The VOLTSWAGON

[Plasticman]

Ah, he put that in cos the bottom of the gutters were /are full of holes and rot so filled them and hid it all with this clag, looks good my ar** as a scouse sitcom used to say.
oh and did the side cover things come off when it was painted, might help me work things out is all
mm

[Cableguy]

The mouldings stayed on. Not sure how they fix. The bodykit planks are stuck on with blocks of foam.

[Plasticman]

that was one of my great fears

[Aidan]

starting with a new unmolested shell might be quicker and cheaper

[Plasticman]

hmm, well the hard work was removing the roof followed by as usual disecting the variouse layers of build to get back to good metal, thern its the fun part of being creative and letting bits in, very clean work and when done should be good for a lot of years, also would need a good westie shell for the dehler and it would need the deep gutters as per the early vans with i think the metal rear grills
mm

[lloydy]

just caught up on this, bloody hell! It'll all soon be good Ray

[Plasticman]

hello, back are we
well on with more unpicking and working the best /easiest way forward, as discussed we dont like the sealnt under the old gutter and i have to have rid of it to enable me to weld the new ones on so

we now have access right to the back pig scraping/cutting it all back but so far have managed to avoid damage to the plaggy....

so onto the corner part, this si a complex area with many overlapping joins and much brazing, ive menchioned this before but there was/is no alternative here

the under side is brazed to the A post and the upper as well, might just see it here

next 2 are just sealant over the rot and painted


now my issue with this is the guy that did the repair and repaint new these issues and the holes under the rubber and yet choose noty to say anything , ok it may not have been in the original brief and he may not have been able or wanted to do it , but at least advise the customer and let them then make an informed choice, lucky in this case only very minor paint will be required to gutters and A post tops and front top rail
so now we do a quick test fit of the principle of the new parts made

bear in mind there is still a lot of edges to clean of and blast and prep.but important to check the idea is correct

and when done the hitop will sit on this all round

so now im halfway into making one end of the new gutter into this

now note on the otherside which is still as is and fitted, there is no place for the gutter water to run off

so either i make a hole in the underside to channal it to the front of the A post trim or reshape it a bit like this

but make it look like its meant to be..a nice oval hole may be more aesthetically pleasing?
mm

[Cableguy]

omg

[Plasticman]

OMG what
ah you wanted to seee what was left ....ok

mm

[Cableguy]

Not much by the looks of it.

[Plasticman]

well the plot thickened,anyhow good progress was made on an evil area so happiness prevailed but first
this had to be constructed

and positioned, note, none of these items can be welded down yet as the whole lot,all 4 corners have to be fab'd then tacked and the roof lowered to confirm all is as I want and it should be , then roof back off, gritblast and treat then weld !!

dont know what happened there
sat in place

bit of old gutter was in the way so lifted it up... was the sealant that was holding it on

now ive had to remove a bit more of the A post, this area is usually brazed but whilst i can braze a hole up it 10 times easier to sort this now, note with the dividers ,this area is not welded by vw but has very god sealant , im going to weld it as im doing the rebuild in a slightly differen order

ditto

im still going to braze this area as there is no other way but have made it solid,,,=zero rot now.
the slight bulge on the inside of the aperature is finer as this will flare out to the next part

next i have to confirm the position of the gutter, too far out and issues,too far in and the roof will intefere,

so now ive placed it and marked it up for subsequent refitting

and

now this part is one of the most important as it forms the outer part of the screen seal, and also carries the folding lip for turning over the hi top lip,it will be brazed on the A post side

so next we have this awkward bit to make .its never seen ,but ive seen it and it may as well bve done right .

so here we have this bit that curves in all 3 planes

these are the nice bits to make

and resting in place

ditto

so this is the nsf corner done, it was hard due to all of it being seen and also the area had to be correct as the roof has very little leeway for making up errors,so replicate the osf and then the rears. they will be relatively easy as they do not have to secure the rear screen
mm

[Titus A Duxass]

As always - nice work! Are you tigging or migging?

[syncropatrick]

Bravo!

[Plasticman]

As always - nice work! Are you tigging or migging?

GAS

[ZsZ]

progress?