Claudia's VW 1303 Restoration - Body Work - Part 3

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  Looks like I got the easy part done. Now moving to the left side. .

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  The support rail need to go, I patched it up 15 years ago.

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  Removed the rail, and found nothing but a pile of rust, wow !

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  Heating channel is also bad, as well the plate between the rail and the channel.

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  Not much left after removing of the heater pipe.

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  Now I need a new heater channel, and the plate that goes between. Also some more pieces to fabricate.

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  Here a few picture during cutting out careful the old rusted pieces, to fit the new heater channels.

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  Laying the whole thing at the side like this makes it so much easier to work on it.

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  Turning it to the position so it's comfortable to work.

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  A section of the old channel is gone, and so some other rusted bits and pieces.

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  Finally, the complete heater channel is out.

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  Now the challenge starts. I sandwiched together the support rail and the heater channel, and the holes do not line up.

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  The rails are made in Germany, the channel is made in Danmark.

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  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.

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  I put in some bolts between the rail, floor pan and channel, and here goes the first test fit.

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  Some pushing and wiggeling and it actually doesn't fit that bad.

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  Looks like I need to fabricate some pieces to fill in the holes, Oh Boy.

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  Checking the inside, and it doesn't look that bad, as well the measurements of the door opening.

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  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.

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  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.

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  One last look on the RIGHT side, to see some positive things, and then it was anyway time for a nice beer.

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  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. .

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  Some of the holes need some grinding.

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  Finally they all fit.

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  Starting on the inside to weld in small pieces where I had to cut of the rusted part.

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  Here after it's welded in, the seam at the bottom get's welded together with the support rail.

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  A view from the outside, more holes to close.

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  Fabricating and welding in the new pieces.

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  Here it is welded in.

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  More small pieces welded in. Next is the outside.

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  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 !