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Old April 17th, 2016, 11:52 AM   #76
moler
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Default Re: Volksrod pickup 'Moler Inc'

So I was faced with a shit load of grinding...


...it took exactly 2 hours to turn this...


...into this...










...I added the fake seam, with fake wrapped around panel...


...after a bit of paint, happy with that...


...on a little job, the tank brackets need moving in a little so I can fit a wrap around tank strap, but that means I need to shrink the access panel beneath it, another piece of metal from my first camper, this used to reinforce the roof...




...bit of shaping...




...one narrower hole...


...new addition to the tank bracket to pick up the original hole...


...I now have a frame to fasten the access panel to...


...stun over for a bit more paint...


...I do like this make shift rotisserie...


...another little job, bench seat back rest brackets. While these worked very well it was bit of squeeze to get the seat back bar underneath them so I've decided to change how the seat back to going to be secured, I'll not go into details of the new method now, I'll just show you the bracket swap, getting rid of these...


...I liberated this bit of 50x50 box section from my new neighbour who was dismantling a wheelchair ramp...


...similar idea with the curved front...




...added the flanges to attach the trim panels to...


...to fit these I need to be able to stand up inside the shell again, so I got a pair of rope winches to help me get him in the air...


...attached to the rafters, the shell is light another not to trouble them...


...brackets in, I'll revist these to drill the holes once the back rest has been updated...




...I decided not to use these vents in the end so that got blanked off..




...on the inner roof surround using those section of ducting bend...


...joggled for a lap joint...


...but these suckers are thin, very thin, even more so once I removed the zinc plating. After just a few tacks I knew this wasn't working...


...that rethink does not mean I'm going compromise on the curved corners though, so while I think I continue with the rest of it...




...picture number 2000 ...


...added a little inner structure...




...the small bits of metal I have left have dictated the method of construction!...






...while doing this I think I've come with an answer, I'll bond them in...


...my new interior light...


...and after my tantrum the other week, my parents have bought me this

Last edited by moler; December 19th, 2016 at 09:27 AM. Reason: New pic url's
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Old April 18th, 2016, 07:31 AM   #77
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Default Re: Volksrod pickup 'Moler Inc'

"Occasional" ?
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Old April 18th, 2016, 11:25 AM   #78
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"Occasional" ?
You watching me?
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Old April 18th, 2016, 04:27 PM   #79
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Default Re: Volksrod pickup 'Moler Inc'

Nope, that little micro-drone hovering around your shop is not mine. Oh, there's a 9/16" box end mixed in with your metric stuff.....
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Old April 24th, 2016, 11:30 AM   #80
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Default Re: Volksrod pickup 'Moler Inc'

I can't hear the drone for the helicopters

Not a massive update as I miss an evening and today, and didn't get much done yesterday!

I'll start with this...


...I've had this for a long time, used to be on the back wall of the garage but has been in a draw for too long so it's out to go up somewhere

This is a section of the pipe I used for the rear of the roof...


...now coming in handy for the inner roof...


...this is, strangely, the odd shape required to able to glue the corner section in...




...drilled and screwed ready for when I get the glue, Araldite Metal is what I'll be using...


...the other side is simply a mirror image...


...I added a bracket for the interior light and mounted it up...


...I've run out 1mm sheet so Will finish the centre of this once I've ordered some...


2 jobs to go, first, battery tray. Is it right I get really excited about my Optima Red Top? ...


...bit more of that angle to be used here...


...through the battery in to see what space I had...


...frame made, it'll have a piece of 3/8 ply for a base and one of those battery mats...




...a pair of front legs...




...sorry for blurred pics...


...going to put compensation pads under the feet and where it meets the bulkhead...


...so next week I'll be rebuilding the engine for the Squareback, so no update here.


Last edited by moler; December 19th, 2016 at 09:28 AM. Reason: New pic url's
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Old May 3rd, 2016, 09:42 AM   #81
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Default Re: Volksrod pickup 'Moler Inc'


keep it up looking great!
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Old May 22nd, 2016, 01:05 PM   #82
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Default Re: Volksrod pickup 'Moler Inc'

So after a couple of weeks playing with the Squareback he has a fresh MOT but the new engine needs to come out again, but that'll have to wait as I need to get back in the game here.

If you remember I was building a battery tray, and that needed some reinforcement under it legs, that reinforcement looked like this...


...welding on the tray done...


...sitting nicely with a plywood insert, there'll be a battery mat too...


...battery hold down lugs added in the form of nuts, the bolts poke through and hold the bottom edge of the battery, making for a neat solution without the ugly strap over the top...






...next was to locate the brake reservoir, I initially intended to use a buggy one that sits on top of the master cylinder, but access would be difficult not to mention the MOT man needing to see the level, so I'm putting up top. I'm using the 12mm box to create a bracket...


...and it's going here...








...so that's the welding on the body 99.9% complete

Back to those inner roof corners, I got this to bond it in, Araldite Metal...


...liberally applied and screwed in place...


...and when it was hard, the excess was removed...


...and then I've just been working through the interior, filling, sanding, priming, and seam sealing...












...the plan is get the inside ready for paint then refit the doors and start on exterior fill, sand, and prime, then sling some paint on before rolling it out the way so I can get back onto the pan. There's also the small matter of the front safari frame


Last edited by moler; December 19th, 2016 at 09:28 AM. Reason: New pic url's
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Old June 5th, 2016, 11:43 AM   #83
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Default Re: Volksrod pickup 'Moler Inc'

Thought I'd add something before you all wandered off to find something better to do

Tiny update, the inside is nearly finished, just one last rub down and another prime because I can paint it...






...I'm losing the will to live with all sanding and filling, this is the bit I hate


Last edited by moler; December 19th, 2016 at 09:29 AM.
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Old June 7th, 2016, 10:08 AM   #84
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Default Re: Volksrod pickup 'Moler Inc'

It's looking amazing though!!
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Old June 7th, 2016, 09:07 PM   #85
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Default Re: Volksrod pickup 'Moler Inc'

"...I'm losing the will to live with all sanding and filling, this is the bit I hate"

Gee, when I finally get to patching up my Single Cab (the guy I traded a project bike to do the work, sort of vanished.) I'll have a lot to look forward to.
Meanwhile, brilliant work!
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Old July 3rd, 2016, 01:06 AM   #86
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Default Re: Volksrod pickup 'Moler Inc'

Thanks guys

I always knew this would be a difficult period of the build, I hate filling, sanding, and body prep mainly because the euphoria of getting the panel looking nice is far out weighed by the trauma I go through to achieve it

I missed judged the rear corner panels and it's taking more of the dreaded filler than ever wanted, though most of it ends on the floor

There are very few pictures too, but here are some I have.

The front inner arches were proving a nightmare (time of trauma ), as how do sand a compound concave shape anyway?...


...I scoured the internet for clues and pretty much found nothing but a very expensive sanding block in the US! I then spoke to a mate in the trade and the sanding blocks he uses were too small.
So I came up with this, a swimming noodle(?)...


...with sand paper stuck to it with double sided tape...


...and i works an absolute treat ...


...after making this, the panel got completely re-worked and is many hundred times better (time of euphoria ), though it doesn't look here...


...I thought this side was pretty much done, but after refitting the other door I have realised the top of this one sticks out to far, so some chopping and welding required


I had a short distraction making a panel this hole...






...though I have since realised that this too needs doing again. Because the fuel pipe will go through the middle of it, it needs a strengthen rib rolled though the centre, oh well!!


This is the extent of the trauma on the offside...


...I have the last 2 weeks of July off week, the first week before the kids are off school/college is going to be a garage week, hopefully it'll involving some paint.


Last edited by moler; December 19th, 2016 at 09:29 AM. Reason: New pic url's
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Old August 6th, 2016, 12:29 AM   #87
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Default Re: Volksrod pickup 'Moler Inc'

Well my 2 weeks off in July didn't go to plan (does it ever!!) the good weather meant I was more interested in going to the beach, which is odd 'cos I hate sand

Some progress has been made though and I'll start with a couple of purchases.
The first is the air tank for the air ride...


...it's not huge at only 10ltrs/2galls, but then it's only for assistance at the front (for now) and because it's small I have the perfect spot for it...




...after some research I have decided to control the air ride with good old paddle valves, I have the first 2 and a dual needle gauge for the front...


...I have a couple of ideas for locating it discretely

So back to the bodywork, I left the door for a change of scene, the bonnet/hood :P I eventually decided to delete the trim holes as I couldn't find any of the same bullet bolts I had on the '67, if I do find some I'll redrill the holes at more even spacing ...


...this thing has had a hard life, if you remember I had to straighten it as it had been deformed in storage/transit, and it had a lot of knocks all over it, lot of dollying before the filler was applied.


While I hate this process a home made tool makes it easier, I made this for sanding long curves...


...I made this originally for doing those wide rear arches that got me my rear tyres, but I've now added handles. It's simply a piece of hardboard with sandpaper stuck on with double sided tape ...


...because of the flex it's great for doing bits like this...




...with much elbow grease I'm nearly there, just the roof and offside inner front arch to do...






...I'm currently building the engine for the rod which will reside in the Squareback until required after a destroyed the Squarebacks freshly rebuilt engine I'll not go into details here, but I will leave with this...


...the above brand new barrel has only done 15-20miles!!


Last edited by moler; December 19th, 2016 at 09:30 AM. Reason: New pic url's
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Old August 6th, 2016, 11:18 AM   #88
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Default Re: Volksrod pickup 'Moler Inc'

Great work, she looks fantastic! Regarding the cylinder...are you talking about the gap at the lower edge of the ring, or the little toy Squareback stuck in the bottom of the sump?
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Old November 6th, 2016, 02:07 PM   #89
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Default Re: Volksrod pickup 'Moler Inc'

It's been a while, between a great family summer, working on the Square and other peoples dubs, the rod has been slumbering, but now that BST has ended and there's no light to work outside in an evening it's back in the garage I go.

While I haven't been working on him, I have been buying parts.

The first to show you is an odd one, I bought this 944 rear end for the first upgrade AFTER his been on the road awhile! Yeah I know I need to get him on the road first but it was a good price...


...I got this from Skeg Vegas in the summer, it's from a late Mexi bug I think, but I like the almost aviation style it has...


...I also got this Viair 444c in Stealth Black...


...not a purchase but a rediscover in the back of the shed, RHD splitscreen under dash shelf, I'm going to see if I can make it fit the rod ...


...and so to some actual work, first a tidy up was in order...




...I pondered for a while what to start on, the logical thing would be to start where I left off, filling and sanding, but I thought sod that I'll sort out the air ride gauge and paddle valve mounts...


...I want a clean look so I 'm going to hide the gauges behind the grille on the right hand side of the dash so I cut the original speaker bracket out...


...and began to make a recessed panel for it...










...I need to get 3 gauges in here, front, rear, and tank pressures...


...popped in to test the fit, looks better than I imagined...


...I need to get a new 52mm hole saw to cut the holes, I'll weld it in after they're cut. Next I started to make a panel for the paddle valves...


...4 valves required for independent corner control...


...cut halfway through with a grinder, them finished off with a jigsaw...


...and this was the sequence of events to cut the short sides...


...this is how I left it this evening...


A short update, but progress has restarted, only evenings at the mo (unless it's raining at the weekend like today) as I still have other dubs to do work on!!

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Old November 13th, 2016, 11:12 AM   #90
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I carried on with the fettling of the paddle valve panel until all the valves fit ok...




...I'd like to say I used a good old fashioned file...


...but I cheated ...


...so I want the valves out of sight for a cleaner look, so I'm mounting them under here...




...to fit this spot properly it needed a little torsional type twist...




...gotta love the rotisserie...


...welds fettled, access was tight on the back...




...and the valves still fit fine...


...back to the gauge panel, and one new holesaw. I find it odd that you still can't buy a 52mm holesaw!!...




...I always get a little tingle when I mock things like this up and you can almost imagine it finished ...


...the tingle was short lived...


...however, it turned out to be an easy fix...




...cutting down was in order, not sure why I originally went for an inch deep?...










...I managed to get it all welded in before I finished tonight.


In other news, I'm helping a US Volksrodder with parts for a RHD conversion
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Old November 20th, 2016, 11:46 AM   #91
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Default Re: Volksrod pickup 'Moler Inc'

First job this week was clean up the weld...


...very happy how it's turned out. While I was priming behind it I thought it was time to prime all of the area under the skuttle...








...and then it was on with the job I absolutely hate...


...I stood there staring at it for a good half hour, I even considered going back in the house and leaving it for another day(year!!) but no I managed to motivate myself to crack on. One lot of filler, sanding and some high build revealed that it was pretty much there, which was nice ...




...some more filler on the sill and sanded the whole lot, and then used some etch to cover the bare metal and got carried away ...


...so the body (except for the roof) is 99% there, I need to get some more gas for the space heater so I can warm the garage up enough for filling and priming, but I hope to have the whole of the body 99% there by this time next week
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Old November 20th, 2016, 11:53 AM   #92
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Default Re: Volksrod pickup 'Moler Inc'

NICE work.
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Old November 20th, 2016, 12:35 PM   #93
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Attention to detail is just brilliant!
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Old November 20th, 2016, 08:54 PM   #94
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Very nice work. Details on this build are unreal!
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Old November 27th, 2016, 10:00 AM   #95
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Default Re: Volksrod pickup 'Moler Inc'

Thanks guys

This week I've been mostly turning this...


...into this...


...to get the Squareback back on the road, he looked pretty good after a wash too.


Anyway all that meant little time for the rod, I did manage to get some more primer one of the inner arch...


...then I lowered the body on the rotisserie to do the roof...


...but it wasn't low enough so he was put on the floor stood on long bolts in the mounting holes...


...last push on the filling and sanding...


...I put the bonnet on for some motivation...




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Old November 28th, 2016, 06:58 AM   #96
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Default Re: Volksrod pickup 'Moler Inc'

Crap, I am now late to work because of this build. I couldnt pull myself away from the pages of this amazing build. I love all the details and finish work.
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Old December 18th, 2016, 02:18 AM   #97
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The first pic is to show you the height. Sat on the those bolts it's only an inch lower than it will end up, I'm 5'8"ish...


...I had a shuffle round as I'm close to needing the floorpan out...


...cleaned off and ready for rolling as required...


...then I've just been working through getting the roof done, filler...


...stopper...


...pesky guide coat...




...put some primer down, looked awesome in one colour again...




...it didn't last long...


...this should be it...


...plan is now to get one coat of topcoat on there to protect it and start on finishing the pan and start building oh and the windscreen frame


Last edited by moler; December 18th, 2016 at 02:23 AM.
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Old December 18th, 2016, 02:28 PM   #98
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Default Re: Volksrod pickup 'Moler Inc'

She's looking fantastic!. 'Can't wait to see her rolling about.
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Old December 19th, 2016, 03:24 AM   #99
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Default Re: Volksrod pickup 'Moler Inc'

I don't believe it- just found your build - bloody fantastic. I am building the same style of Rod at the moment as well.I haven't started on the body yet- still planning stuff in my head for the build. Like what I see in yours.
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Old December 19th, 2016, 11:24 AM   #100
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Thanks guys

I've just re-tagged all the pictures from the beginning so you should be able to see all of them again now
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