The GASWAGON (act III)

[lloydy]

Gentleman jack... i need some of that after seeing all this rust!
Trailing arm off then eh? I liken this van to a onion, so many layers! At least the arm will come off easy, seeing as its only just gone on.
Bloody rust eh! This was meant to be a rust free syncro!

[AdrianC]

next to position the front of the inner sill correctly, the rear is easy but the front only has thin air as a reference so

measure the rear
then place the front after doing the same

Is it worth making jigs for things like this, or would they need so much tickling on a van-by-van basis that it wouldn't be worth it?

[Paul_Van_Denton]

mmnmmmmm Gentleman jack! spent many a night with him! also....

[Plasticman]

That's my sort of bribe lol
mm

[Paul_Van_Denton]

E D I T...

If we talking bribes than hands down its this!

[Plasticman]

Fine just bring a bottle when your here

[Paul_Van_Denton]

will do!

[kevtherev]

Bloody rust eh! This was meant to be a rust free syncro!

it will become one though..mine still is where mm's been

[Plasticman]

Well putting back nice new steel ,always a pleasure
assemblage

new jp welded up and fitted,i cant fold this gauge of steel with a very tight 90' so easier to fabricate

note how it sits in relation to the cut out in the inner sill.

i have puddled through the 2 x 12mm holes for good grab and tacked it down the sides, and at the bottom its seamed to the inner sill,so now all the forces are transmitted vertically up the B post as they should be,
brace is now off as its served its purpose, this is why i braze this sort of thing as it only needs a bit of heat and its off ,instead of cutting and grinding etc

and now a coat of WT

other side, at the bottom I have done 2 full beads of weld so it is stronger than needs and will do no harm

now the kit of parts at the rear

you will see there is an extra bit, i have masde a further brace above the jp, its something that i suppose doesnt need to be there but will do no harm and well ive done it so its staying.....

i think this bit is self explanatory, any way this plate has also been puddled through to the inner bits i have added

normally this part extends down to the bottom of the inner sill lip where the outer fits , but this is cos its easier for vw to spot it, I think its better done this way and is certainly strong enough, and will save having to relieve the outer sill as i do in the past.if there is no advantage then i go back to the previous way

and with a coat of WT .

so at the rear i have the outer shell of the C post to knock up and same at the front and then extend the outrigger to fit and tie it all in
mm

[lloydy]

Looking good! Guess I'll have to start using these jacking points now you've put all this work into them

[Plasticman]

next to position the front of the inner sill correctly, the rear is easy but the front only has thin air as a reference so

measure the rear
then place the front after doing the same

Is it worth making jigs for things like this, or would they need so much tickling on a van-by-van basis that it wouldn't be worth it?

not worth it as its hard to get a reference that would apply to all, so as long as you know where to take the measurements from then its not so bad,
i do have jig for the rear arm mount though as thats rather critical
mm

[Plasticman]

Well,just a quick pick of the inner sill showing the penetration,

modified a lower B post to fit

no need to fit any more

this is the repair piece for the main outrigger and is in 2mm plate,it has a fold at the top and replicates the OE
also a good picky of the inner support for the JP

here you can see a small bit i have added to the inner part of the B post, ignore the shape as it will be formed later,main thing is to have it joined now as i cant get to it later, also note how it is sandwiched between the chassis outrigger lip and what will become the rest of the outer B post , all will become apparent

here i have spotted it through to the inner sill and tacked it to the rest of the outrigger

i will square the lip off neatly etc when its all welded.
this is the top lip of the chassis outrigger and also forms the base for the rear of the arch/batterybox back, then the floor closure plates fit over this

this is the inside rear of the outer B post, just a small part to make and weld in

a quick whip over with the disc, it needs a bit more tapping around and i will add some weld to the sides to then remove so we have zero filler

the large lip to the rear will be mostly removed and will look nice and tidy when the remainder of the closures are made and added.
nice way to spend the afternoon
mm

[lloydy]

was the outer B post not as good as you first thought then? Looks like you had to muck around with bottom part of it?
(the crescent shaped cut out for jack)

[Plasticman]

Well. yes it did need work sort of in a way, the scalloped out bit is yet to be welded.
so we start with this hole


and make this bit to fit it

and

sat in place

to me its important to fit stuff like this also it really adds to the strength and integrity of the jp area, also dont forget that the outer sill etc fit to it

front bit added, this is part of the inner arch and open to the elements

on a previous picky you could see a small dip where the lower joined the upper part of the outer b post skin, this imperfection was just into the seam area ,so i have added a bit of weld to each side and sanded it off,so will be able to avoid filler with luck


will just need to mig a few bits tomoz
this is the small part that sits on top of the outrigger and is part of the rear of the battery box

will post this up now and do the rear in 5 minutes
mm

[Plasticman]

back

sort of self explanatory

error here as i made the lip with the 3 holes in too wide
again migging to do but need a new argosheild
gound over

so a nice little bit to make

and

a quick tidy with a disc

and

roughly in place

a quick touch with a soft pad and a coat of WD

and


again it doesnt have to be done like this but the next picks show the sill roughly in place and again it compliments the fit of the sill and also the floor closure plates fit in here so may as well do it right

like that

so just a small strip along the arm mount to affix the wing to and were about there with it so a most enjoyable afternoon
mm