AWD 964/911 Bus

Show off your pristine van, restoration, or daily driver.
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

B Pillar puzzle. Lots of stuff about this on the forums and it is a confusing layering of various bits of metal but with enough photos it should be easier for those that come after.

The bulkhead gets sandwiched between the forward B pillar panel and the rear B pillar panel. Thus

ImageB Pilar repair by Duke of Boots1966, on Flickr

ImageB Pilar repair by Duke of Boots1966, on Flickr

ImageB Pilar repair by Duke of Boots1966, on Flickr

ImageB Pilar repair by Duke of Boots1966, on Flickr

ImageB Pilar repair by Duke of Boots1966, on Flickr
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

Today I dropped the engine and gearbox in and bolted it all up, was half expecting to see the front end 'wheelie' up when i let the jack down but all good. I even have some clearance between the front of the engine and the rear subframe, phew.

Gear box goes in in -

ImageRolling Clearance by Duke of Boots1966, on Flickr

Sneaks through the rear subframe -

ImageRolling Clearance by Duke of Boots1966, on Flickr

Engine bolted in and hanging off the rear engine mounts (surprised the spot welds held!) -

ImageRolling Clearance by Duke of Boots1966, on Flickr

ImageRolling Clearance by Duke of Boots1966, on Flickr

A wee bit of clearance between the rear subframe and one of the heat shield nuts -

ImageRolling Clearance by Duke of Boots1966, on Flickr

ImageRolling Clearance by Duke of Boots1966, on Flickr

more tomorrow.
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Coolerdub
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Location: Wells, Zummerzet.

Re: AWD 964/911 Bus

Post by Coolerdub »

Nice work
Always lurking here somewhere ;-)
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

Today was all about seam welding and fabricating the strengthening plates for the chassis. Felt like a good day today.
Plate on front chassis join where the rear mount for the subframe attaches

ImageSeam Welding Day by Duke of Boots1966, on Flickr

Rear sub frame area with strengthening plate -

ImageSeam Welding Day by Duke of Boots1966, on Flickr

Getting the captive nuts into the frame for the gearbox mount -

ImageSeam Welding Day by Duke of Boots1966, on Flickr

ImageSeam Welding Day by Duke of Boots1966, on Flickr

Mig wire fed down through the frame -

ImageSeam Welding Day by Duke of Boots1966, on Flickr

Hook on the captive nut and gently pull into place -

ImageSeam Welding Day by Duke of Boots1966, on Flickr

and plug weld -

ImageSeam Welding Day by Duke of Boots1966, on Flickr

ImageSeam Welding Day by Duke of Boots1966, on Flickr

All done -

ImageSeam Welding Day by Duke of Boots1966, on Flickr

Closing off the front chassis legs -

ImageSeam Welding Day by Duke of Boots1966, on Flickr

ImageSeam Welding Day by Duke of Boots1966, on Flickr
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Coolerdub
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Re: AWD 964/911 Bus

Post by Coolerdub »

Like it, looks the bees knees that.
Always lurking here somewhere ;-)
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

Another couple of days welding stuff on, then cutting it off and grinding it and welding it back on and so on.

ImageOut riggers by Duke of Boots1966, on Flickr

ImageOut riggers by Duke of Boots1966, on Flickr

ImageOut riggers by Duke of Boots1966, on Flickr

Had to adjust the outriggers as my box section chassis is not the same as the 1mm section that she originally came with.

ImageOut riggers by Duke of Boots1966, on Flickr
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

The first panel goes on! :compress: :compress:

ImageFirst panels by Duke of Boots1966, on Flickr

ImageFirst panels by Duke of Boots1966, on Flickr
splitintwo
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Re: AWD 964/911 Bus

Post by splitintwo »

Great work mate! It’s taking shape, I have a window open in my browser especially on this thread to watch your progress. Keep it up 👍🏼
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

so just when I thought I had sorted the tubs it has started fighting back and i realised there was not enough room at the top of the strut to get in and adjust the suspension so.....

Out with the old (new) and in with the new (er).....

ImagePesky Tubs by Duke of Boots1966, on Flickr

ImagePesky Tubs by Duke of Boots1966, on Flickr

Using the new old inner panel that i had cut to short to create a new joint for the tub and suspension mount.

ImagePesky Tubs by Duke of Boots1966, on Flickr

ImagePesky Tubs by Duke of Boots1966, on Flickr

A few cuts to help profile

ImagePesky Tubs by Duke of Boots1966, on Flickr

A home made bendy thing mer jigg -

ImagePesky Tubs by Duke of Boots1966, on Flickr

A few spot welds (switching from 1mm to .6mm mig wire makes all the difference here) -

ImagePesky Tubs by Duke of Boots1966, on Flickr

ImagePesky Tubs by Duke of Boots1966, on Flickr

ImagePesky Tubs by Duke of Boots1966, on Flickr

ImagePesky Tubs by Duke of Boots1966, on Flickr

ImagePesky Tubs by Duke of Boots1966, on Flickr
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

For the love of 6 spot welds.

Today was all about building the front so i could position the lower inner valance and spot weld it in place before taking it all to bits again to start building back up and spot welding as I go. If Formula 1 ever allows Splitscreen in I will be a shoe in for the pit team given the speed at which i can now swap out a front panel :compress:

Image6 spot welds by Duke of Boots1966, on Flickr

Image6 spot welds by Duke of Boots1966, on Flickr

Image6 spot welds by Duke of Boots1966, on Flickr

Image6 spot welds by Duke of Boots1966, on Flickr

Image6 spot welds by Duke of Boots1966, on Flickr

Image6 spot welds by Duke of Boots1966, on Flickr

Image6 spot welds by Duke of Boots1966, on Flickr

Image6 spot welds by Duke of Boots1966, on Flickr

Image6 spot welds by Duke of Boots1966, on Flickr

And my top tip for the day, when you think you have enough G clamps and mole grips and welding clamps, count them all up, times by 3, memorise the number, then go in doors and order the number you ended up with!!! You can never have enough clamps.
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

All panels are equal but some panels are more equal than others! Screwed up cutting on my new inner leg panel so ordered another but not from the same supplier and guess what........

ImageSomething ain’t right here! by Duke of Boots1966, on Flickr

No cut out for the bulk head bulge.

ImageSomething ain’t right here! by Duke of Boots1966, on Flickr

So luckily I had kept the old (new) panel that I bodged so a bit of cutting and shutting and hey presto the panel i should have ordered!

ImageSomething ain’t right here! by Duke of Boots1966, on Flickr

ImageSomething ain’t right here! by Duke of Boots1966, on Flickr

ImageSomething ain’t right here! by Duke of Boots1966, on Flickr

ImageSomething ain’t right here! by Duke of Boots1966, on Flickr
type21f
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Re: AWD 964/911 Bus

Post by type21f »

Very elementary naive question.. before you tack it all up.. you have doors to hand to check the gap all round. Not my work but my bus..... this was rolled and all the NS including the lower segment of the front panel was rebuild from VW official spare panels and held together with 400 (I lost count there) pop rivets.

Our plan was replace roof and NS then replace chassis and floor. Image
1965 Type21f
Westfalia Hamburg Type155i 003 viewtopic.php?f=8&t=64012
1965 Devon Caravette, L360 L289 Hammock, Tent, M W Pop
Image
Peebles 1964 Devon Caravette Gentlux Pop
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

Thankfully yes I do and top tip so many thanks. Unfortunately the doors need attention before fitting so that’s on the list before the front goes back on and gets tacked.
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

Another good day in the garage today with the front lower panel being spot welded on and a test fitting of the Porsche 964 gear stick mechanism, the panel under the tool box and the front transmission. Not convinced by the gear selector solution as i will have to bend the shaft around the front diff so i think i may be heading for a wire system.

ImageBits and bobs by Duke of Boots1966, on Flickr

ImageBits and bobs by Duke of Boots1966, on Flickr

ImageBits and bobs by Duke of Boots1966, on Flickr

Front diff nestled nicely under the tool box like it was always meant to be there....

ImageBits and bobs by Duke of Boots1966, on Flickr

ImageBits and bobs by Duke of Boots1966, on Flickr

ImageBits and bobs by Duke of Boots1966, on Flickr

ImageBits and bobs by Duke of Boots1966, on Flickr

ImageBits and bobs by Duke of Boots1966, on Flickr
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john&hannah
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Re: AWD 964/911 Bus

Post by john&hannah »

Finished off modifying the off-side tub today so the top of the shock mount can peep through. The top of the shock is anodised so it should make look quite pleasing as it joins us in the cab.

ImageTubby by Duke of Boots1966, on Flickr

ImageTubby by Duke of Boots1966, on Flickr

ImageTubby by Duke of Boots1966, on Flickr

ImageTubby by Duke of Boots1966, on Flickr

ImageTubby by Duke of Boots1966, on Flickr

ImageTubby by Duke of Boots1966, on Flickr
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