Tortugas-van

[Plasticman]

G i think
mm

[Plasticman]

Well onwards
sorting the mounting aspect

will need a set of new bolts

and together

the inner part shown here is 3mm, this is held here to confirm its insertion in the rear and also to show how it is all constructed

then this outer part is next

this is without the inner but gives the idea

this shows them together, the area marked on the right will insert into the cut of chassis end and will be puddle welded through, over the top but why not. also i never just butt join a structural member

here is the web that extends into the shorter front part and helps give stiffness and rigidity

nearly there


and

one side/size fits all. ive a few internal bits to make then test fit and confirm mounting hole positions with the bare subframe up in place, then i can weld the box up complete and thence onto the van, happy days all round
mm

[kevtherev]

Stone me that is a work of art!

[Plasticman]

Well now p bucket is back up and running,
there is the matter of the remains of the old item,,, either cut it off and make good and so on and so forth ,so rather than Pee about ive gone down this route

like this

I have made the slot by hand this time, only oblong punches are 16 and 30mm so have a set on order

it works

you dont want the hole much bigger than needed but there is a backstop so no chance of loosing the bar down the chassis leg
main bit in place with inner stiffener and spring turret supports

the brace here is not quite right but soon will be,its all 3mm plate


this shows the other side


ive jacked the cradle up to confirm it will fit

closer ive yet to drill the holes in the msain chassis to accept the inner at the rear

hole lines up ok

this is awaiting the inner brace that will tie it all together

saving grace is the other side is made as i did them both together
silly question..... what are these called in vw speak


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[lloydy]

very very nice

[keith]

clever stuff.
how do you punch and form heavier gauge Mike.

[Plasticman]

Brake press ,drill holes or use a punching press lol
Oh and small lips can be done cold in a vice or get some heat on,it depends on the shape

[silverbullet]

I had another look at our C-reg this morning, blistering nothing like as severe so I'm still hopeful of doing a less invasive repair. I think the original purchasers must have paid the extra for the full underbody wax, as well as the Caravelle stonechip/sound deadening.

[Plasticman]

It rots from the inside out and nothing will have gotten on there to provetect but you may be lucky
mm

[silverbullet]

Fully appreciate that once water gets in, they sweat and what goes on where multiple skin construction is involved. I had a Rover once

[syncroandy]

Wow, just seen this. I've seen the pics (vid?) of Russel doing Jakes, but this is much more thorough. Both my vans need this repair, and I'm sure they're not the only ones. Might it be worth having these parts laser-cut and folded 'in bulk' ? Lars sells a repair section but its very expensive.

[Plasticman]

i was rather thinking i would offer a quick turnaround repair service wasnt lars bits over 300 a pop ?
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[jes*b]

Great to see , MaW.

[Plasticman]

well
no return now, spotting the inner and outer together for keeps

penetration

through this hole you can make out the inner brace for the level change

here

support for spring turret going on

note the cap head is stood proud, this is because i have added an internal bridge so that when fitting/removing the subframe the captive bar will not float up about just out of reach of the bolt

the option is 10.9 capheads or 8.7 hexheads ?
now going up into place

in ! you can see the weld through the old part of the chassis leg into the new inner,all inner is 3mm outer is 2mm,all braces are 3mm

front end

no point running a disc over it as the welds are decent ,so a coat of teamac and it and then some seam sealant on a couple of areas

note the slight change in height,

this is meant to be as the outrigger fits here and the crease adds a little strength and also make the underside of the chassis flat once the rigger tabs are in place , dont know if this is the reason or the result though ??

hmm

this is the vertical leg that connects to the cut of part of the rear of the turret support

going

gone

not as bad as the other side but too much rust in here to do anything but replace


inner support trial fit

mm

[ninja.turtle007]

It's all much more complicated than I ever imagined but it's coming together nicely!

Rest of the bits were ordered today. Should be with you by Tuesday.