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Thread: VW Cabriolet Project for the wifey

  1. #376
    Sr. User Array juicedz4's Avatar
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    Quote Originally Posted by cougarspeed View Post
    Your builds are really nice but could benefit from some attention to detail!!!

  2. #377
    Sr. User Array juicedz4's Avatar
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    Finished playing connect the dots on the lower core support piece and ground it smooth.





    Then tackled the top side.











    Still need to do two small pieces on the vertical part of the core support under the frame rails, as there are a couple holes there I dont need or want seen, then I think it will be ready.


    Up next I need to pattern the wiper box / heater area so I can sheet over it in one smooth piece.


    Dan

  3. #378
    Sr. User Array juicedz4's Avatar
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    Worked on the wiper box a bit last night. Trimmed the lip off of the heater box hole, and cut out the one bump above the pedal area.


    Created a paper template and transferred it to a piece of steel. Hopefully if we have enough dies Ill bend the edge today after work.











    Finished welding the other end of the core support to the frame rail. Didnt get a chance to do the small pieces under the frame rails yet.





    Overall shot looking forward.





    Dan

  4. #379
    Double Wrapped. Cause, you know, well its GM Array ultradriver10000's Avatar
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    I love the work you do... but I sometimes question the cars you do it to.

    The Cavy and Cab are amazing, but inside I would like to see you do a '70 cuda and a '70 Buick GSX

    Wife = "Honey please don't drift this corner, we have soup in the car."
    1997 Corvette 418| LSX E36 M3 | 2013 Ram Cummins | 1997 Viper | 3800SC Cavy

  5. #380
    Sr. User Array juicedz4's Avatar
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    Quote Originally Posted by ultradriver10000 View Post
    I love the work you do... but I sometimes question the cars you do it to.

    The Cavy and Cab are amazing, but inside I would like to see you do a '70 cuda and a '70 Buick GSX
    Me to man, me too. I really want to do something old and awesome, but I just cant decide what that might be that Id like. Someday when I figure it out at least Ill have lots of practice?

    Dan

  6. #381
    Double Wrapped. Cause, you know, well its GM Array ultradriver10000's Avatar
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    Awesome man!! I wish my cavy was 1/2 as nice as yours

    Wife = "Honey please don't drift this corner, we have soup in the car."
    1997 Corvette 418| LSX E36 M3 | 2013 Ram Cummins | 1997 Viper | 3800SC Cavy

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    Sr. User Array juicedz4's Avatar
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    Quote Originally Posted by ultradriver10000 View Post
    Awesome man!! I wish my cavy was 1/2 as nice as yours





    Rain tray panel is tacked in! I had to trim a piece of the firewall out in front of the heater box hole and hammer it back about a 1/4" to allow the panel to sit back all the way and maintain a nice straight line at the bend. Added a few holes around the middle of the panel to attach it to the OE panel below and hopefully stop any rattles or vibrations. I may also add a few small welds from the inside to do the same.








    Dan

  8. #383
    Sr. User Array juicedz4's Avatar
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    Nearly finished up the rain tray last night. I just need to go back and blend the bottom side of the welds along the firewall and it should be good.


    I need to mount up the wiper trans and figure out if Im going to put the factory support back in (that I already modified) or fab up a new one.





    This is the side I had to add a ~1" piece at the end as it wouldnt fit in as one long piece. Turned out good enough I think.









    Up next I have a little work to do around the shock towers and I should be really close to sandblasting and priming.


    Dan

  9. #384
    Sr. User Array juicedz4's Avatar
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    Lots of progress last night.


    First, I thought Id see how the OE master cylinder brace looked with some dimpled holes. I was going to make something new but I think this will look nice cleaned up and coated.





    Next I tackled the seams between the upper core support and fender.


    Orig



    Much better



    Drivers side



    Filled this random "dent"






    And this groove or whatever by the pass shock tower



    The lower piece was fun



    Much better



    Next, there was this huge molded in dent (for who can remember what) at the base of the drivers shock tower. I failed miserably at trying to pull it out with the spot weld puller, pounding it out from a hole i drilled in the wheel well (its double steel here), so I finally cut out a piece of metal, hammered it into roughly the right convex shape and welded it in.



    Finally, to try and get an idea how its really coming along, as its very hard to see I put a light coat of rattle can primer on..



    Dan

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    Sr. User Array maxwell's Avatar
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    Damn.
    MAXWELL
    BLAOWW!!

  11. #386
    Sr. User Array juicedz4's Avatar
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    Ok so looks like Im going to HAVE to do the firewall now. I just used my ballR MSpaint skills and came up with this.





    Dan

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    You're sick.

    ...and I mean that in the most complimentary way possible!

  13. #388
    Sr. User Array juicedz4's Avatar
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    Back to work after a week in FL and Thanksgiving etc.




    Started on my makeshift paint booth this weekend. For reference its 16x12x8.





    And started on the fire wall smoothing. So glad I decided to do this, its going to look so much better.



    Still need to do a bit of welding along the wheel well but for the most part its good to go.



    Dan
    Last edited by juicedz4; 12-07-2015 at 11:09 AM.

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    dan is that your badass silveraado in the pic? duramax?

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    Sr. User Array juicedz4's Avatar
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    Quote Originally Posted by svtcobra View Post
    dan is that your badass silveraado in the pic? duramax?
    No its not. Its my friends shop truck. He dropped it off so I could wire up the 938473908473 lights hes put on it. They just dont have time at his place to do it now that its autostart season. Its not a duramax, just a silverado with like a 5" lift or something.

    Dan

  16. #391

    Black Forest Motorsport


    www.BlackForestMotorsport.com


    4585 Genesee St.
    Cheektowaga, NY 14225
    (716) 634-1200
    NYS Repair Shop #710634
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    Holy crap, Dan. Really seriously nice work

  17. #392
    Sr. User Array juicedz4's Avatar
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    Thanks Jason!

    Dan

  18. #393
    Sr. User Array juicedz4's Avatar
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    Got a good start on the passengers side last night until I ran out of wire. Lame. Should finish up thrusday night.


    Before



    Cut out



    Tacked



    So much better



    I did get the top, one side and part of the bottom welded before running out of wire. I managed to get a little smoothed out before quitting time.



    Dan

  19. #394
    Sr. User Array juicedz4's Avatar
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    Finished up the firewall last night.

















    I welded up two holes in the pass side motor mount (no pic)


    Then I tackled the uneven lip on the inside edge of the core support.


    Before there were multiple widths which were quite wavy:








    After. Now there are just two widths, but nice and straight:













    I think about all thats left to tackle are the 4 holes in the frame rails near the firewall, and a couple on the lower and upper core supports and it will be ready for real primer.




    Dan

  20. #395
    Sr. User Array juicedz4's Avatar
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    Small progress last night. Got the 4 large holes in the top of the frame rails near the firewall welded up. I think that just leaves one in the upper core support....











    Dan

  21. #396
    Sr. User Array juicedz4's Avatar
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    No much progress as Ive been working on a ton of other stuff lately.


    Finally welded up the last ball for the shifter assembly.


    Now everything (including a couple washers for my MK6 motor mount) are ready to go out for coating. Probably going to do black E coat since it plays well with threads and is super cheap. Though, nickel would be nice.....








    Dan

  22. #397
    Sr. User Array maxwell's Avatar
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    Dangggg dude, I missed a big chunk of updates. Incredible stuff!
    MAXWELL
    BLAOWW!!

  23. #398
    Lifetime User Array ubengineering's Avatar
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    I love when you update your threads!
    15 Focus SE - 01 S10 4.3L - 96 Viper GTS - 95 Neon R/T

  24. #399
    Sr. User Array juicedz4's Avatar
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    Thanks guys.


    Spent some time cleaning up the shop yesterday and unearthed the unfinished lower x brace. Decided it was time to finally weld it up. I think my shifter parts are finally done at the coater, so ill probably pick those up and drop this off for powder today or tomorrow.








    I also spent some time figuring out what lenght wheel studs I need. Turns out I already have one set of ARP's in stock, just need to order a shorter set for the rear.


    Dan

  25. #400
    Sr. User Array juicedz4's Avatar
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    Picked up the shifter parts from being E-coated last night. Dropped off the lower subframe brace for some textured red powder. They are also going to redo the strut tower brace. There were some thing spots I wasnt 100% happy with.





    Dan

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