AT LAST! Hairys Resto!!

Hairyarse said

Thanks for the advice Graham, that's spot on  

Out of general interest, should you ever apply zinc primer before welding, or only to areas not accessible after welding is finished? So far I've been zincing everything I've been  welding thinking it was the right thing to do  

It's fine to apply the paint before to all surfaces as long as you remove it again before welding. The Idea is to get paint in all the areas that you can't once welded, if that makes sense. You're doing it the right way bud

Ah fair dos

Well I got a couple of hours in tonight and a few more welds. I'm still struggling on all welds to keep the two panels flat together even with clamping close either side of all welds. I think the issue is when I cut the outer arch off, it's just on the start of the radius where the arch curves in to the body. If I had cut it on the flat part of the arch (in profile) I think it would be much easier.

Hence, I've been spacing my welds but not completely evenly as have been welding where it will clamp flat - or appears to at least

Not much of a pic update - just the same as yesterday's really but with more dots on it!  



What I'll most likely do once I've finished it if I'm left with a fine gap between panels - and it is small - is line the edge with body solder before laying down any filler. This way I hope that I'm not filling a crack (oo-er!) and running the risk of filler ever cracking out in the future.

Oh and two of my welds are out of whack, I missed the join between the two panels - didn't realise until I lifted my visor!  

zorg said

if you havn't done so already you can use an air line to cool down your spot welds, but as others have said move around the panel rather than on one area.

-z

Good tip - I'd forgotten about that - I have a compressor too!  

Well done Andy !!…I'm looking forward to progress with great interest.

Looking good Andy. I think it took me about two weeks to weld each side of mine, there's no hurry mate. I've been welding for 15 years+ and still go off course now and then  I always blame a dirty screen!

LOL glad I'm not the only one to go off course.

I did turn the wire speed up just a smidge yesterday - about half a point - which made things a little better too.

Regional meet tomorrow for MK1 and MK2 clubs but Sunday should be back on it, will carry on with this whilst starting to prep the OS sill and bottom of B post repair for welding.

If I do all the noisy work Sunday then I can weld in the evenings next week without annoying the neighbours!

campaignjerry said

Well done Andy !!…I'm looking forward to progress with great interest.

Cheers Jerry, hope before too long I can be bombing down the A1 in it to come and see you

I look forward to that day.

when is the diesel engine going in hairy?  
Bert

Bert said

when is the diesel engine going in hairy?  
Bert

Ha ha! Er, never! 8V GTI all the way for me, it's a sound you can't beat  

Not much of an update this weekend. Only got a few hours on it this afternoon as had to reseal the threshold under my garage door as it's letting rain in - hopefully not any more!

I ground the welds down on the arch, didn't go crazy or put too much heat in. Then thought I'd start off getting the OS sill to fit so I could weld that during the week.

However, whilst I have two sill panels, they've both been stored in my garage for about 8 years and are peppered with little rust spots on the outside. Also I'm not happy with the quality of the panel. The step in the panel just above where the sill trim fits isn't anywhere near as pronounced as the one on the new arch panel, so I've decided to order a new one from VWH.

Even if the step isn't any better at least it wont be rusty!!

Plan for the week - more welding of the outer arch  

Wow dude, what an epic thread, just read it from the top!

Thought my build had taken it's time lol…. Some serious determination and learning invloved on this ..

Not sure i'd have the balls to do any of that myself, fair play..

Keep it up bud!

Alfie


 

Cheers Alfie    There's been an epic amount of time not spent on the car, plus some steep learning curves but I'm really enjoying it now that I have a decent MIG and I'm feeling at least slightly competent with it.

Blowing holes is a frustration still but overall it's satisfying getting this done. Just hope I can get it done for the AGM now, that's all  

If you didn't blow holes, you wouldn't know how not to blow them!!!

LOL, true, it's all part of the 'curve!'  

Blowing holes is a standard part of welding!! If I hadn't learn to fill in the blown holes, my car would be more use as an aero bar  

Small update: put some more welds down on the rear arch: End of update  

Ok, a pic then - not very exciting though lol



Oh and my new OS sill turned up from VWH today. Much better quality overall than the two I had and it's longer at the A-post end which will help. However, the 'crease' in the panel above where the sill trim goes still isn't as pronounced as the arch repair panel so I'll have fun sorting that I'm sure  

An updates an update  I see it as proof of what's been done, that's why I post nearly every pic I take lol.

My sills were the same mate, just had to blend them in as best I could

I'm terrible at updates so its refreshing seeing the odd pic here and there 

Good stuff then  

Andy, when you say you had to blend yours in, in what way? With filler? Hammer?