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Topic Review (Newest First)
Today 10:21 AM
Too Many Projects Damn !! You keep at it like this and you'll be driving it by fall...
Today 08:49 AM
123pugsy I hit with weld thru primer where required. Welded everything in and cleaned up.

Today 08:44 AM
123pugsy Exploding transmissions make me nervous so I added a 1/8" steel band. This is done the same way as the other floor brace/mount locations.
I mentioned exploding trannys to my daughter and she insisted on another one as she likes to ride shotgun when I go for a cruise.

Started with a template or two......

The 4th pic shows the cardboard template. I then used that to transfer to the 1/16" thick wood keep on hand. Clamped the 1/16" wood to the 11 ga steel sheet and use the power nibbler to cut around the perimeter. I then pounded it into shape over open vise jaws using a piece of cutting board plastic to spread the blows. I could have drove to work to use the roller, but I didn't feel like washing my hands ten times by the time the trip was done. It worked out about the same time all in.

Today 08:32 AM
123pugsy The factory had four mounts close to the front of the body, so I figured I should do the same since the fenders bolt on there.

I started with some 18 ga brake formed channels. I zip cut them to size, drilled drain and mount holes. I used some large rings of tubes as anti crush sleeves.

The mount bolt goes thru a 1/4" thick stainless disc that is welded into a round tube, welded to the floor.

Today 08:23 AM
123pugsy Roto time is always fun. Although carrying all the bits from the shed and assembling this thing, not so much.
Had to make new arm adapters for the front as it was hooked to my temporary firewall last time I used it.
This allowed bottom access to finish the welding and clean up.

Today 08:16 AM
123pugsy A bit of clean up...........

Today 08:10 AM
123pugsy Everything leveled off and ready to weld..........

Today 08:03 AM
123pugsy I brought the firewall and cubby to work and had the young lad run tack welds around the full perimeter and the plug weld holes. I shouldn't have even punched the holes as it needed full perimeter welding in case of fluid leaks. That was the point of all this extra work from the git go.

The second pic has a sneak preview of a bearing mount location for the throttle cable.

03-27-2020 06:52 PM
123pugsy I trimmed the firewall panel and cowl.

03-27-2020 06:49 PM
123pugsy I took the firewall to work to spot weld the reinforcing channels/angles in place.

I used some aluminum scraps from work for temples for the lines chase.

03-07-2020 10:51 AM
Originally Posted by Too Many Projects View Post
Looks great. Just remember, your leak test is not nearly the 900-3,000# force exerted on those lines in use... be careful with the first test drives.

I've had some luck making tight bends with fine play sand in the tube to prevent kinking/collapsing.

Not worried. Welding is good stuff. I did a line on CURSE without the bonus sleeve. It had a small drip. I found a pin hole because of my poor vision, added a drop of weld and she's good now.
03-07-2020 10:03 AM
Too Many Projects Looks great. Just remember, your leak test is not nearly the 900-3,000# force exerted on those lines in use... be careful with the first test drives.

I've had some luck making tight bends with fine play sand in the tube to prevent kinking/collapsing.
03-07-2020 10:01 AM
Rip VW Amazing stuff there Pugsy.
03-07-2020 06:18 AM
Molon Labe Agree on the Ni-cop lines. So easy to work with.
03-07-2020 04:56 AM
123pugsy AC and heater hoses ready to go and holes punched in cowl side for bulkhead fittings. Hoses/tubes will run under passenger fender.

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