1972 fastback. nwe 532k

For Type 3 and 4 restoration projects, interesting history, adventure trips etc
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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 14th October 2016 - 12:15am

Its in the same location as this.

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And there are two more panels, to be fitted, before the wing cover panels.

The ope surround panel, and the top drain panel above this.
Last edited by kaddy on 15th December 2017 - 1:49pm, edited 2 times in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 14th October 2016 - 7:40pm

Wheel arch endpiece repair added, and airduct surround shroud,

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 19th October 2016 - 10:28pm

New metal replacing rust in drivers side rear wheelarch.

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New panels around air intake and tail.


Inner edge panel at engine bay.


Existing rust damage at body support mount that needs replacing.



Outer panel repaired at the base.
Last edited by kaddy on 15th December 2017 - 1:59pm, edited 2 times in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 20th October 2016 - 10:43pm

New body support mounting welded in and repaired.

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Another view of the support bracket.


Bulkhead panel also welded in


Bulkhead now completed
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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 26th October 2016 - 11:52pm

More rust damage in the usual places in a type 3.

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New roof repair section hammer formed with roof gutter.
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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 29th October 2016 - 1:08am

Yet more rust removed from the inner corner,

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New panel made to replace the support metal.




New support panel welded in.



New roof and gutter panel welded in.



Lastly new corner panel offered up for marking and then welding.
Last edited by kaddy on 15th December 2017 - 2:51pm, edited 2 times in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 29th October 2016 - 3:17pm

Final piece of the wing corner made up and welded in,

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 9th November 2016 - 9:40am

Rusty corner at tail end of the rear, behind the bumper, cut out.

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Rust cut out.



New panel made up and welded in.




Drivers side rear finally finished
Last edited by kaddy on 15th December 2017 - 3:48pm, edited 3 times in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 11th November 2016 - 8:31pm

Heater pipe welded in.

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Heater flap reconnected.







Drivers side heater channel completed bar the cill.
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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 19th November 2016 - 6:52pm

Left hand cill fitted


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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 24th November 2016 - 1:54pm

New cill formed,
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Chino
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Re: 1972 fastback. nwe 532k

Post by Chino » 25th November 2016 - 10:21am

Great work as always, very much enjoying following this thread :)

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 25th November 2016 - 11:02pm

Appreciate the encouragement. Thanks. :)

I think i,m finally over the major parts of the welding on this car. I just have the two corners
below the front windscreen. And then a bit of tidying up and grinding. then priming and seam sealing
any new metal.

Long road to get this far i must admit. And there were times i thought...to hell with it.

But now I,m this far, i,m glad I stuck with it.

And the fact that you guys out there have some class cars after a similar venture,
kept me motivated.

So........more pics to come.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 8th October 2017 - 10:57am

I,ve managed to remove the pbucket ransome notes, and replace them with all the relevent fasty details.

Thanks to Chevereto software imaging through my own website.

So after many months, and my daily aircooled hack heater channel replacements, i,m now back on track,

and fasty will be full steam ahead.......finally

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 16th October 2017 - 8:50pm

Working on stripping , cleaning, painting and rebuilding the front discs.

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Cleaning and painting.
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Caliper split in two.


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Before disassembly.

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Editor
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Re: 1972 fastback. nwe 532k

Post by Editor » 17th October 2017 - 12:25am

How do you get the pistons out? Use a press with a collar on the piston flange? I guess it's all a matter of whether they have damaged the bores, or have serious corrosion. I've several pairs here that have seen better days, but I'm reluctant to label them as scrap until it's obvious they are.
Dave.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 17th October 2017 - 9:38am

Dont scrap them. These pistons were seized, but I successfully removed them all.

I,ll post pictures today of how i did them carefully
But basically....

Split them in two by undoing the four allenkey bolts, and then they seperate.

Take the caliper half that has the flexible hose and remove it.

Then put the piston side face down on a bench, and put WD40 into the caliper,

through the back of the caliper, where the hose attaches. And leave for a while

Now find a strong machined metal drift of good quality, similar quality to a pump shaft.

That will fit through the centre of the hole at the back of the inserted piston, and tap gently.

Keep checking after a few taps to see if the piston is moving. Dont bash the hell out of it.

This is an operation that needs patience , The other half is trickier :-)

I,l go and get some pics...

Caliper face down showing the steel rod to punch out the piston, and the hole to insert the rod.
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Rod inserted in position.
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Rod position from inside caliper.
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Position rod will strike inside piston edge.
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Other caliper half with no hole access for rod.
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Lubricate around piston, and raise caliper half above a solid surface.
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And strike down hard with force onto a solid surface, making sure to strike flat .
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Back of caliper half with no hole
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Caliper half with hole for brake hose, that allows the slim metal drift.
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It will require a large amount of blows to get movement started. But once it is keep wd40 applied.
Left and right taps on the piston will also allow movement against the seal in the caliper, which then allows
wd40 to enter.
Rinse and repeat.

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Editor
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Re: 1972 fastback. nwe 532k

Post by Editor » 17th October 2017 - 11:34am

I'll take a closer look at what I've got - some are clearly better than others. None of them has been in use recently, so I don't expect too much success.
Dave.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 17th October 2017 - 11:58am

These ones have not been in use for 3 years or more, and i cant
say for definite that when they were , they were 100%

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 18th October 2017 - 12:29pm

Various pics of the cleaning process i used for my brake caliper components
Caliper placed into solution.
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Connected up to standard charger
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Power setting at 8 amps, and let the show begin
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Woeking well at removing the rust, and softening the paint coat, which is hard and appears to be baked on.
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Checked periodically, and taken out and brushed off with a wire brush, and popped back in.
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Finally it appears to have done its job.
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broady_6
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Re: 1972 fastback. nwe 532k

Post by broady_6 » 22nd October 2017 - 10:06am

I do enjoy electrolysis, I really must do more of this! got a photo of the finished result?
The sultan of swing

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 22nd October 2017 - 9:51pm

Yes I do, but its after they were washed, cleaned, neutralised from the solution.
And then given 3 coats of hammerite;-)

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 26th October 2017 - 9:14pm

New ball joints fitted today, and the beam fitted back to the frame head.

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In the absence of the correct VW tool to compress control arms, I used a short robust sashcramp. It did the job great
as its extremely strong and easily closed.

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Spindle positioned carefully, before clamp is released to allow balljoint to engage.
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Sash cramp released and bottom control arm pops ball joint into spindle location, forcefully.
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Now for the other side.
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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 27th October 2017 - 9:05pm

Onto the steering box now that both discs and new top and bottom ball joints are fitted.

Existing steering unit has some well baked crud on it and needs cleaning
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Unit is in poor fettle on all sides.Image

Steering damper too, needs a tidy upImage

Between electrolosys on the mounting cap and arm..Image

And good old elbow grease and a soft wire brush, I managed to clean them up to this.Image

I,m not going to open the steering unit, as i know it was in good mechanical order before the resto.
Last edited by kaddy on 18th November 2017 - 12:49am, edited 1 time in total.

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kaddy
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Re: 1972 fastback. nwe 532k

Post by kaddy » 27th October 2017 - 11:51pm

I cant seem to source some balljoint spring washers at all, despite my best efforts.

If someone can point me in the direction of these elusive items, I would be very greatful for the help

Thanks
Tim

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