The GASWAGON (act III)

[Plasticman]

i have all i need

[lloydy]

coolio, it's nice not spending, could get used to it..

Really appreciate the work you have put into all that, it really is fantastic

[Plasticman]

well should now be able to offer a cooler with a simpler fitment if required and a base template
mm

[lloydy]

they should fly out the door!

[Plasticman]

Hope not cos they are well secured in there

[max and caddy]

Could be intrested.....got another tdi brewing here.

[Cableguy]

Ooh me too please Mike.

[Plasticman]

suppose you'll want it fitting
Well packages keep arriving ,today this

and

so if anyone want a tinted front with built in antenna then these are the numbers (for the green tint)
nsr 1/4, yes you can buy the lower repair sections and they are quite good,but i haven't one in and i prefer them out of thicker steel
so i make them,
heres the old

unpicked, and

and lookiehere

dont think we need any of this pod

heres its tacked on and i have fully butt welded it (gas of course )
inside view

they can warp but you get a feel for how its going and compensate, dont work every time but does mostly
also dont forget these are not straight, they have a gentle curve to them that needs to be created or it will look an ***

first planish and hammer, i have also removed the large dent that was solid filler

now with a coat of wt on , it will need a teaspoon of filler in it at most

here you can see the inside , i need to remove a few mm from the arch back as you can see from the marks i made

mm

[lloydy]

mmmm green antenna glass
Nice work on that panel, found even more filler in there then eh!

[Plasticman]

well theres always filler to be found as theres always rot,,,
this is one of the hardest bits of the rear to make,
the slight depression they all have

its all welded on now, i braze these parts as you cant get in to spot correctly and its better than the factory sealer they add
I will run a slight groove into it

adding a lip to the inside, im weighting it to keep some curve into it, these pattern skins are just so thin that its almost hit and miss ,there are ways to keep the spring in them but its not pleasant

seam to rear 1/4 and lower swage is better now

front

old wing swaged to accept new skin

..

mm

[max and caddy]

Is that a gold bar?

[lloydy]

any gold found in the van is legally mine

[Plasticman]

nah, i have mineral rights
got loads of iron ore and ferrous oxide
now not a visualy interesting post but i have fitted the cooler and am re positioning and mounting the relays and solenoids and stuff,
engine bay first with all the cut connections to remake, these have been soldered and shrink wrapped .
even found my old bullet pliers , though not much use on this job

take care with crimping

all the wires at this end re connected and this is where they will position themselves.

so more interest tomorrow back to sticking the panels on
mm

[lloydy]

Oops, nice spot with the crimp!

[Plasticman]

Well back to more usual stuff. bodies,
i cut a bit too much off the old wing so have made a bit for each end and

and welded and a quick sand

got to do this as you do not want a void here
tacked into place

gaps are up to standard so happy here

centre panel side same

spotted through in the rear, keep these close to the outside to ensure a tight seam

inside arch ready to spot up

copy outer needs tweaking at either end, also they are 2-3mm too short where they return to the inner sill

but they line up reasonably well. and the rear wing is now very much welded to the new 3mm strip i added to the arm mount area

here the shiny part is the rear wing and this is first spotted to the C post then coated with wt and then we set the center panel correct to it and weld this through the holes i made earlier when removing it

nearly there with positioning so will drill it out in the morning then add it and then make the inner closures and fit thom, i will add some 19mm holes with grommets so i can inject dynax etc without grovveling under it

mm