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12th September 2012, 12:56 PM #91Too many projects, so little time, even less money!Are you a registered member? Why not? click here to register. It's free and only takes 37 seconds! Doing work around the home? Wander over to our sister site, Renovate Forum, for all your renovation queries.
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13th September 2012, 09:02 AM #92
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15th September 2012, 08:30 PM #93
Dry assembly
With this forum upgrade effecting the viewing of pictures, I've refrained from posting for a couple of days. But now they're all sorted, it's time for some more show & tell!
I thought I'd better have a trial fit of the roof and sides to make sure all the modifications not only worked, but made the changes worthwhile doing. So here they are...
VW Beetle w.i.p 057.jpg
VW Beetle w.i.p 058.jpg
VW Beetle w.i.p 059.jpgToo many projects, so little time, even less money!Are you a registered member? Why not? click here to register. It's free and only takes 37 seconds! Doing work around the home? Wander over to our sister site, Renovate Forum, for all your renovation queries.
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15th September 2012, 09:19 PM #94
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16th September 2012, 01:02 AM #95
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16th September 2012, 01:34 AM #96
The first glue...
Part of tonight's effort was to make the rear "engine block" section to enable me to start gluing the roof onto the sides, and clamp it without it collapsing in on itself. And that required a thicker piece. Problem was, a piece that I'd smoothed and glued together a while ago had two different colours...
VW Beetle w.i.p 060.jpg
...and if I'd put the template on square with the block, the join and the two colours would have been noticable.
So I attached the template with the outward facing angled section in line with the outer face of the block,...
VW Beetle w.i.p 061.jpg
...so the cut through the join is unseen, inside the car behind the back seat.
VW Beetle w.i.p 062.jpg
A final cut...
VW Beetle w.i.p 063.jpg
And a bit of time on the sander, has the main shape of the rear section ready for its role in the first gluing.
VW Beetle w.i.p 064.jpg
As there are no plans for the modified roof, I have to think of what might be the best way to do it. I thought I'd glue the centre section of the roof first, that way I can marry the front and rear edges to match it's angle on the side section precisely. If the time is spent getting this first one in the right place, the other two should mate up either end of it without even trying.
VW Beetle w.i.p 065.jpgToo many projects, so little time, even less money!Are you a registered member? Why not? click here to register. It's free and only takes 37 seconds! Doing work around the home? Wander over to our sister site, Renovate Forum, for all your renovation queries.
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16th September 2012, 11:50 AM #97
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16th September 2012, 12:14 PM #98
Thanks Pete, I appreciate the feedback. Once the three roof sections are in place, I can properly round it all off and will hopefully look more like a beetle than the plans do.
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16th September 2012, 08:19 PM #99
Great job Yonnee, the roof looks great, once it been sanded to shape it will look just like the original one
Proud to be an AUSTRALIAN
Scotty
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16th September 2012, 08:31 PM #100
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17th September 2012, 12:12 AM #101Too many projects, so little time, even less money!Are you a registered member? Why not? click here to register. It's free and only takes 37 seconds! Doing work around the home? Wander over to our sister site, Renovate Forum, for all your renovation queries.
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17th September 2012, 12:49 AM #102
More fiddly stuff...
One thing that has had me pondering a how-to was the steering wheel. Firstly, the plans describe the making of a three spoke wheel (which the original is not), Secondly, they show the measurements for a wheel both smaller & thicker than the orignal. The plans are also a little vague on how to make it, so I trialled an idea I had, which worked a treat.
I started by finding a piece of Jarrah I've had for 20 years, and drilling the inner diameter with a spade bit...
VW Beetle w.i.p 066.jpg
...then the outer diameter with a hole saw. I did it in this order because once the hole saw pilot was drilled, the spade bit wouldn't have centralised properly.
VW Beetle w.i.p 067.jpg
Both holes were drilled about 5-6mm deep. Then I trimmed the tag off.
VW Beetle w.i.p 068.jpg
I then set the guide to about 3.5mm
VW Beetle w.i.p 069.jpg
Pictures tell a thousand words...
VW Beetle w.i.p 070.jpg
I stopped about halfway, and I didn't want to move the guide to see how the cutting was going, so I just removed it from the saw.
The ruler shows what's happening, and by now you'll see where this is going.
VW Beetle w.i.p 071.jpg
And voilà. Success!!
VW Beetle w.i.p 072.jpg
The next step was to carefully sand the corners around the entire circumference to round it off.
(A time consuming task that I didn't take photos of...)Too many projects, so little time, even less money!Are you a registered member? Why not? click here to register. It's free and only takes 37 seconds! Doing work around the home? Wander over to our sister site, Renovate Forum, for all your renovation queries.
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17th September 2012, 01:04 AM #103
Next on the list was to work out attachment of the wheel to the spokes. The plans show drilling through the wheel and inserting toothpicks into the steering column. But this wheel is too skinny for even a 2mm hole for a toothpick,
VW Beetle w.i.p 073.jpg
So with my trusty sharp knife, I notched out a section wide enough for the toothpick...
VW Beetle w.i.p 074.jpg
...then trimmed the toothpick to length.
VW Beetle w.i.p 075.jpg VW Beetle w.i.p 076.jpg
Once it fitted correctly, the spoke was fed through the column and glued to the wheel.
VW Beetle w.i.p 077.jpgToo many projects, so little time, even less money!Are you a registered member? Why not? click here to register. It's free and only takes 37 seconds! Doing work around the home? Wander over to our sister site, Renovate Forum, for all your renovation queries.
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17th September 2012, 12:18 PM #104
You are being sucked into the vortex Yonnee. Looking good keep the pics and how to's coming.
Bret
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21st September 2012, 12:31 AM #105
A little more...
I got around to a little more...
I bit the bullet and carved out the driver's side panels around the speedo too. I'm reasonably happy with the result.
Here's a couple of shots of the dash and steering column dry assembled to the firewall. The two lower toothpicks have had their 'pointy' ends removed, and these ends are what you can see protruding from the dash. Hopefully they look like knobs...
VW Beetle w.i.p 082.jpg 69 beetle - steering wheel.jpg
Any opinions as to whether I should add the vertical vent lines too...??
The steering column will be trimmed once all is in place and glued to the right depth. I've got to remember to put some sort of finish on the steering wheel & dash before they get glued into the car for the final time...
VW Beetle w.i.p 081.jpg
I also made a start on the rear guards...
VW Beetle w.i.p 083.jpgToo many projects, so little time, even less money!Are you a registered member? Why not? click here to register. It's free and only takes 37 seconds! Doing work around the home? Wander over to our sister site, Renovate Forum, for all your renovation queries.
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