Oss på "værste" (garasjen med de rare i)

inside there was the nut for the bolt of the subframe, I had to reweld it....some welding primer on and then...

 

 

this is the panel I made for this part... and than I ran out of welding wire , so I couldn't finish yesterday....

 

 

et voila.... removed some rust...

 

 

looks very shiney.... all the other rust in the engine bay will be removed later...

 

 

this primer is used for protecting oil platforms...

 

 

 

let's see if it works here, too...

 

 

 

next step will be fitting these panels; a brand new a-pillar and the part between a pillar and strut tower.... both panels were supplied by polardego....

 

maybe a small step for mankind, but a huge step for me ;D

today I started with the a-pillar; well, I wanted, but had to some other weldings before I cut out the pillar;

 

 

this is where I started....

 

 

tried out the air saw from my company, nice thing, I need to buy one...

 

 

cut out the rusty metal between inner sill and floor, I have to put in new metal all the way, but important for today was the piece where the a-pillar is welded on...

 

 

 

then again I put some metal bars under the front to reinforce the front...

 

 

cut out some more rusty metal .... removed surface rust and primered it...

 

 

then the first homemade panel was welded on..

 

 

and another one...

 

 

primer again.... I like this work the most, you can cover your welding under nice fresh paint ;D

 

 

also primered the brand new a-pillar from Polardego, hopefully it will find its place tomorrow....

 

today was a good day, with temperatures about 20° and blue sky, it was hard for me to stay in the workshop... but I continued to remove the a-pillar :

 

 

here it is, together with some other no more necessary panels ...

 

 

now that looks scary, the inner pillar ( probably 30% missing 8-) ) is now treated with Fertan, a rust remover .... but the fusebox acces now is very easy ;D Of course the inner section will be rebuilt before welding the new panel onto it...

 

 

trial fit of the new one....

 

 

yeah, that's better... after that I was fed up with the metal work, and I did some work on the blue 87 Passat. Someone threw a brick on the bonnet :

 

 

 

So that's going to the paint shop now, too..... after changing the left CV joint I found out, that the dome bearings are shot again ( 1,5 years old, probably 5.000 km since then).... aaaahhhh... so a major suspension rebuilt will follow this year too. That gives me the excuse to buy some H&Rs and some Ronal Turbos

another day in the workshop behind the welder

 

 

cut out some rusty metal again (i think if I keep all the panels I have cut out, I can clone a second car

 

 

made a new one...

 

 

welded it in...

 

 

then trial fitted the upper section...

 

 

primered the inner pillar before welding...

 

 

then I forgot to take pictures, I was really enjoying welding today... thick , rustfree panels, that was a pleasure to weld...

 

 

bzzzt...........

 

 

I weld the spots next to the dashboard later, as soon as I have removed it.... tomorrow there is some more welding in this section from the inside, but I am really happy with the progress...

Da tar jeg en liten pause så dere får lest det som er lagt ut til nå...

 

Enjoy...

Mein Gott, det er noen som virkelig har pågangsmot av en annen verden!

Ser jo nå at jeg ikke har så mye å tenke på i forhold til han..

Sandblåser han vekk rusta før han tar på den røde guffa eller..?

Lurer litt etter å ha sett et par av bildene..

Fortsetter litt her så folket har noe å lese til morgenkaffen i morgen...

 

 

today only some small work done, finished the upper part :

 

 

and then primered the rest of the welded areas...

 

 

 

one of my favourite works, putting paint on fresh metal...

 

 

now I will reassemble the steering box and the front suspension, so that the car will roll again, then turn it into the other direction, to start rear quarter panel and axle mounts...

 

hello again, welcome to the weekly update. As the wifes had a coffeine overdose i'll hurry up, plenty of jobs to do in the house... but : today no metalwork, some easy working on mechanical parts; the steering box :

 

 

As the rubber part was broken and the only way to replace it is to remove the steering box from the car (which also includes the removal of the gear box) I was happy, that I already took it off the car. Even if the rubber part would have been ok, I would have replaced it . It is still available as it also fits the Audi 100.

 

 

heres the new one ready to go. I also cleaned , removed rust and painted the metal parts of the box.

 

 

no, this is not a KONI damper, also not a ghostbusters weapon, I just took the chance to add some other colour than black ... done

 

then I removed the dashboard and the windscreen.

 

 

besides of some more rust I also found the traces of an accident the car obviously had :

 

 

something heavy must have fallen into the windscreen, as the panel is bent and I found a lot of glass parts.

 

 

this also explaines the amount of filler I found here. But no problem, this panel is still available and I will just replace it, it is only 34 Euros...

 

 

then I removed some of the sound-deadening and found rust.,....

 

 

and another hole... quite pleased with todays work...

easter update, I had the norwegian TUV inspector in the house today :

 

 

and obviously he found a hole :

 

 

but this problem was solved easily :

 

 

so, as we put one wing on, we had to equalise this so we put another one off :

 

 

today was tool killing day, killed so far:

 

- drill for spot welds

- 2 drills

- chisel

- spray gun

 

 

 

this picture was taken by haakon, it is showing me wearing my chainsaw safety helmet... it is good for the missus , too, when she moans, you have the ear protection 8-)

 

 

love those 1mm grinder discs ....

 

 

et voila....

 

 

2008 is gone....

 

 

better than expected, still some rust....

 

 

Volkswagens idea of rust protection, PU foam

 

after killing that much tools and nearly falling twice over various wires, we decided to finish before anyone gets hurt....

some small work done today, not much ...

 

 

removed the rest of the old quarter panel....

 

 

 

I am keeping all the stuff I am cutting out, so I can clone the car later 8-)

 

 

trial fitting of the new inner arch...

 

 

also clamped the new quarter panel on, if I was already there

 

 

taking off all the parts gave me the necessary route : first fix the rear axle mounting, then the inner arch and then the quarter panel....

 

 

also have to repair the chassis rail, what looked ok from outside came out rotten....

 

 

so then I removed the handbrake cable, the brake lines and the fuel lines.... tomorrow we will change position of the lift on the sill and probably cut out rear axle mount...

 

 

oh, btw, tools killed today :

 

- one more drill

- and the compressor

 

hello again..... nothing happened in the last weeks, but ...:

 

 

 

there is a small review of the project in a german classic car magazine.... though the mag came out a couple of days ago, there is a lot of feedback; some people think I am insane ( ahem...), but I got offered a sparecar, and one of my neighbours in the company has offered me a set of period alloys... for free of course.... ;D I am really far away from putting back wheels on this car, but hey, one day i'll have it finished

Herregud, galskap! Men må være fantastisk morsomt å kunne sånt...

Det er bra det finnes optimister som faktisk får det til

Her var det litt rust ja... Stor respekt til folk som begynner på noe slikt altså!

Da tipper jeg at de aller fleste har fått i seg frokostkaffen og legger da inn litt mer slik at de som drikker ettermiddagskaffe får noe å lese på...

 

was very busy the last weeks (fixing the oil leak on the Van, make a new TÜV on the Scirocco and work, work, work....), but today I had a couple of hours time... time to take the angle grinder :

 

 

 

like a hot knife through butter

 

 

trial fitting of a new panel :

 

 

now I need thicker metal for the lower section, this is/was 1,5mm.... time to buy some new steel (on't be the last time though

 

ah yes, and probably there is a spare car arriving next week (if everything goes as it should); a friend of me bought it for spares, and gives me the rolling shell. Some panels (front panel for example) are in good condition;also i'll have a usable dashboard then and i'll get the car delivered to the door ....

 

 

 

and now the bad news : this is one of approx. 1000 Passat GLI built with the Golf GTI engine.....sad to see this go, but the engine is dead anyway and the shell is almost as rotten as mine....

bad news today: no donor car, the GLI Variant will be restored > But I get the dashboard, so that's fine for me...

 

today I continued working;

 

 

this is the old chassis rail, new metal was cut out ith the grinder, as this is a 2mm metal sheet...

 

 

easy task....

 

 

already in place.... much easier to weld thick metal...

 

 

Primer....

 

 

this is what it looks like from the floor...

 

 

then the outer panel was welded ....

 

 

another panel and some more primer....

 

I have to work out something for the bump stop, I think i'll bolt it onto the axle....

 

 

trial fitting of the inner arch, but first the rear axle mount has to be done.... stay tuned, this will happen next week....

another weekend, another update.

 

To get the quarterpanel on, I have to fix the inner wing, before I can do that, the rear axle mount has to be replaced... so, take the grinder and :

 

 

I have found some 0,8mm grinder discs, wonderful to work with...

 

 

I only had to cut it inside the sill, the part at the floor pan was removed with the hands ...

 

 

still looks frightening :

 

 

trial fitting of the new mount :

 

 

this is what it looks like from the inside :

 

 

so I had to reinforce the sourrounding metal and made a plate to fill the gap in the floor...

 

 

only tacked it in, proper welding will follow...

 

 

next weekend I can hopefully continue....

puh, another (hot) weekend in the workshop; before welding in the rear axle mount, I had to fix this corner :

 

 

this starts at the axle mounts and continues to rust to the front; I will fix the other stuff when the sills are out; otherwise it would be too much to cut out

 

 

the rust next to the new panel is the is the mount for the safety belt, so this has to be done properly (but later...) of course I cut out the old metal, don't want to put new metal on old rusty parts..

 

 

 

then I cleaned it up a bit, the panel I welded in here was zinc plated, so welding was a bit "dirty"....

 

 

then it was time to weld on the mount; though the metal in the back ground looks rusty, it is solid, couldn't poke a hole in it, so that should be ok...

 

 

after grinding down the spots it was time to put some primer on it....

 

 

next week i'll reconstruct the part of the inner sill which is missing here.... then the inner arch and probably the quarter panel can go back ....

 

by the way; this is a pic from a 1994 Passat VR6 :

 

 

mine can't be so bad ?

Syke mann. Det prosjektet der hadde eg lagt på hylla for lenge siden hvertfall. Men bra noen tar det som en utfordring.

Dæven, han har LITT pågangsmot!! Hadde enda slik pågangsmot vært å få kjøpt...

while waiting for the teabags to arrive, I continued welding :

 

 

 

removed some more rusty metal :

 

 

made a cardboard template and back in :

 

 

et voila :

 

 

trial fitted the inner arch, too big of course (i didn't want to put the full panel in) so I had to cut it down :

 

 

now it fits ...

 

 

now welding here is most fun, because you have good access, no more rotten (thin) metal , this is how I really enjoy :

 

 

welded from the outside and inside...

 

 

and finally grinded down the spots...

 

 

and put some primer on :

 

 

this was the result of 2 hours on saturday and 3 today... next weekend, when most of you are at the gathering, i'll bring the spot welder from the company and put the new quarter panel on....

ok, another sunny day outside and me inside the workshop.... now, after meeting Dave in Lobbach and really enjoying his tea ( as most germans, I drink coffee like hell but no tea) he has sent me a parcel :

 

 

thanks a lot mate, it really tastes good.... and it contains "antioxidants", so probably I won't rust anymore...

 

back to business, grabbed some heavy tools in the comany today :

 

 

the spot welder, not in use anymore, as Renaults stopped rusting in the 90s...

 

 

the tank straps are from an Espace, i'll try them on, as the ones from the Passat have transformed to dust... it could be, that they are too small, but I just make them longer...

 

 

trial fitment of the new quarter panel; looks ok, but still some work needed, before I can start welding.... i'll do that tomorrow...

 

 

off topic, but new to the fleet :

 

 

a very early Jetta Mk.I, from the VIN it is a 1980 model.... it gets a service and will stay over the winter here, it belongs to a friend of me. No mods planned unfortunately

today I found out, that my electrical system in the workshop doesn't like spotwelders ok, we'll change that for the sills, the quarter panel was welded in the old fashioned way.... but before that, I had to trial fit the door, as VW obviously changed the doors each year .... that means, I have the wrong quarter panel, as the door shut is different....

 

 

but I managed to modify the panel :

 

 

ok, that is probably not the way I want to work, but when it is painted, no-one will see....

 

 

then everything under the quarter panel was sealed, there is no way to do this afterwards....

 

 

after welding the panel to the car the seams were grinded down...

 

 

looks so nice, once it is cleaned....

 

 

Prime®-Time !

 

 

 

so, not much left to do on this side of the car , so I am really happy about the result....

 

 

 

 

so there is only one small panel and the mounting point for the bump stop to eld, then the right side is finished.... then we are going to the left side and after that the rear axle comes back in again.....

Stakkars mann... Her var det mye rust.

Stakkars mann... Her var det mye rust.

 

Andreas han kommer hit til sommeren, kan ikke du fyre opp seilbåten og ta dem (oss) med på tur, jeg kan være motvekt eller ballast...

 

Fikk forresten en hyggelig pakke i posten fra en i England som arva den gamle skjermen som stod på Passaten min... Te, Sjokolade og 50 euro for skjermen...

 

 

Også fikk jeg dette fra FFFE (foreningen for flere einsere) idag...