1972 fastback. nwe 532k

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 12th November 2017 - 8:01pm

Here is a method i use that i find handy for getting profiles of irregular panels,
some of you might find this useful. Its a common practice used by cordwainers for
shoemaking, taught to me by a shoemaker.

Panel template profiling.

Very simple accurate process that takes the guesswork out of the panel shape you need.

First pick the panel you to copy or repair and tape the longest side first, ad continue
with strips as per the photos, until the panel is covered with lengthwise strips of masking tape.
Then alternate the direction of the tape and cover again, as per photos. Do this at least twice in
each direction. If there is a large piece of the panel that is missing already, then you will have
to place a light piece of card in place, and consider that to be the metal and cover with the tape
accordingly.

When that's complete, you will then mark around the panel out line required on the masking tape, and then
cut the outline with a sharp razor like blade. You then remove the waste tape material. You are now left
with a good panel template, as shown in the photos. This should be very gently peeled off the metal,
making sure that all four layers are removed together, if one starts separating, then stop and make
sure they all come off together.

As shown in the photos you have a template that still holds the general profile contours as well, that
you will be aiming for in metal. And to cut out the metal, lay the temp down flat on the metal, and trace
your line around the pattern. You can mark over size a bit to allow you to finally trim to fit, after
you have worked the metal into your general pattern.

This method also works for a part that has one surface at say, 90 degrees vertical to a horizontal plane.

Hope this makes sense for you.



This is the panel that we need to take a profile of.

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This is the process in alternating masking tape application.

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Alternating rows of masking tape.

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Marking outline of proposed panel cut.

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Now cutting the outline of the required panel, direct from the body.

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Finished body template cut.

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Note that the template holds the body contoured profile.

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Template flattened onto metal sheet for cutting.


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Last edited by kaddy on 17th November 2017 - 11:20pm, edited 1 time in total.

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Kai
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Re: 1972 fastback. nwe 532k

Post by Kai » 12th November 2017 - 8:42pm

^^^^^ I'm impressed with that technique! ^^^^^^

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Kai
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Re: 1972 fastback. nwe 532k

Post by Kai » 12th November 2017 - 8:43pm

Fortunately I only have flat pieces to repair within the rear wheel arch tub. Nobody will ever know :)

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Kai
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Location: Surrey

Re: 1972 fastback. nwe 532k

Post by Kai » 12th November 2017 - 8:46pm

Oh oh oh!!!

Any tricks for bending metal neatly without have a metal sheet metal bending machine.

Like a 45 bend/crease in a sheet of metal.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 12th November 2017 - 9:06pm

What area.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 12th November 2017 - 9:11pm

Some of the tools that i would use for hammer forming small panels

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Last edited by kaddy on 17th November 2017 - 9:20pm, edited 1 time in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 12th November 2017 - 9:25pm

These are some of the panels i,ve made by hammer forming with the tools shown.
Plus any shape of metal bench, edge, pipe ect that i need to form around.
So very basic tools really. Plus a small bit of ingenuity and luck.

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Last edited by kaddy on 17th November 2017 - 9:18pm, edited 1 time in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 12th November 2017 - 10:14pm

Here again is another wheel inner arch section that was hammer formed,
and then planished to clean it up with a bench mounted air planishing hammer.


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Last edited by kaddy on 17th November 2017 - 9:09pm, edited 1 time in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 15th November 2017 - 9:10pm

Here is the original rear IRS unit that was on my fastback.
As you can see its rough enough, but luckily the only parts I need are the suspension bushes
which were good, and the stub axles and cv units , which ere also good.
Plus the ancilleriy brake parts.

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This platform here can elevate to 6 ft high, and carries a substantial load.
I have had my beetle up on this.
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Considering that the body is supported here by attachment to the rubber supports, this part of the IRS
was an accident waiting to happen.
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Here again major corrosion taking place
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Glad to get this off the car, and the nos irs unit and back on.
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In case you are wondering what the green frame underneath is, its a ordnance lift from 1965. It was used for loading weapons ordnance
onto tornado aircraft during the vietnam war.
Last edited by kaddy on 17th November 2017 - 9:05pm, edited 2 times in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 15th November 2017 - 9:17pm

Existing axle components will be examined , painted and re used. Along with new pipes, brake hoses
and shoes.



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Last edited by kaddy on 17th November 2017 - 8:56pm, edited 1 time in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 15th November 2017 - 9:23pm

These are what i,m really after. Now to strip them down, inspect them and rebuild and re grease them.
I know from driving the car with these, it drove like a dream, so I dont expect any nasty surpises.
But thats why we call the unexpected, surprises.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 15th November 2017 - 9:36pm

As you can see from the first picture, you are starting off with a crud covered piece of metal,
and we are hoping to finish up with a good serviceable cv unit each end of a good stub axle.
After a lot of elbow gease, lathe wire brushing, solvent dipping and cleaning, hopefully we
end up with nice clean parts for re assembly.
All went well, and the 2 boots were in great shape, so back on they will go.

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All ready for a slap of grease.
Last edited by kaddy on 17th November 2017 - 8:44pm, edited 1 time in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 16th November 2017 - 7:59pm

Last cv joint finally finished and ready to be greased.
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Finished stub axle with re greased cv joints ready for fitting.
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Second stub axle finished with re greased cv joints ready for fitting.
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Rebuilt passenger side pivot arm with new pin and bushes ready for the stub axle.
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Drivers side rebuilt pivot arm
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IRS sprayed and new bushes fitted, as well as new bearings for the stub axle.
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This is my existing gearbox that I will be re installing.
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Existing gearbox needs cleanup a new clutch arm spring, and new oil. Clutch release bearing has only about 2k miles, so I wont be re newing it.
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Bell housing of the gearbox needs a good cleaning
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Last edited by kaddy on 17th November 2017 - 6:06pm, edited 2 times in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 16th November 2017 - 8:22pm

Nearly cleaned now. Underneath all that muck is a decent looking gearbox.
And I know from driving it, its in good shape.

A coat of a decent paint should keep it in good shape for a few more years.


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Last edited by kaddy on 15th December 2017 - 4:19pm, edited 1 time in total.

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broady_6
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Re: 1972 fastback. nwe 532k

Post by broady_6 » 17th November 2017 - 11:44am

I sat and read this over the course of the last two evenings, this morning I came to comment and all of you images are dead :(
The sultan of swing

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 17th November 2017 - 12:44pm

Server issue my end, but being dealt with at the moment.

Probably gonna be a few days before the pics are back up.

But dont let that stop you commenting, good bad or otherwise.

I, me here to learn too :)

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 17th November 2017 - 1:16pm

Current state of play, i,m working on cleaning the gearbox, and testing out imjur :)

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 17th November 2017 - 1:19pm

Looks like i'll be re vamping all the pics through imjur.

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sparkywig
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Re: 1972 fastback. nwe 532k

Post by sparkywig » 17th November 2017 - 3:56pm

I've gone to postimage.org

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 17th November 2017 - 5:19pm

Is there any particular image hosting site any better than the rest??

or is 1/2 doz of one and six of the other.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 17th November 2017 - 6:50pm

Just need to figure out how to link multiple pics from imjur to here at once,
instead of one at a time.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 17th November 2017 - 11:26pm

A couple of more pages to do, and we are back to square one finally.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 18th November 2017 - 12:58pm

Finally back on track.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 18th November 2017 - 5:21pm

Finally managed to clean out every nook and cranny, and managed to get the gearbox into a presentable
appearance.

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Its fitted back into the irs axle now, as well as the two stub axles.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 21st November 2017 - 7:25pm

Existing backplate stripped of brake parts for inspection of condition.

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Ready for cleaning. And if its useable, it will go back on as these are scarce enough
so I'm told.

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Gearbox and stub axles refitted. And rear brake lines fitted, and wheel to hose sections
rough fitted for sizing.

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Axles now ready for wheel drum and brake finishing.

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Backplate cleaned and ready for rustproofing, priming painting and popping back on.

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Might have a finished rolling chassis before christmas which would be great.

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