The VOLTSWAGON

[Cruz]

I'd do it properly mike. just that the damn conversion is carpeted glued ply. So one to look forward to stripping out in the future. also lpg tank will need to come out. kitchen side has been done to a decent standard in the past

[Plasticman]

well.last few bits to make for the osf then trial fit the roof again

sat in place ready to tack

could always turn it into a poptart

it sits nearly right,a little easing required, also bear in mind the gutter sections need adding so this will help close the gap here alos most of the remnants are in place still. im mainly concerened with the front as this is roof support and screen so has to be correct

n/side

o/side

the centre here is sat higher than id like but will be easy enough as there is a little sika or whatever still around.
end of the day i needed to confirm that theory and measurments were near enough else it would have been the w'end ripping it off and re-doing i have to laugh really
mm

[Plasticman]

Well front welding done save for the attatchment of the new gutters but all seems to fit ok.
the front edge which i had to turn inside out (not helped by the fact it was also bonded)to release the roof is now ready to turn back

the gap you see will be ever so slightly reduced but its where it was to start with

first turn up done, will need to move the roof back down to confirm the ends again as they are cut shorter and cant do this till the gutters are back on, anyhows it will become plainer i hope as it progresses

gap along here is now even and will be spot on with the 2 new bits to give depth (gutter and top closure plate)

well now the plot thicvkens


ive been told that the issue of the mastic filling the area under the gutter has been discussed,well i beleive it does need some but now i fully see the reason it came about
the hitop was cut away to allow the removal of the rotten bit of gutter at the rear, it must have been Really bad
and theres loads of what looks like P40 and my pink is pointing out a mig spot

and off pops this

a bit of made up gutter tacked on

and the mastic hides the work and on the other side its a support for the rotten gutter and stopped the filler falling through the holes


so in fairness the guys that did the repair did it the only way you could unless you do it the way im doing it theres not a lot of other options, all depends on what was in their breif and ,,,,,,,,,,,,,,,,,,,,,
so plain sailing now
mm

[Cableguy]

Looking good Mike
Hope you don't find any more horrors in there

[300CE]

Great work Mike! Looking forward to seeing it completed

[Plasticman]

Well busy removing crap and treating,

light years away from what it was

the areas where im welding (under gutter face and top vertical bit ) are solely weld thru
so i have a simple rear gutter end to form and then its nice new metal to weld it up

mm

[Plasticman]

well was going to get involved with the new steel but decided to finnish the last of the "pooh" stuff and get the n/s ready

same at the front

will get the gutters on and the top closures all tacked then final drop of the roof to ensure all is well and then off again and finnish the welds, just got a couple of hundered holes to drill so a sharp one goes in the pillar drill
first offer up of the rear corner, but as this will sit on the gutter im only getting it something like for now

mm

[Plasticman]

Well appx 260 holes to drill each side. anyhows this is what the gutter will look like from under,it needs to be out a few more mm'

i have centred to holes at appx 30mm on the gutter part,need to get the spotting near to the outer edge of the plate under, easier to show tomoz as its welded
this is the area the roof will sit back down on

ditto

mm

[lloydy]

that looks awesome

[max and caddy]

Agree...I had to repair this very same area to a much lesser degree on my vw hiroof van when I got it...not much fun and had to do it in a bit of a rush to be honest.really wish I could get the roof off again and do it a little better but have nowhere big enough to tackle it now.

[Cableguy]

Wow, amazing. That's a lot of spot welds to do

[b-f-c]

Amazing work MM, inspiring me to crack on with mine and stop hiding from it.

[Plasticman]

well it seems there are a few roofs out there that are unhappy, had a look at one only yertserday
anyhows back to it.
just had the rear corners to form , relativly simple compared to the fronts.



then its a case of sorting the length and then join ing them
11 and a half foot !!! weld through drying in the sun

had to butcher a pair of grips so they fitted between the body mouldinng and gutter mount

nsr sat in place

so its tacked down in place and i have inntroduced a gentle curve from F to R and the roof dropped down again to check all is good before wellding up this stage

this is the os rear showing the roof with the bit missing

might just make out the shape here

and Voila

it fits.... so having a day off and if n as i get bored on sunday than i shall whip the roof off again and weld the gutters up and start the inner closures which are already made
mm

[300CE]

Superb work, looks fantastic. Certainly looks like a well deserved break & a bevvy is in order

[Cableguy]

Awesome!
Out of interest, seeing how matey chopped the lip off the rear section of the roof, what's the plan for making sure it's held down and sealed?