Project 411

Paul L · Post by **Paul L** » 27th March 2011 - 6:34pm

Hi all

have been enjoying the projects on the forum so thought we would share ours. Here it is, we picked it up from Bristol last week (some of you may have seen it before!). Described as solid

, but..............

as picked up

http://www.flickr.com/photos/48638537@N03/5564111241/

http://farm6.static.flickr.com/5136/556 ... 8251_m.jpg

http://farm6.static.flickr.com/5140/556 ... 871e_m.jpg

then we took the (fibreglass) front wings off.........you can guess the rest......

http://www.flickr.com/photos/48638537@N03/5564701036/

http://www.flickr.com/photos/48638537@N03/5564130647/

So the welding begins!

http://www.flickr.com/photos/48638537@N03/5564127953/

http://www.flickr.com/photos/48638537@N03/5564136477/

almost finished the offside. Have shaped it in behind the headlight, its not quite as original, but not a million miles away.

http://www.flickr.com/photos/48638537@N03/5564721120/

http://www.flickr.com/photos/48638537@N03/5564723864/

Hope to have all the welding done in the next couple of weeks. Thers is some to do beneath the rear arches too. This week we will rebuid the nearside inner wing, which is worse than the offside. Hope the photos work!

Paul and Dani

shawn71 · Post by **shawn71** » 27th March 2011 - 7:26pm

I've seen this one before and was hoping that it would see the road again. Shame the 'solid' isn't as solid as what most of us would call solid

However it looks like you've made a good start on changing that.

Good luck with the project

kps70 · Post by **kps70** » 27th March 2011 - 9:02pm

That looks oh so familiar! My rust went right in from the inner wing to the boot hinge - nightmare welding job. Good progress in this dry weather. I hope your floors are solid - mine weren't!

Keep up the good work

volkswalker · Post by **volkswalker** » 27th March 2011 - 11:06pm

good job dude!!!!!!!!!

Paul L · Post by **Paul L** » 28th March 2011 - 12:31am

Thanks everyone, we may need some encouragement as time goes on! The floors are pretty good to be fair. The rear inner wheelarches are going to be a bit tricky and there is a lot to cut out of the n/s inner wing. That said i am pretty pleased with the o/s inner wing. I have 2 weeks off in April, so plan to hit all the welding and sort the engine out (which is in the boot!). More pictures to come.

Paul L · Post by **Paul L** » 22nd April 2011 - 8:11pm

Some more progress today. Have sorted the rear end welding today. Here is the nearside before:

http://www.flickr.com/photos/48638537@N ... hotostream

and the offside

http://www.flickr.com/photos/48638537@N ... otostream/

Spent all day out in the sun today and rebuilt the bottom of both inner wheelarches, repaired the inner panel and replaced the vent panel that sits between the wing and the inner wheelarch.

Here is the nearside painted up:

http://www.flickr.com/photos/48638537@N ... otostream/

and the offside:

http://www.flickr.com/photos/48638537@N ... otostream/

Just need to cut the holes in the vent panels then that's the rear end done (as far as i can see!)

Will finish the nearside front inner wing on sunday. Next week: Gearbox out an start on the brakes etc......

shawn71 · Post by **shawn71** » 22nd April 2011 - 8:35pm

Excellent progress being made there...soon be done at this rate

Paul Hayward · Post by **Paul Hayward** » 22nd April 2011 - 8:50pm

solid is not quite correct term is it

GRAND JOB YOUR DOING THERE

..Will look forward to seeing her all finished off at vw action

Paul L · Post by **Paul L** » 22nd April 2011 - 9:20pm

Now there's a challenge! If we get it running right then we'll be there! No, 'solid' wouldn't be my choice of word to describe it!

Post by **purplepeter** » 22nd April 2011 - 9:57pm

Its looking good paul !
I spoke to the previous owner last week,& can confirm that as i said to you previously..He didnt know about its imperfections when he sold it to you...No consolation i know,but at least you werent knowingly sold a rotter

Paul Hayward · Post by **Paul Hayward** » 22nd April 2011 - 10:24pm

most of that you would be able to see on the inside of the front boot area? oh well your cracking on with it and your doing a great job on the welding

...one day i really must learn! good luck with the Action debut

Paul L · Post by **Paul L** » 22nd April 2011 - 10:37pm

Thanks for your comments everyone. I was slightly narked when we discovered the holes, but never mind, it gives me a chance to rediscover my welding skills (ahem!) and be sure that it is done. We are really enjoying this project. Can't wait to get the engine in!!

kps70 · Post by **kps70** » 24th April 2011 - 7:35pm

Here's some more encouragement from me,
WELL DONE!

Paul L · Post by **Paul L** » 25th April 2011 - 10:12pm

Some more progress yesterday and today. With the rear inner wings done, we turned to the nearside front inner wing. Quite a lot needs doing so deep breath here goes......

started by forming and repairing round the strut top:

http://www.flickr.com/photos/48638537@N ... hotostream

http://www.flickr.com/photos/48638537@N ... hotostream

http://www.flickr.com/photos/48638537@N ... hotostream

then took it back to the door pillar:

http://www.flickr.com/photos/48638537@N ... hotostream

Then the tricky one around the headlight/washer bottle area. This one took quite a while as it's a fairly big plate and needed a lot of dollying to put the curve in around the washer bottle. Its not quite as original, but its not bad. The washer bottle bracket isn't as originally fitted, but it was the best i could do with the repair put in:

http://www.flickr.com/photos/48638537@N ... hotostream

http://www.flickr.com/photos/48638537@N ... hotostream

http://www.flickr.com/photos/48638537@N ... hotostream

http://www.flickr.com/photos/48638537@N ... hotostream

Trial fitted the wing and all ok. After that went to the beach for some sunshine and a pint! 6 more plates and all the welding is done. Hopefully get some more done tomorrow.

Paul Hayward · Post by **Paul Hayward** » 27th April 2011 - 12:38am

looking mighty fine work your doing there!

...and you certainly dont hang around ...will be back on the road in no time

Paul L · Post by **Paul L** » 27th April 2011 - 9:34pm

I feel like I'm showing off now. Spent a full day welding etc, so here's today's progress.

Started by finishing off the nearside inner wing:

http://www.flickr.com/photos/48638537@N ... hotostream

then finished a couple of bits on the offside:

http://www.flickr.com/photos/48638537@N ... hotostream

http://www.flickr.com/photos/48638537@N ... hotostream

Repair to the corner of the front panel:

http://www.flickr.com/photos/48638537@N ... hotostream

Made a small hole into a big hole in the wheel well with the grinder! Had to dig out the foam and sealer from the front panel to stop it from catching fire!

http://www.flickr.com/photos/48638537@N ... hotostream

Then all welds seam sealed and the panels coated in red oxide:

http://www.flickr.com/photos/48638537@N ... hotostream

http://www.flickr.com/photos/48638537@N ... hotostream

http://www.flickr.com/photos/48638537@N ... hotostream

Hopefully that's all the welding. Having a pint and a lie down now!!!

Paul Hayward · Post by **Paul Hayward** » 27th April 2011 - 9:56pm

well done

...so come on.........when you booking the MOT

Paul L · Post by **Paul L** » 27th April 2011 - 10:16pm

lol....lots to do before the mot!!

Paul L · Post by **Paul L** » 20th November 2011 - 4:56pm

After something of a hiatus over the summer, due to work etc, I finally got an afternoon on the 411. The summer has been spent collecting bits!

To start, final undersealing uncovering the bumper bracket holes which had been welded over.

http://www.flickr.com/photos/48638537@N03/6370161405/

Headlights in...(number plate fitted to spur me on a bit!)

http://www.flickr.com/photos/48638537@N03/6370155515/

Wings refitted

http://www.flickr.com/photos/48638537@N03/6370150519/

Bumper fitted up and headlight covers in.

http://www.flickr.com/photos/48638537@N03/6370152627/

Have also fitted front calipers and tidied up some of the wiring. Now for wine.....!

shawn71 · Post by **shawn71** » 20th November 2011 - 6:42pm

Looking good

Paul L · Post by **Paul L** » 17th April 2012 - 9:47pm

Some more progress whilst dodging April showers. We have the week off so have been putting our collected bits together! We acquired an engine (thanks Phil!), which we plan to run whilst rebuilding the original. Having stripped it of all ancilliaries and tinware and cleaned it up, we checked it over and fingers crossed it seems ok.

http://www.flickr.com/photos/48638537@N ... hotostream

Spent a day and a bit on it and have repainted most of the tin and cleaned, checked and replaced parts as required. Cheeky use of yellow on the engine (couldn't resist!)

http://www.flickr.com/photos/48638537@N ... hotostream

Photo doesn't quite do it justice as dizzy is refreshed and in, breather pipes are pretty much all on as are the vacuum hoses. As the engine mounts are missing, we have adapted some others to fit (which can be easily replaced when I find some proper ones.

Engine going in tomorrow!

Paul L · Post by **Paul L** » 18th April 2012 - 8:50pm

Engine in today, in between heavy showers!

http://www.flickr.com/photos/48638537@N03/

Loom is connected up, just need to repair the wiring to the coil, fit the exhaust, fill up the gearbox and we should be nearly ready to turn it over. Bolting up the torque convertor was fun.....

Anyway, time for a beer.........

Paul L · Post by **Paul L** » 8th August 2012 - 7:43pm

Busy couple of days on the car. Engine loom repaired and engine turns over ok. Replaced the fuel pump and all the fuel lines and couldn't get any fuel out of the tank (the fuel in there was very stale!). Turns out that the tank pick up was choked all the way up. Removed the pick up from the tank (good job we had a 41mm socket!) and spent 2 hours cleaning the pipes up, had to cut the gauze filter off

.

We'll see if it runs tomorrow! Found out recently that it hasn't run since 1984......

shawn71 · Post by **shawn71** » 8th August 2012 - 8:00pm

Fingers crossed for you

Paul L · Post by **Paul L** » 22nd October 2012 - 6:04pm

Ran out of time last time, however as work has quietened off spent a few hours doing some jobs. After getting all the stale fuel out and sorting a couple of fuel leaks, we turned it over and ........it runs! First time in nearly 30 years. Now to the brakes.......

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