Felicity slush fund currently:

£1,409.29

Saturday, 5 March 2011

The body - filler time!

Not having used car filler before, or any other type for that matter, I thought I'd have a go.

It was difficult to think where to start. Car filler should be applied to bare metal and seam sealer can be used over painted surfaces. In some areas the joints that would flex and need seam sealer met those that needed filling.


One of the more difficult areas to fill was the ridges/ gutters above the engine compartment.






I purchased a random orbital sander. 125mm. It was smaller than most so will hopefully reach further into more corners.


A few of the holes that needed filling required extra support so I got some mesh.


An area requiring mesh and filler. Drivers side, engine bay.


Easy to bend to the shape required.



A few other bits ready for use.


Whilst normal car filler is fine for small holes, I've been told that larger areas/ holes should first be filled with fibreglass filler.


Hardner.

Fibre glass filler and hardener before mixing.


Around the bakerlight tube areas, under the rear of the body, several edges of body panels meet. I wanted to remove the possibility of rust occurring again by sealing these areas up.




Before sand blasting, I thought I had removed all items from the body. It seems not to be true as this rubber plug shows!







The rear seat area just needed some cleaning up with filler.



Some small holes under the rear/ side windows.




Wings - removing old captive nuts




Sunday, 30 January 2011

Tidying up the floor pan before painting the floor

Steering damper is missing a nut and bolt.




A few clips should hold the brake line to the tunnel.


The bump stop mounting should have greater protusion in the middle. This one is worn down. I could replace them, but I'd thought I'd try adjusting these so that they hold the bump stops.


The right size coach bolt should do the trick. I just need to make a hole...


The bump stop fits over the coach bolt snugly.


Pedal cluster tunnel bracket. Need to drill some holes in the tunnel.



The correct holes are on the other side.


Accelerator need fixing to the floor.



The other end of the pedal cluster has a bracket that needs securing.



At the end of the steering column is the steering coupler. It seems in good shape but all the nuts and bolts could do with replacing.



As the new floor is originally for a left hand drive, this hole for the brake master cylinder needs covering.


Saturday, 29 January 2011

Rear bumber mount areas - one final bit of welding!

The last few holes got patches welded over them today. Nothing particularly structural, just a bit big to use filler. As I guess with all projects like this, you have to stop somewhere.







Engine compartment - last bit of welding

The welder, Malcolm has these supports he has lent me. They have a mechanism that allows you to turn a car body over. Unfortunately they don't fit the beetle very well, so we've used them to raise it off the ground.


It makes reaching the underneath of the car a lot easier!


Didn't take long until the first panel was in place.








Sunday, 16 January 2011