Robsey's Rusty Wreck.

Thin bits of metal and bright blue light. Including glass & trim.

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Robsey
Posts: 95
Joined: 19 May 2012, 20:45
80-90 Mem No: 11137
Location: East Manchester

Re: Robsey's Rusty Wreck.

Post by Robsey »

I fully understand, and thank you for your valuable advice.

"36 staples"!! - ouch...
Yes I think I would have quickly reviewed my safety regime after an injury like that.

Is there not a Wiki on safety information like that?
It is common sense and probably natural for people who use cutting and grinding discs on a regular basis.

But there are a lot of "have a go heroes" that have the best of intentions, but barely enough knowledge.

I would like to think that I have enough "way with all", to be moderately safe. But it does not hurt to be reminded of even the most basic safety information.
1983 Tin Top with a poorly DF.
Soon to have a whizzy DJ.

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Dazco
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Joined: 18 Dec 2011, 15:44
80-90 Mem No: 10544
Location: Sheffield. 1984 autosleeper trooper. 1.9 petrol called Jambo

Re: Robsey's Rusty Wreck.

Post by Dazco »

You're cracking on with it . Kind of looking forward to getting stuck into mine .
Check ya nuts
http://forum.club8090.co.uk/viewtopic.php?t=96433" onclick="window.open(this.href);return false;
Auto sleeper fitted with EJ 20 subaru lump

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Robsey
Posts: 95
Joined: 19 May 2012, 20:45
80-90 Mem No: 11137
Location: East Manchester

Re: Robsey's Rusty Wreck.

Post by Robsey »

a bit more progress.

Troy (the owner of the unit where the van is stored) had already decreed that he wanted to spend tonight on the van, despite having his Nova, an MX5, an XR2 and a Capri yearning for his attention.

He was keen to put some metal on the van, rather than continuing to cut more metal off.

Using the right side for a pattern, the first job was to make up a diagonal outrigger lower panel for the left side.

Image

There is a big hole on the right side member, but I could not see this on the left.
It shows a big hole on both in Haynes.
Any idea if the big hole is needed, and if so, what it's function is?

Whilst he did this, my job was to cut out the rear of the arch, where it was very rusty.

Image

Then I decided that I really wanted the remainder of the bottom wishbone off the van.

Image

Strange how the biggest bolts still seem to be the easiest to undo.

Image

Troy made a brew, so I set about removing the underseal from the underside of the inner arch.
(Sorry no pictures).
But he pointed out that heating the other side of the panel (very hot) caused the underseal to almost fall off, meaning that a scraper quickly removed any unwanted material. Heated too hot, and the underseal goes quite rubbery.

Final job was for him to make up and fit a new piece, for the rear of the arch.

The man in action.

Image

And the first panel welded in place.

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Check out the formed oval - it is used to locate the left fuel tank expansion bottle.

I felt a bit of a spare part at various stages of the evening.
Tricky trying to be useful, without getting in the way.
Last edited by Robsey on 26 Aug 2020, 22:33, edited 1 time in total.
1983 Tin Top with a poorly DF.
Soon to have a whizzy DJ.

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Dazco
Posts: 2207
Joined: 18 Dec 2011, 15:44
80-90 Mem No: 10544
Location: Sheffield. 1984 autosleeper trooper. 1.9 petrol called Jambo

Re: Robsey's Rusty Wreck.

Post by Dazco »

Fantastic work , itll be back on the road for the weekend :ok
Check ya nuts
http://forum.club8090.co.uk/viewtopic.php?t=96433" onclick="window.open(this.href);return false;
Auto sleeper fitted with EJ 20 subaru lump

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Robsey
Posts: 95
Joined: 19 May 2012, 20:45
80-90 Mem No: 11137
Location: East Manchester

Re: Robsey's Rusty Wreck.

Post by Robsey »

at about 4 hours per week,
I think you are being a tad optomistic - ha ha.

I totally expect that there is a couple of years of work to do at that work rate.
(Based on my skill level, and the ongoing costs of parts, materials, labour, storage etc...)

Thanks, but I have to give Troy the lion's share of the recognition for any progress made.

Cutting metal off and cleaning up edges in preparation is very easy to do. The clever bit is putting it all back together again.
1983 Tin Top with a poorly DF.
Soon to have a whizzy DJ.

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Robsey
Posts: 95
Joined: 19 May 2012, 20:45
80-90 Mem No: 11137
Location: East Manchester

Re: Robsey's Rusty Wreck.

Post by Robsey »

A bit later than hoped, but here is this Mondays small bit of progress.

Three strips of rot cut out, and two small pieces welded in.
A nice mix of puddle-welds and seam welds.

I made the triangular bit at the back of the inner arch.

As usual Troy welded it in.
From this...

Image

To this...

Image

The strips that were cut off, were the base of the wheel arch 'tub' and the passenger footwell where it meets the base of the passenger seat / back-up battery box.

Metal cut out.

Image

Image

And fresh metal welded in.

Image

Still plenty of tidying up of the welds to do, but they are nice and solid.

Amazing how much quicker Troy is at making up a piece of metal, virtually by eye, free hand.
Whereas I was doing a more old-fashioned cardboard template approach.
1983 Tin Top with a poorly DF.
Soon to have a whizzy DJ.

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Robsey
Posts: 95
Joined: 19 May 2012, 20:45
80-90 Mem No: 11137
Location: East Manchester

Re: Robsey's Rusty Wreck.

Post by Robsey »

Aaaand Week ten of the rebuild.
I didn't think that I achieved much this week.

In reality, I cut away the spare wheel carrier from under the front of the van. Everything was rusted solid and the carrier disc itself was toast.

Cutting disc to the rescue.

Image

And I made a couple of tiddley patches for the cab floor.
I spent ages doing what should be a quick and simple job.

As usual, Troy welded them in.

Image

He is very specific, so ensured that the same 'gap' remained between the plates.

A light dressing off for now to remove the excess weld.

Unfortunately, this week was hindered by the arrival of a Harrison lathe, which brought memories flooding back of my early machine-shop days.
Even the smell of the gearbox grease took me back 30 years.

So we spent a good hour or so with me giving him a lesson of operating a lathe, including screw cutting, setting spindle and travel speeds, and of course general safety. - "take that chuck key out of the chuck!!" - yikes!!
1983 Tin Top with a poorly DF.
Soon to have a whizzy DJ.

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Robsey
Posts: 95
Joined: 19 May 2012, 20:45
80-90 Mem No: 11137
Location: East Manchester

Re: Robsey's Rusty Wreck.

Post by Robsey »

New parts Klaxon!!

Image

Image

Original VW parts - the upper box section is no longer available.

Making their way onto my van this autumn.
I will be cleaning any remnants of the old left outrigger from the van next week.
1983 Tin Top with a poorly DF.
Soon to have a whizzy DJ.

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Robsey
Posts: 95
Joined: 19 May 2012, 20:45
80-90 Mem No: 11137
Location: East Manchester

Re: Robsey's Rusty Wreck.

Post by Robsey »

Hmm - a quick question for Mick. (Plasticman).

Can I box off the front of the B post and wheel arch before looking at the sills and jacking point?

Or do I need to sort the inner sill and jacking point before repairing the front and bottom of the B post.

It is pretty much toast underneath the B post and around the jacking point.
1983 Tin Top with a poorly DF.
Soon to have a whizzy DJ.

User avatar
Robsey
Posts: 95
Joined: 19 May 2012, 20:45
80-90 Mem No: 11137
Location: East Manchester

Re: Robsey's Rusty Wreck.

Post by Robsey »

Week eleven was quite a random affair.

First thing was to compare Troys left lower outrigger panel to a VW original right lower outrigger panel.

He was very pleased with his masking-tape pattern panel.

Image

Image

Very close indeed. We still never sussed out the reason for the huge hole on the wide end.
There is a big square nut in there, but it is captive, so spanner access is not required.

As per my proposal last week, I cleaned the remnants of the old outrigger away.
It took a long time because of limited access preventing the use of the spot drill.

And a hidden bolt (15 hex head bolt) in the A pillar holding the box section in place, via the captive nut mentioned above.

I also had to cut another section of floor out to remove an old support strip.

Image

So lots of grinding and chiselling ensued.

Until I was able to offer up the first big panel - the new upper outrigger panel.

Image

The bolt holes did not quite line up, but a little fettling should get a good fit.

More next week.
1983 Tin Top with a poorly DF.
Soon to have a whizzy DJ.

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