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Old January 17th, 2016, 11:20 AM   #51
moler
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Default Re: Volksrod pickup 'Moler Inc'

This pic gives some perspective to the build...


...OCD satisfied, the inners now match...




...back on the car and the gaps are fairly ok...




...on to the top then...






...rounding the corner off...






...a few pics missed but here it's done and I've started on the door aperture...


...happy with that...


...just the door handle to go...






...all done and primered, you can hardly see it, which is sorta the idea...


...last picture like this for a while as now the body can come off...


...this is as far I got...


:)

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Old January 17th, 2016, 03:29 PM   #52
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Default Re: Volksrod pickup 'Moler Inc'

Looking really nice. I'm really liking all of the detail. Keep up the great work.
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Old January 17th, 2016, 03:51 PM   #53
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Default Re: Volksrod pickup 'Moler Inc'

Super cool project. Details like the door latches (if they really exist ) are slick!
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Old January 24th, 2016, 10:56 AM   #54
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Default Re: Volksrod pickup 'Moler Inc'

Thanks guys

I haven't had much time in the garage this week due to late meetings at work every day, but I did get out there on Saturday to get things swapped about.

With the nose up can anyone else see the Gasser?


...first thing was to roll the pan out, nice dry day forecast thankfully...




...I knocked up some bogies so it supported off the floor and I can move it around freely...


...why does tidying always get worse before it gets better


...next week then, I start on this area first...





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Old January 31st, 2016, 10:37 AM   #55
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Default Re: Volksrod pickup 'Moler Inc'

Because the inner wings/fenders no longer follow the heater channel I need to create a closing plate, started with a card template...


...transfer to metal...


...tacked in...


...nice and flat...


...welded in and onto the next section, this is to bridge the shortened inner naps hat and upper cross member...










...drilled for plug welding...


...not the nicest vertical weld, the welder was stuttering, I think it may be time for new inner sleeve?...


...the other side...








...I love my 3in1 metal worker, it means I can make panels like this...


...a little joggling at the ends...


...and just because I still have the bead roller on loan...




...drilled for plug welding and screwed into place...


...I then removed the screws one by one plug welding as I went...






...I then welded the handbrake frame to the inner skin of the bulkhead...


...not been looking forward to these bits...




...I started with this small L section...


...shaped and tacked in...


...and welded, not sure if I should try and bridge the gap to the left with weld or simply cover with seam sealer!...




...this is my current work space...



Last edited by moler; December 19th, 2016 at 09:20 AM. Reason: New pic url's
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Old January 31st, 2016, 04:29 PM   #56
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Default Re: Volksrod pickup 'Moler Inc'

Looks Great! Loving this build.
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Old January 31st, 2016, 05:17 PM   #57
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Really cool work!
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Old February 1st, 2016, 10:29 AM   #58
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Default Re: Volksrod pickup 'Moler Inc'

Awesome as usual!!
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Old February 7th, 2016, 06:54 AM   #59
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Default Re: Volksrod pickup 'Moler Inc'

Thanks guys

I welded the gap up...


...that half could be aided with so copper on the back to support the weld pool...


...but I couldn't get to the back of the other half, but managed...




...on to the curved part of the bulkhead to inner wing/fender panel, this is the curve I need using the trusty cardboard template...


...the stretching used here, then knocked the return over...






...cut to length and held in place with a magnet so I can mark it trimming...




...trimmed and welded in...




...on to the A pillars, I'd already trimmed this bit off...




...first part of the panel...


...this is on the limit of what the stretcher can do...


...but it managed...


...trimmed to fit, it was clear it needed to curve the other way too...


...so I shrank the return lip...






...it fit great then...


...last bit to finish it off...




...welds fettled...


...welds have knackered me paint though ...


...also fettled the welds around the handbrake structure to bulkhead...


...for the other inner wing/fender to bulkhead I decided to try and do the infill piece in a oner...




...not too bad that...










...the other A pillar bottom section didn't quite reach the inner wing/fender so I decided to cut it all off...


...new curved piece started like this...


...can you tell I like a cardboard template?...


...first pass, you beauty...


...pretty good, but need the other curve too...


...stretched and shrunk...


...and for those who only have the one block but sets of jaws like me, slotting the mounts makes for very quick jaw changes...


...not sure where I was aiming the camera, but you get the idea, it fits ...


...before the knocking the return lip down, I welded the centre section...




...covered the unwanted holes in the heater channel...






...more weld fettling and the last of the paint removal...








...I need to get the bead roller back it's owner so have started the jobs I need it for, rear window inner surround first...












...this is where I am now.

Question for the tyre geeks, I'd like the front tyres, 195/45x15...


...to have a tread that looks like this...


...any ideas?


Last edited by moler; December 19th, 2016 at 09:21 AM. Reason: New pic url's
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Old February 14th, 2016, 11:39 AM   #60
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Default Re: Volksrod pickup 'Moler Inc'

I've finished welding the rear surround, fettling later as I need to get all the bead jobs done...


...to that end attention was turned to the bonnet, I need to create a closing panel for the under bonnet area...


...I've ben saving this piece of 30mm x 15mm box section for this very job...




...for the closing panel itself I need a good card template...




...transferred to the metal...


...ready to roll...


...and rolled...


...just a few tabs for welded it to the bonnet...


...only a tiny amount of fettling was required to get it to fit spot on...


...I decided to bond the lower edge of the closing plate to the crossmember...






...a couple of days curing time later, I'll weld the tabs another day...


...on to what I think is the last panel I want through the bead roller. This panel will strengthen the front edge of the bonnet, it isn't very good, it's both battered and stretched...




...lots of panel beating required to get the multitude of dents out...


...I need to lose this too...


...if I had oxy/ace id heat it up and beat it flat, but without I need to do this...




...frankenclamp came out to play again ...


...then I discovered my auto darkening welding shield was dying, it's not done too badly it must have had 10 years of abuse...


...this looks to be the issue, this or the non replaceable battery...


...but it means I get to go welding shield shopping tomorrow after work

It was working just enough to get this done...








...on to the lip...


...with the top lip cut away you can see a second strengthening lip...


...I'm going to replace it with something more substantial...


...first 2 attempts, I put a bend in the bottom one that was a bad idea, with the 2nd I discovered the panel wasn't symmetrical while marking out for the bead roll, I cut it in half to mark out the 3rd one...


...3rd one turned out ok...


...as that's the last panel I need the bead roller for I'll carry on with this...


...I added a 12mm x 12mm box section crossmember to add strength to the panel, and worked around the edge tacking the lip to the panel...




...unfortunately the very front of the bonnet has been knocked about quite a bit subsequently it's stretched and does want to cooperate, it's also quite thin so I'll replace it...


...using this




I've had a little side project on the go too, something for Valentines day













Last edited by moler; December 19th, 2016 at 09:21 AM. Reason: New pic url's
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Old February 21st, 2016, 12:05 PM   #61
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Default Re: Volksrod pickup 'Moler Inc'

Haven't auto darkening welding shield prices come down, this little gem was only 70 and is a massive improvement over the old one.


For those that might be interested in which bits of a late bug engine lid are almost the prefect shape for repairing the tip of an early bonnet, here you go...


...after cleaning the pieces up I have these...




...one has some very local perforation, the other is ok. The curve is perfect...




...I had company in the garage, he's modifying Hotwheels cars ...


...this is the extent of the required repair...


...preparing the first half...




...tacked on...


...some over enthusiastic trimming left the gap on the front a little bigger than I'd have liked, but some copper on the back helps hold the weld pool in place to make gap filling a doddle...




...I had get creative to get the copper on the back of this bit...








...sorted...




...backed with copper to sort the perforation out...






...those little magnets are very useful...




...this little piece of copper working to pull heat out the panel quickens progress...












...drain holes ...


...while I don't want to weld all the way around this, I do what improve it a little and add a little more weld...


...these are slightly the wrong shape, off they come to be remade and rewelded on...




...better...




...that, I hope, will do, though I have visions of the vibration breaking this off ...


...seam welded this bit too...


...that's the front half sorted...


...after buzzing with a wire wheel, it's in much better condition than I expected...






...however, there is this...


...rustbeater applied while I ponder...


...I dug this out from behind the shed as I thought it might come in useful...


...unfortunately I was wrong...




...repair panel time...


...rolled to get the first part of the curve...




...then used the brake to tighten the curve up...


...then added the return...




...it was a bit of back breaker cleaning the area up ready for the repair panel...




...a useful new (to me) tool that I liberated from my dad, thanks Pa ...


...it means you can cut the panel back square in a very awkward place...










...that'll do, I'll get some waxoyl behind there eventually...


...I prepped the bonnet and this...


...for a spot of primer.

Sorry, that's all there is, as yesterday I only got a couple of hours in the garage and today I was at Dubfreeze!


Last edited by moler; December 19th, 2016 at 09:22 AM. Reason: New pic url's
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Old March 6th, 2016, 12:27 PM   #62
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Default Re: Volksrod pickup 'Moler Inc'

So I got the primer on the under bonnet and bonnet itself...




...I put the bonnet back on to check that it hadn't pulled and still lined up ok. It was fine...


...still not sure whether to flatten the badge plinthor not? I quite fancy a hood ornament actually...


...latch is still good...


...and the closing plate for the under bonnet area...


...on to the dash then, and the one of the extravagances not covered by my budget, a double DIN touch screen stereo with Carplay ...


...I don't want to fit it with the snatch plate and ugly plastic surround though...


...so while I plug the holes in the dash I don't want, I'll make a nice hole for it...


...so grab handle deleted...


...I need to get rid of all these switch holes too...




...and these...






...ready for bigger lump og plate for the middle...






...new hole ...




...I need to make a bracket instead of welding the dolly in




...making use of the fresh air box brackets...




...piece for bolting the stereo too...


...and some gussets to strengthen the fresh air box brackets...




...I spent ages getting the hole just right, time well spent ...


...deleted the interior light too, I'm gonna to fit a bulkhead light in the centre at the back...


...something to help pull it back flush for tacking...




...ground the welds back on the rear window surround too, a lot of work for something that ultimately is going to be covered up!...


...I've got my tank back too after my buddy Shaun welded up the ends, moved the filler tot he end and made a boss for the fuel sender...




...I'm going to have to move the brackets inboard a little as the straps won't clear the new filler location...


...time for some more browny points, while I had the wood working gear out I made some more soap molds for my wife :D ...


...what it's actually out for...


...making a rollover jig...




...this wasn't very stable so MKII came along very quickly...


...and a packer at the rear to clear the gutter...


...33" from the floor to the pivot point...




...on to the last BIG job on the shell, heater channels, I cleaned the edges up to reveal the spot welds...


...there's one or two to drill out...


...the blasting grit got everywhere...




...the condition is remarkably good...


...the other side got the same treatment...






...all wire brushed to remove the loose rust...


...and a good coat of Rust Beater...


...I was originally going to use Hooky's closing plates, but due to what I've decided to do with the sills, a flat closing plate will work better. I'm using 2mm plate to do this...


...I'm having to make it in two halves as my plate comes on 1mtr squares...


...unfortunately I drop one of the halves on to the inside of the roof :angry: ...


...body mounting and plug weld holes drilled...


...I'm using these for the captive nuts...


...prepped for welding...


...and welded...




...now one piece...


...and a coat of zinc paint for rust protection.


Just for kicks I had a play at cutting some laminated glass. This glass came out of my old split screen panel van that had been converted in to a camper so has a slight curve to it...


...after watching the numerous videos on Youtube I learn't that you score both sides, ease the break in to each side, warm the laminate to open the cut, and cut the laminte. First go was straight and flat...


...second go was against the curve...






...and the third go was a bend against the curve...




...although this was only 4.7mm thick overall and not 6mm, I'm pretty confident a laminated screen is doable. I've just ordered a new one so we'll soon see


Last edited by moler; December 19th, 2016 at 09:23 AM. Reason: New pic url's
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Old March 13th, 2016, 12:46 PM   #63
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Default Re: Volksrod pickup 'Moler Inc'

Just Kampers had laminate screen back in stock so I snagged one quick...




...I made myself a couple of brackets to help centre the screen for marking out...


...deep breath...






...corners off as pair YouTube tutorials...


...and the top off...


...I was very careful but I still managed to get a small crack...


...but I found this...


...and it worked quite well, I'm 90% happy with the result...


...so back to heater channel closing plates...






...I was going to use the bakelite tubes to go through the body to bring the hot air inside, but the more I thought about how hot that was going to be in such a small cabin space, the more I went off the idea, so I've turned to a Type 3 for help. These are the heating air mixers that do the same job as the bakelite tubes on a Beetle, but these regulate the hot with a thermostat that will bring in cool air if they get too hot...




...I've had the 44mm OD tube for a while now, but I couldn't find any 44mm bends, so I've had to go with 50mm bends in the form of a mandrel pressed donut...




...it wasn't quite long enough...


...so I extended it...






...I decided to use the heater boxes at 90 to their usual orientation...








...I'm going use a flange and spreader plate matching the flange on the heater boxes...




...trusty rivnuts...


...trusty neodymium magnets holding the flange in place for marking the hole...




...I think I need some shorter screws...








...so far so good...


...so get from the 50mm bend to the 44mm pipe I made a reducer...








...these are to locate the heater tube inside the channel away from the sides...






...so I need to get from there to here...




...just uesing a mitred join inside the channel...


...copied the first one to make the others easier...


...happy with that...


...at the other end I need to able to get a pipe up to the demister...


...to get the pipe over the centre of the hole Iused another mitred join...


...capped off the end but I haven't welded all the way round yet...




...as I'll need to weld in the pipe up to the demister, as I'm not using hose...


...I got far enough on that I could set the flanges...


...and then bolt the boxes on...


...so the last bit is the footwell vents...






...first part of the vent...




...and that's where I left it tonight

Last edited by moler; December 19th, 2016 at 09:24 AM. Reason: New pic url's
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Old March 13th, 2016, 04:54 PM   #64
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Default Re: Volksrod pickup 'Moler Inc'

Damn! As usual, brilliant and inspiring work on a incredibly cool project. Your attention to detail is phenomenal. I can't wait to see more.
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Old March 20th, 2016, 11:13 AM   #65
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Default Re: Volksrod pickup 'Moler Inc'

Thanks dude

Top part of the heater outlet tacked on a trimmed...


...then trimmed to suit the vent...


...top section...


...and sides...


...nice...




...time to permanently weld this sucker in, for those that wondered ...










...I started with these to get the heater air up to the dash vents...


...did a bit of this...


...2 small bends required...


...same idea for welding this in as the other end...






...there's a sleeve on the inside of the top end...


...a liberal coating of cold galv spray should help keep rust at bay, or it'll just get burnt off ...


...the other side is well on the way to be finished too.


There'll be no update next weekend as I have my parents camper in for a little work, service and get ready for MOT

Last edited by moler; December 19th, 2016 at 09:25 AM. Reason: New pic url's
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Old April 3rd, 2016, 01:47 PM   #66
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Default Re: Volksrod pickup 'Moler Inc'

I got one of the final pieces for the body jigsaw...


...I only need 2 bits like this...


...to go in here to continue the inner roof edge around the back...


...but that's for later. I got the other heater channel tube installed...




...sill time...


...temporary fixing of the closing plate...


...upper sections of the sill...




...temporary fixings so I can mark the curve of the door out...




...refitted and that's when I noticed this, my mistake but not happy




...I needed to slit the door skin halfway across the door to get the curve even...




...this will do you now...


...offered up a section of sill for the bottom closing plate...


...marked the curve out...


...I need a longer bender/brake ...




...heater channel closing pate removed to repair the paint...


...and welded the upper closing plate...


...after being left over night, this is heater channel closing plate finally welded in place...


...penetration baby ...


...one sill, another part from the VW parts bin ...


...paint off, marked for slitting...


...slit and curved a bit...




...then I noticed this, another mistake on the door, the bottom isn't straight ...


...I then had a tantrum, attempted to murder a Bosch jigsaw, and went off for a walk to cool off. When I returned I locked up and left it alone before I did something incredibly stupid

I returned a couple of days later with a plan, one part of that was to forgot my idea to try and include a seam at either end of the door width, deciding that VW would have brazed the gap smooth ...


...the sill is straight, I'll sort the door later...


...another compound corner required, just like the roof...


...this is a piece off my very first camper...










...a shit load of grinding later (I really must learn to TIG!)...


...I need to close the end of the sill off...




...I started like this...


...and then forgot to take pictures While I'm at this end, there's this to sort...


...when I made to rear panel it would seem I was a little short. No worries, I'll weld the gap up, I closing the top of the gap from the inside...


...copper on the inside to support the weld pool...




...ugly big weld!...




...save for a bit of paint...






...that's it

In other news, these arrived for the Squareback...


...another job I haven't got time to do!!

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Old April 3rd, 2016, 06:15 PM   #67
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Default Re: Volksrod pickup 'Moler Inc'

Awesome work
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Old April 3rd, 2016, 06:37 PM   #68
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^^^ X 2!
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Old April 4th, 2016, 08:38 AM   #69
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Default Re: Volksrod pickup 'Moler Inc'

damn, such a great looking project.

much respect for you and all the other builders doing all the work themselves.

i have the ideas and the vision but dont posses the skills..i have to resort to paying someone to help me with my visions.

cant wait to see your project complete
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Old April 4th, 2016, 03:24 PM   #70
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Default Re: Volksrod pickup 'Moler Inc'

I really like the lower door sill with the radius on it! Great work!
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Old April 10th, 2016, 01:14 PM   #71
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Default Re: Volksrod pickup 'Moler Inc'

Thanks guys, nice to know peeps are watching and liking what they see

Next job to finish the door both axis of the bottom...








...the primer highlights any missed weld, so I've been sorting that on this side too...


...missed a hole under the dash...


...love these magnets for holding stuff for tacking...




...I think I may have forgotten to grind this back as there's no pic

I've completed the welding of the front structure now I can get easy access...


...I've ground the plug welds down on the heater channel closing plate as they may impede the body to pan seal...


...last bit for this side is the continuation of the side seam, obviously it's fake ...


...a full depth chamfer means I can grind the weld flat to the seam but it'll remain stuck!...






...I need to create a return lip...














...I then moved the body across the garage and moved all the gear round to start on this side...


...hmmm, can you see it? it's not all perfect, and that's not the door it the channel ...


...so this is a cover sat on the bottom of the door and it's parallel with the sill on the opposite side...


...but the door bottom is like this...




...basically the back of the heater channel is low, which explains one side of the seat bracket needed a packer...


...after much pondering on what to do I decided that the sills should be parallel, so I cracked...








...the first sliding door cover was an unused repro one, this side is getting a 2nd hand one so I had to remove the paint, dusty job that!...


...all the burnt zinc primer was replaced and left over night to dry, this was this morning (Sunday 10th April) clamped ready to go...


...plug welding complete...


...started to tack the sill on...


...the start of the welding, I'm using compressed air to cool thing down as I go, so I can go faster ...


...all done...


...rear corner time...






...and that's were I left it tonight, massive grinding session on Tuesday...


So Davewin on VZI is sculpting the hood ornament for me using this pic...


...his initial sketch...


...and his progress so far...
















...to say I'm happy with this is a massive understatement

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Old April 10th, 2016, 02:40 PM   #72
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Would be a cool shift knob
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Old April 10th, 2016, 05:06 PM   #73
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Default Re: Volksrod pickup 'Moler Inc'

That's brilliant! Don't know about a shift knob though, the little critter looks like he might bite...
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Old April 11th, 2016, 02:27 PM   #74
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Default Re: Volksrod pickup 'Moler Inc'

I don't envy all the grinding you have ahead of you. Hood ornament looks sweet! It's going to be cast? How?
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Old April 12th, 2016, 10:34 AM   #75
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He will bite, that's what he's goi g to live outside on the hood

Just done the grinding, 2 hours solid hood ornament will sand fast in bronze, polished, and chromed
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