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 Post subject: Nose Job!
Unread postPosted: Mon Nov 27, 2017 8:35 am 
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Location: Sun Diego
As you all well know, I bashed in the Dormy's nose into the hitch of a Suburban a couple of years ago putting this wrinkle into it. :roll:

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After banging it out this is how it looked like and why I rather had it wear the bra all that time. :sad:

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De-skinning starts with uncrimping the crimped edges. Hammer, screwdriver and chisel is needed here. It's actually a miracle my hand is not broken or at least bruised for the many times I bashed it with the forkin hammer! :-x

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Next is drilling out and/or chiseling the spot welds. Opted for cutting the top as you'll see a bit later...

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Noticed just how bad the lower nose was already. Had been patched quite a bit before as well as been hit and bondoed. The valances were almost all rusted on top of mangled. Trash, nothing left to save here.

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New nose and valances to go in! :smile:

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Inner valance.

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Outer valance, needs to be "placed" there, then the new skin needs to be positioned where it should be in Oder to determine the exact position of the outer valance. Then it can be welded.

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Windshield frame is in such bad shape that it would probably be unweldable. However, since I don't have the replacement for it and it goes over the front skin, I decided to continue on and replace it later. :neutral:

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For the Signals I measured from the edge and the "V" line. Made a template and traced it where they should be.

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Used a YUGE hole bit and a hole punch and file for the slots.

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^^^Spot welds^^^

Grinding the welds is my nephew/apprentice.

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Crimping the edges...

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Final weld at the bottom. Then hammer and crimp!

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Solid Bondo-less Skin \:D/

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Cheap paint is better than no paint bare metal. :-k

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Finally = Yard Art
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 Post subject: Re: Nose Job!
Unread postPosted: Mon Nov 27, 2017 11:00 am 
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Great work Ivan. =D> =D> =D> =D> =D>

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 Post subject: Re: Nose Job!
Unread postPosted: Mon Nov 27, 2017 11:54 am 
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Definitely looks like you know what you're doing (or found all necessary videos on YouTube!) Nice work!
=D>

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 Post subject: Re: Nose Job!
Unread postPosted: Mon Nov 27, 2017 12:01 pm 
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Video shmeedeo! :roll:

Ain't got no time to be wasting on that! [-(

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 Post subject: Re: Nose Job!
Unread postPosted: Mon Nov 27, 2017 1:05 pm 
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damn that is a lot of work

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 Post subject: Re: Nose Job!
Unread postPosted: Mon Nov 27, 2017 5:32 pm 
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So are you going to put the VW insignia back on or leave it on the yard art?
I saw his handy work in person!!! very knice!

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 Post subject: Re: Nose Job!
Unread postPosted: Tue Nov 28, 2017 9:24 am 
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Make it into a bar.

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If 4 out of 5 people SUFFER from diarrhea....does that mean that one out of five enjoys it?


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 Post subject: Re: Nose Job!
Unread postPosted: Tue Nov 28, 2017 2:08 pm 
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Nice work Always wondered about the section where the skin attaches to he windshield frame.


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 Post subject: Re: Nose Job!
Unread postPosted: Thu Nov 30, 2017 6:52 am 
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Quote:
Your DHL EXPRESS shipment with waybill number 5005112136 from FABRICACIONES CLASICAS S.A.S is on its way and may require a signature.

The current scheduled delivery is Fri Dec 01 2017 by End of Day.


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 Post subject: Re: Nose Job!
Unread postPosted: Thu Nov 30, 2017 8:11 am 
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pyrOman wrote:
Quote:
Your DHL EXPRESS shipment with waybill number 5005112136 from FABRICACIONES CLASICAS S.A.S is on its way and may require a signature.

The current scheduled delivery is Fri Dec 01 2017 by End of Day.


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Getting a windshield frame?

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 Post subject: Re: Nose Job!
Unread postPosted: Mon Dec 04, 2017 7:22 am 
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Slayer wrote:
pyrOman wrote:
Quote:
Your DHL EXPRESS shipment with waybill number 5005112136 from FABRICACIONES CLASICAS S.A.S is on its way and may require a signature.

The current scheduled delivery is Fri Dec 01 2017 by End of Day.


Image Image


Getting a windshield frame?


:smt045

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 Post subject: Re: Nose Job!
Unread postPosted: Mon Dec 04, 2017 7:23 am 
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Should I do safaris??? :???:

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 Post subject: Re: Nose Job!
Unread postPosted: Mon Dec 04, 2017 8:05 am 
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pyrOman wrote:
Should I do safaris??? :???:


At this point why not?? :smt023

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Slayer Out!!!
(Chris C.)

"Marine Sniper - You can run, but you'll just die tired!"

56 Kombi (The Slayer Bus)
65 Sundial Camper
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03 Passat
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 Post subject: Re: Nose Job!
Unread postPosted: Mon Dec 04, 2017 9:34 am 
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I enjoyed following the process. I admire your skills and wish I'd known you in '93 when a woman made an illegal u-turn in front of me causing me to hit her a couple of times. I hit her once and her car bounced back off the curb and I hit her again. I drove the bus home but the front end was definitely crunched . The lady paid for the damage, but it was a nightmare. Oh, to have known you then!

Good work, Ivan.

Tony
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 Post subject: Re: Nose Job!
Unread postPosted: Tue Dec 05, 2017 10:25 am 
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Lurking
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pyrOman wrote:
Should I do safaris??? :???:


Watch out for bees...

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 Post subject: Re: Nose Job!
Unread postPosted: Wed Dec 06, 2017 8:02 am 
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Turbo_g wrote:
pyrOman wrote:
Should I do safaris??? :???:


Watch out for bees...


Turbo_g, be quiet, that could be the deal breaker for him. 8-[

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Slayer Out!!!
(Chris C.)

"Marine Sniper - You can run, but you'll just die tired!"

56 Kombi (The Slayer Bus)
65 Sundial Camper
68 Single Cab
61 Rag Top
03 Passat
SV2s Member #231


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 Post subject: Re: Nose Job!
Unread postPosted: Mon Dec 11, 2017 7:48 am 
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Round 2! :shock:

Old rusty frame

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The new frame comes with this inner piece which I didn’t know “why” until I mangled the OG rusty one.

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The OG one just sits there, it isn’t attached to the dash at all! I did put a weld spot on the new one though.

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“Staging “ the frame.

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This tool is perfect for straightening the dash edge after hammering out the weld spots.

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Now, these here tools are awesome for spinning the whole bus in place! Had to do it to have better room and access to the welder.

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Staging, drilling, welding, grinding…

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Finally the crimp!

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That goop is “seam sealer”, I also used it between the frame and the front skin. :cool:

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 Post subject: Re: Nose Job!
Unread postPosted: Tue Dec 12, 2017 6:43 am 
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Just realized that I had started a thread on doing this job so I'm locking this thread in favor of using the first one. Sorry! :oops:

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