UK VW Rusto-ROD epic
 

Hi all, A while back, Dec2010 I decided to give my old '72 bug a bit of lovin', nothing too involved, just a quick patch n go project to make a slam door driver out of her, shouldn't take a coupl'a months tops!!:blink:

Well, so much for that plan.......here's how it went:

This is NOTHING compared to the RODical work elsewhere on this site but I thought you might like to see what we're doing over here.

This is how she looked

http://i77.photobucket.com/albums/j6.../Bugfront2.jpg

Just before I stripped the wings:

http://i77.photobucket.com/albums/j6...-refurb006.jpg

Only to find the usual tinworm:

http://i77.photobucket.com/albums/j6...-refurb001.jpg

At this stage I was still relaxed, ya gotta find some sh*t eh?

Meanwhile, I had been dicking around with the horn grills and rear number plate light:

http://i77.photobucket.com/albums/j6...2-11-10006.jpg

http://i77.photobucket.com/albums/j6...ugstuff006.jpg.

Then I found this :ohmy:

Front n/s heater channels
http://i77.photobucket.com/albums/j6...09_1338511.jpg

http://i77.photobucket.com/albums/j6...109_131817.jpg

Next.....

Re: UK VW Rusto-ROD epic
 

Also, this :panic:

http://i77.photobucket.com/albums/j6...9-01-11002.jpg

http://i77.photobucket.com/albums/j6...9-01-11009.jpg

Ultimately .....this:

http://i77.photobucket.com/albums/j6...build001-1.jpg

http://i77.photobucket.com/albums/j6...ugbuild024.jpg

http://i77.photobucket.com/albums/j6...04-2011055.jpg

http://i77.photobucket.com/albums/j6...-2011050-1.jpg

http://i77.photobucket.com/albums/j6...04-2011027.jpg

http://i77.photobucket.com/albums/j6...-2011035-1.jpg

Basically, the whole bottom 15cm of the body had to be renewed as well as the floorpan edges.

Remember, this was supposed to be a quick patch n go !! :unsure:

Re: UK VW Rusto-ROD epic
 

Anyhows, I pressed on regardless, many would've bailed at this point I'm told (most of my friends) but me being me, I didn't:

Instead I did this :sawzall:, Jimmy did a lot of this :welder: so it ended up like this::clapping:

http://i77.photobucket.com/albums/j6...03-2011011.jpg

http://i77.photobucket.com/albums/j6...03-2011010.jpg

http://i77.photobucket.com/albums/j6...03-2011001.jpg

http://i77.photobucket.com/albums/j6...03-2011015.jpg

http://i77.photobucket.com/albums/j6...-5-2011052.jpg

http://i77.photobucket.com/albums/j6...-2011009-1.jpg

http://i77.photobucket.com/albums/j6...05-2011013.jpg

All still a 'work in progress' but looking much better :wink:

Re: UK VW Rusto-ROD epic
 

You can multiply by x2 all of the welding in the previous post as both side were just as fooked as each other.

This was a girl with a 'past' to say the least, remember that C pillar shot :

http://i77.photobucket.com/albums/j6...ugbuild024.jpg

Well, the entire roof had been nailed on by an ape with a glue gun, alignment issues were coming to the fore:

I always knew something wasn't quite right! This B pillar shot shows how bent it was:

http://i77.photobucket.com/albums/j6...04-2011022.jpg

Check out the lump of bondo in the top corner of the window apperture:

http://i77.photobucket.com/albums/j6...-5-2011010.jpg

A little fettling was required:

http://i77.photobucket.com/albums/j6...0052011009.jpg

http://i77.photobucket.com/albums/j6...1052011010.jpg

You can also see the roof cut across the C pillar.

Pillar cuts as they were uncovered:

http://i77.photobucket.com/albums/j6...4062011004.jpg

http://i77.photobucket.com/albums/j6...4062011008.jpg

http://i77.photobucket.com/albums/j6...4062011002.jpg

Broke this joint free with a nail file :ohmy:

http://i77.photobucket.com/albums/j6...4062011014.jpg

Now all safely welded:
http://i77.photobucket.com/albums/j6...4062011026.jpg

Here's the bit I like, while cutting out rust on the rear gutter we did this:

http://i77.photobucket.com/albums/j6...1052011014.jpg

http://i77.photobucket.com/albums/j6...1052011029.jpg :thumbsup:

Re: UK VW Rusto-ROD epic
 

Inspiration :licklips:

http://i77.photobucket.com/albums/j6...mmer-10-07.jpg

http://i77.photobucket.com/albums/j6...VWroadster.jpg

http://i77.photobucket.com/albums/j6...kz-d3bfd3t.jpg

Oh yes, if mine looks even half as good as these I'd be a happy guy. Notice how they're all brown? That's because I'm going brown, satin dark chocolate brown to be exact, already got the tank done:

http://i77.photobucket.com/albums/j6...build006-2.jpg

Pleased with that :smile:

Re: UK VW Rusto-ROD epic
 

We're now into May 2011, so 5 months have elapsed since I started, optimistically, with a view to ending by end of Feb'11 sooo a little longer than planned :rollingeyes:

All the time I've been doing stuff, almost every day:

Setting up how I want the lights:

http://i77.photobucket.com/albums/j6...6-02-11019.jpg

Fixin' the hood

http://i77.photobucket.com/albums/j6...122_131002.jpg

Painting stuff:

http://i77.photobucket.com/albums/j6...-2011006-1.jpg

Buying stuff:

http://i77.photobucket.com/albums/j6...-2011-2003.jpg

http://i77.photobucket.com/albums/j6...rottletube.jpg

Patchin stuff:

http://i77.photobucket.com/albums/j6...5052011020.jpg

http://i77.photobucket.com/albums/j6...05-2011029.jpg

http://i77.photobucket.com/albums/j6...-5-2011014.jpg

http://i77.photobucket.com/albums/j6...-5-2011012.jpg

Restorin stuff:

http://i77.photobucket.com/albums/j6...05-2011007.jpg

http://i77.photobucket.com/albums/j6...7052011010.jpg

http://i77.photobucket.com/albums/j6...05-2011004.jpg

http://i77.photobucket.com/albums/j6...1042011003.jpg

http://i77.photobucket.com/albums/j6...UGbuild004.jpg

Generally working my way through a tick list as long as my arm :smile:

Re: UK VW Rusto-ROD epic
 

The last round of work has moved into the filling n rubbing stage as the bodywork receives attention:

http://i77.photobucket.com/albums/j60/LemonBUG/013.jpg

http://i77.photobucket.com/albums/j6...3062011012.jpg

http://i77.photobucket.com/albums/j6...3062011003.jpg

http://i77.photobucket.com/albums/j6...3062011007.jpg

Oh yeah, remember that bent B pillar? A gentle PortaPower session soon sorted it :wink:

http://i77.photobucket.com/albums/j6...nBUG/003-1.jpg

http://i77.photobucket.com/albums/j6...nBUG/009-1.jpg
Now I have a decent enough shutline:
http://i77.photobucket.com/albums/j6...9062011003.jpg
and a reasonably straight B pillar, (filler required)

http://i77.photobucket.com/albums/j6...9062011001.jpg

Still got a was to go yet but it does seem like there is a light at the end of the tunnel (and it's not a train coming the other way!!).

Thanks for reading through this far, any comments of feedback would be welcomed.

Laters..........:chillin:

Re: UK VW Rusto-ROD epic
 

Keep up the good work :thumbsup:! Your eather a very brave man for working with so much rust or just plain crazy:panic:.:grin:

Re: UK VW Rusto-ROD epic
 

Why thank you DaddyO, I have to admit it was a LOT more rust than I expected and I have to thank Scotty (using his workshop/equipment) and Jimmy (welding/metalwork) if it wasn't for my buddies I wouldn't be where I am with it.

Can't wait for paint :dancing:

Re: UK VW Rusto-ROD epic
 

Amazing!
that's allot of work!!:bow:

Re: UK VW Rusto-ROD epic
 

Dude that must suck to find that much rust in what looked like a perfectly good car... still, good on ya for perservering!!

Love that color too!! :thumbsup:

Re: UK VW Rusto-ROD epic
 

love it, love it, love it!!!!!!!!!!!!!!!!!!!!!!

Re: UK VW Rusto-ROD epic
 

I want those body jacks Dammit ...

Coming long nicely too ... lots of hard work but always a good result ... :clapping::clapping::clapping:

Re: UK VW Rusto-ROD epic
 

wow.........thats was some severe cancer, you have grave patience man! kudos!! keep it up, i wanna see the brown shine! :)

Re: UK VW Rusto-ROD epic
 

Hi all, Thank you all for your comments, well a long time has passed since June but a lot has been achieved:

All that pushin n shovin, fillin n rubbin resulted in a body ready to paint :licklips:

http://i77.photobucket.com/albums/j6...1072011030.jpg

http://i77.photobucket.com/albums/j6...1072011033.jpg

Much, much flatting ensued!

Then colour.......

http://i77.photobucket.com/albums/j6...1082011020.jpg

Here it is fresh out of the oven

http://i77.photobucket.com/albums/j6...1082011029.jpg a particular favourite photo :grin:

Tidied under the hood:
http://i77.photobucket.com/albums/j6...2082011007.jpg

Couldn't decide on Porsche or Rossi??

http://i77.photobucket.com/albums/j6...8092011009.jpg

http://i77.photobucket.com/albums/j6...8092011008.jpg

Went with Rossi:

http://i77.photobucket.com/albums/j6...0092011011.jpg

Rear end with modified plate housing and reworked gutters...giving it a wider, fuller back end view I think:

http://i77.photobucket.com/albums/j6...d240911004.jpg

http://i77.photobucket.com/albums/j6...0092011006.jpg

Well, that's where it is folks......hope to have it on the road within 3-4 weeks. Thanks for watching

Re: UK VW Rusto-ROD epic
 

This is the interior:

http://i77.photobucket.com/albums/j6...Front2rear.jpg

http://i77.photobucket.com/albums/j6.../Doorpanel.jpg

http://i77.photobucket.com/albums/j6...G/rearseat.jpg

I think it'll contrast well with the dark brown, got some ideas of how to detail the dashboard and make it look a bit more like a 50's rod :wink:

http://i77.photobucket.com/albums/j6...92011001-1.jpg

Loving my Moto-Lita wheel. Looking to fix the same outer trim along the middle of the dash from speedo outwards on both sides. Along with the pinstriping (inside and out, classic red, cream & grey) I have planned it could look cool.

Re: UK VW Rusto-ROD epic
 

Can't believe anyone would spend that much time, on a worthless rust bucket!













LOL
Sure glad you did!:thumbsup:
Anyone would be very proud, to own your car!:bow:
You all did an excellent job -- any plans for the next one?:Idunno:

Re: UK VW Rusto-ROD epic
 

Haha.....If I knew then, what I know now maybe I wouldn't have started this whole project. I'm more than pleased with how it's turning out..... believe it or not there's more to come, this is only phase1.

Phase2 included removal of engine and some tarting up in certain areas :wink:

Thank you DT, very kind of you to say.

Re: UK VW Rusto-ROD epic
 

Beautiful work on such a 'patina ridden' bug. Until your rod I wasn't a real fan of brown...but WOW! :clapping::clapping::clapping:

Re: UK VW Rusto-ROD epic
 

looks great. good job. someone did a good job hiding all that mess. glad you sorted it out right

Re: UK VW Rusto-ROD epic
 

None of the rust (mess) was hidden, all was cut out and replaced with, mostly, genuine VW metal (T4 van side panels) or repair sections. Mind you there is a lot of welding under the bondo, can't be helped when the complete panel isn't replaced, I know what's there, but hell, it 'll be OK :grin:

Why thank you V8, you're not alone in coming around to brown....most of my friends in the VW world didn't like the sound of it either, but gradually as they see it for the first time they have to admit to liking it. It's actually turned out a little shinier than I had first planned...too much hardener in the 2xpack paint made it that way, next time I'd go to 30% matting agent rather than 20%.

As I add the shiny stuff the contrast becomes more apparent which is what I was looking for :grin:

Thanx both of you for your replies.

Re: UK VW Rusto-ROD epic
 

Dicking about with the small jobs.......that take forever to do :ohmy:

Like sorting a bad contact coupled with seized spindles on the wipers, round and round wondering why they don't spin up. Finally traced a bad contact in the loom/earth and the seized spindles meant all out again, then in then out as I had to set the 'rest' position....that took a bit of thinking to sort out :rollingeyes:

Now I like the positioning at rest:

http://i77.photobucket.com/albums/j6...8102011001.jpg

Re: UK VW Rusto-ROD epic
 

I went for Rossi headlights cos I love the lights on this 40's Ford and I think they look like them. I'm aware of the irony though - Late bug with early slopey wings (wrong 'un) going for an after-market upgrade to uprights, fuck it :smilespin:

http://i77.photobucket.com/albums/j6...0092011022.jpg

http://i77.photobucket.com/albums/j6...BUG/40Ford.jpg

Even the blade bumper (fender) look alike and the general roundy shape, like the curves on a woman :wink:

Re: UK VW Rusto-ROD epic
 

Over here on our heavily salted little island, that car was in 'good condition for its age'.

Re: UK VW Rusto-ROD epic
 

i ment before you tore into it. the car looked nice and solid with your begining pics. i would never have guessed it was that rusted.

you have done a steller job:thumbsup: