My 84 rusty project

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boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

A bit more done... weather has been really bad but the work must go on.

Two bits cut out and new bits let in to the C post...

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Cut off the corner of the rear valance, cut out rot and butt welded patch in...

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This is what the phosphoric acid does to the metal if you leave it for a few hours....

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And after you rub off the black stuff (iron phosphate) with water and a bit of scotchbrite

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Rear support bar needed some attention...

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Valance back on...

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Made a patch for this...

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Bottom of the quarter panel needed work, so I cut it off and worked in it in the vice... don't like welding upside down so this is easier. Pink measuring tape has been borrowed from my wife :oops:

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Quarter panel bottom back on...

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New panel made up for the bottom of the infamous "box"

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Tricky little sucker to make...

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Last edited by boatbuilder on 27 Jul 2017, 00:48, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Got the "box" all welded up now....
You can just about see where I wrote some measurements before I started cutting the rusty "box". It all gets a bit floppy when you cut that much away, so I took a few measurements beforehand so I have something to line it up with when re-welding it all back together. Hopefully the tall panel will line up reasonably well with it.
Don't particularly like this UPOL weld through primer, takes ages to dry and scratches off real easy even with your fingernail, goes into bubbles with the heat from welding as well. ProXL stuff was much better all round.

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Re-building the inner arch.... chose to patch rather than remake the whole thing from new.

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Last edited by boatbuilder on 27 Jul 2017, 00:49, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Inner arch remade and welded back on after a good few patches!
Nice smell of burning wood as I welded... :lol:

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Here are the welds on the inside... still have a square patch to do at the front. A bonus of repairing the arch and not making it from scratch is that you can use the remaining old spot weld holes and drill marks to line it up when putting it back...

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Painted some epoxy primer in here with a brush.. never tried brushing epoxy before but it smoothed out and went on nicely. The weld spatter isn't mine, its VW original! :tsk

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I'll weld this bit on tomorrow... used a bit of an old front panel as it seems to be a good thickness of metal.

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Welded on the new rear lower corner too. This side lines up perfectly with the arch bottom. Very strange, as on the other side of the van, the same brand repair panel was a bit too low. I thought it was the lower corners that were dodgy, but it must be that the tall arch panels are hit and miss. They're the Klokkerholm ones from Just Kampers.

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And from underneath. This repair panel didn't have the "tabs" in it so I had to cut em myself. Drilled some holes in the tabs and spot welded in place.

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Last edited by boatbuilder on 27 Jul 2017, 00:49, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

Plasticman
Trader
Posts: 8075
Joined: 12 Oct 2005, 20:55
80-90 Mem No: 1948
Location: lincolnshire

Re: My 84 rusty project

Post by Plasticman »

nice one, those klockers are pants, ok if your just sticking it over the rubbish to make it look good but useless if doing it right, schofields ones are as near a replica as you can get, saves me loads of time.
up late arent we :wink:
mm

Wookster
Posts: 17
Joined: 13 Jul 2012, 19:54
80-90 Mem No: 0
Location: Ammanford, S Wales

Re: My 84 rusty project

Post by Wookster »

And here's me just having bought a pair :(

Repairs are looking well tidy even so.
Could you do me a favour please and take a pic of the rear valance about 6" further round from where you have welded the new panel on. I have a thin section where the spot welds are and then a rusty hole.
Need to make a new section but no idea what it should look like.
Your valance looks in good nick from the pic and would give me a good starting point.

Cheers

Wookster

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

metalmick8y wrote: up late arent we :wink:
mm

Kids taking up a lot of my time during the day so having to work at night! :roll:

Wookster I'll get a photo later on today or this evening. :ok
1984 1.9D (AEF Code) T25
My 84 Rusty Project

Wookster
Posts: 17
Joined: 13 Jul 2012, 19:54
80-90 Mem No: 0
Location: Ammanford, S Wales

Re: My 84 rusty project

Post by Wookster »

Brilliant mate, thank you. :ok

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Wookster wrote:Brilliant mate, thank you. :ok

here ya go

http://t25.boatbuilder.info/IMG_0886.jpg" onclick="window.open(this.href);return false;
http://t25.boatbuilder.info/IMG_0887.jpg" onclick="window.open(this.href);return false;
http://t25.boatbuilder.info/IMG_0888.jpg" onclick="window.open(this.href);return false;
Last edited by boatbuilder on 27 Jul 2017, 00:49, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

Wookster
Posts: 17
Joined: 13 Jul 2012, 19:54
80-90 Mem No: 0
Location: Ammanford, S Wales

Re: My 84 rusty project

Post by Wookster »

Thanks for the pics will help no end once I move further along on the valance.
I obviously didn't explain very well cos the pic I need at the moment is to repair the end bit, just visible in your last pic. Laptop keeps telling me the card from me camera isn't formatted so couldn't post a pic at the time.

Just like yourself I have the bottom corner to replace amongst other bits, but nothing to attach it to.
This is what I have at the moment, if I even breath on it another bit falls off!!

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There's no rush but if you could another pic it would be very helpful.
Will definitely return the favour at some point.

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Try these.. if the other side is not to bad, you could make a cardboard template of the shape and just mirror it over for the bad side.

http://i192.photobucket.com/albums/z282 ... G_0889.jpg" onclick="window.open(this.href);return false;
http://i192.photobucket.com/albums/z282 ... G_0890.jpg" onclick="window.open(this.href);return false;
http://i192.photobucket.com/albums/z282 ... G_0891.jpg" onclick="window.open(this.href);return false;
http://i192.photobucket.com/albums/z282 ... G_0892.jpg" onclick="window.open(this.href);return false;
1984 1.9D (AEF Code) T25
My 84 Rusty Project

Wookster
Posts: 17
Joined: 13 Jul 2012, 19:54
80-90 Mem No: 0
Location: Ammanford, S Wales

Re: My 84 rusty project

Post by Wookster »

Absolutely spot on mate.
Printed 3 of them off, sort of a face on view and then the slight angle from each side. :ok
Mega thanks

Wookster

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Time is getting short now... back to work on Tuesday! Distracted again by some long overdue gardening.

Got this bit welded on this evening
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Next is to tackle this... the bottom of the C post where the lower sliding door track meets it... took a few measurements before I started cutting...

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Will make up new pieces in the morning...

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Last edited by boatbuilder on 27 Jul 2017, 00:50, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

waltraud
Posts: 692
Joined: 27 Aug 2008, 12:59
80-90 Mem No: 5824
Location: London

Re: My 84 rusty project

Post by waltraud »

:ok Amazing! I can't believe your patience but can see the excellent results, its going to be more solid than when it left Germany. :ok
1983 1.9 Ivory Westy Joker

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Thanks... some of it is really frustrating but it all comes together in the end...

First bit of C post repair...

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Second bit...

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Next to tackle the bottom slider rail and outer sill...
First job was to remove the seal channel from the new outer sill.

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I laid out the old and new parts side by side, took note of lots of measurements before I started cutting.

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Note the bend in the panel along where the black line is. Will have to try to recreate that bend in the new part.

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Note the surface that the vert. roller rides on has a slope outwards...

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I cut the rusty worn bit out and used it as a template to mark the new outer sill.

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Last edited by boatbuilder on 27 Jul 2017, 00:50, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Can anyone help me find a photo of what this area should look like on an early van (up to 84)? Can't figure it out from my "remnants".....

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Last edited by boatbuilder on 27 Jul 2017, 00:50, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

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