims a permanent fixture...






...I welded the bottom edge up...


...next a couple of bottom corner repairs...




...I decided to make use of one of the scrap doors...










...I seem to have missed taking pics of the other corner

Next was the door handle housing...


....then over for some more welding, I'll let the pics do the talking...














...I've removed most of the paint now, I've left the centre as I think I'll have to remove it to sort the window mech out...


...last bit of the inner frame...


...I'm beginning to hate pie cuts, so decided to take a different route with this one using some of the other frame...


...I liberated and shaped this section...










...door back on and looks better now it's all bare metal ...


...the inner gap is looking good too.


The bottom of the B pillar wasn't flush with the door...




...that's better...


...but it took this to achieve it...


...I ended up gardening all day today (Sunday) so this as far as I've got.

In other news, I went mobile

Last edited by moler; December 19th, 2016 at 09:15 AM. Reason: New pic url's
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Old September 20th, 2015, 05:48 PM   #42
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Default Re: Volksrod pickup 'Moler Inc'

Excellent.
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Old September 24th, 2015, 09:06 PM   #43
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Default Re: Volksrod pickup 'Moler Inc'

You make that looks easy in pictures, what a fantastic job you did making that door fit just right


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Old September 26th, 2015, 10:41 AM   #44
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Default Re: Volksrod pickup 'Moler Inc'

Nicely done
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Old November 1st, 2015, 10:58 AM   #45
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Thanks guys

The first lot of pictures are from a little over a month ago, I then had a bit of a wobble, and have since changed the overall plan back to plan 'A' which was MOT'd and on the road at the earliest opportunity, and finish while using

So carrying on with door I moved onto the window winder which is now a little too big, and needs shortening...


...to do that I needed to remove the winder mechanism...






...so with it in position it needs a new bend...


...like so...


...I then had to replicate the cut out for the mech...


...temporary fixings...


...not too shabby...


...except when installed it sticks out too far, it needed to go over the hump...




...so I straightened it...


...and re-bent to go over the hump...


...I should point it out I'm going with one piece windows as I like 1932 Ford 3 window coupes, so when I noticed this sticking out...


...I needed I rethink. How about lowering the winder?...


...I sat in the rod and tried the position and it was fine, so that's the way round. Seeing as the winder was moving I removed a section of the inner door to gain access to the window runner...




...measurements transferred...


...and holes cut, and time for a runner...


...except this where the plan changed, I don't need side windows for the MOT so I've left the door there. In the interim I haven't been completely idle, I've been working on the Squareback, but I'll leave that for another thread

So fast forward to this last week, and for some motivation I put him back on his wheels...




...he's ace

Someone asked about surface rust, this is pretty typical...




...so after the discussion about primer before filler I've decided to get him into some primer, I started by keying the original paint on the roof...




...I had some occasional help today...


...so this is where I start...




...all the bare metal has once again had the surface rust removed with a clean & strip disc, I then removed dust and grease with white spirit then panel wipe, and finally I used a tack cloth. Then I started priming...


...the roof and scuttle dried over lunch, then after my youngest wanted a go, so in the fresh air of the garage doorway I let him do the tip on the bonnet...


...I did the rest wearing my mask ...




He'll left like this now for a week as the missus is at work all week so no garage time save for maybe getting him turned round so I can start the next job, the other door

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Old November 2nd, 2015, 09:24 AM   #46
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Default Re: Volksrod pickup 'Moler Inc'

I always look forward to these updates!
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Old November 3rd, 2015, 01:12 PM   #47
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Default Re: Volksrod pickup 'Moler Inc'

^^ As do I ! This is a great project.
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Old November 8th, 2015, 11:11 AM   #48
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Thanks guys, nice to know the updates are enjoyed

I've managed an afternoon in the garage today, which started with me turning him around...




...random picture of one of the sticker on Jet Rockets original tailgate, time to resurrect that I think...


...this is the reason for the turnaround, the passenger door...


...my OCD won't allow the doors to have two different inner pressings, even though once the door cards are you'll never see them...


...so my other door will be giving it's inner structure...


...the reduction in size of this door is the same as the other, so I'll skip through the pics...






...that pesky inner pressing doing one ...




...it fits nicely just need to finesse the gaps



Last edited by moler; December 19th, 2016 at 09:17 AM. Reason: New pic url's
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Old November 17th, 2015, 11:17 AM   #49
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Nothing to report on the rod as I've had little project to accommodate a new toy, TOOL, I mean tool

This is one of those 3 in 1 sheet metal tools...


...but it needed a stand, something on wheels so I can move it around as it weighs 112kg (or 247lbs). I've had this box section lying around waiting for me to make a frame for a press, but it's perfect for this job too so I'll use it here instead...






...the only things bought new were the castors...






...it's taken about 4 hours to remove the transit oil and get it set up, but I have to say I'm impressed with it. There are 2 very specific jobs I have in mind for it on the rod, they don't justify it's purchase price (do new tools need justifying?) but I have a couple side projects that may help it pay for itself, quite literally

Last edited by moler; December 19th, 2016 at 09:18 AM. Reason: New pic url's
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Old December 5th, 2015, 12:18 PM   #50
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I've had a very little time on the rod over the last couple of weeks, and have also been doing a couple of other jobs, first was a new door for the garage, the other was broken last year in the wind and I hadn't been able to use it, but with the colder weather here I needed it back usable again...


...and then I had another beam to narrow...


...so back to the passenger door, and sorting those gaps out. With a couple of shims the front edge was easily sorted...


...rear was far to wide so I had to chop the tack welds to sort that out...




...I'm missing a few pics here, but I tacked it back together with the gap closed up and then removed the door to repair the bottom edge...


...the first repair panels from the 3in1 ...




...new corner section from the other door...


...it took me 5 minutes to find my measuring tape, seriously ...


...new bottom section of the door skin...




...good plug welds...


...lots of welding later...




....followed by lots of grinding!...


...next job will be to repair the inner panel

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