Claudia's VW 1303 Restoration - Body Work - Part 3
Looks like I got the easy part done. Now moving to the left side. .
The support rail need to go, I patched it up 15 years ago. Removed the rail, and found nothing but a pile of rust, wow ! Heating channel is also bad, as well the plate between the rail and the channel. Not much left after removing of the heater pipe. Now I need a new heater channel, and the plate that goes between. Also some more pieces to fabricate.
Here a few picture during cutting out careful the old rusted pieces, to fit the new heater channels.
Laying the whole thing at the side like this makes it so much easier to work on it.
Turning it to the position so it's comfortable to work.
A section of the old channel is gone, and so some other rusted bits and pieces.
Finally, the complete heater channel is out.
Now the challenge starts. I sandwiched together the support rail and the heater channel, and the holes do not line up.
The rails are made in Germany, the channel is made in Danmark.
Looks like I have to do some fitting of these holes, between the channel, rail, and the floor pan. Also the front end piece I had to flatten out, because it was too short.
I put in some bolts between the rail, floor pan and channel, and here goes the first test fit.
Some pushing and wiggeling and it actually doesn't fit that bad.
Looks like I need to fabricate some pieces to fill in the holes, Oh Boy.
Checking the inside, and it doesn't look that bad, as well the measurements of the door opening.
On the front side I have to make some pieces. I got the outer skin, but there are some pieces to fabricate. A little more as it was on the right side.
Here it is fitted in. Next weekend I will check it out again, mark all the holes which need rework, and if it's all good, tak-weld in the channel.
One last look on the RIGHT side, to see some positive things, and then it was anyway time for a nice beer. Here is more progress, line up of all the holes between the support rail, the heater channel and the floor pan. This took more time as I have expected. . Some of the holes need some grinding. Finally they all fit. Starting on the inside to weld in small pieces where I had to cut of the rusted part. Here after it's welded in, the seam at the bottom get's welded together with the support rail. A view from the outside, more holes to close. Fabricating and welding in the new pieces. Here it is welded in. More small pieces welded in. Next is the outside. The last hole between inside and outside is now closed.
I found that the piece which goes under the section, is available, so I ordered that. Saves some cutting, bending and hammering.
To be Continued !