O/S bulkhead and wheel tub

Removed the windscreen after the trial fit and removed the sliding door window to avoid getting grinding sparks embedded in it. 

Spent some time getting the door gaps for the sliding door and cab door to the point where I’m happy with them. This should do nicely for us: 

Making a start on the bulkhead and wheel tub. The wheel tub isn’t in too bad nick, it’s had some awful repairs in the past which will need to be chopped out and repaired properly. Hoping to get the bulkhead all welded up this week.

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Sourced a genuine VW toughened windscreen and had another go at fitting with Max helping this time. Got it fitting near perfect, but the corners will need a bit of sealant to pull it tight against the metal. 

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Driver’s door skin welded up and trial fitted to the van; a much better fit than the passenger side. Now onto the front arches and wheel tubs!

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Dressed the welds on this cab door and got it trial fitted with the front arch. Not too bad at all. The front gap needs some work but I’ll come back to that when I come to fit the arch.

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Support braces bonded to the door skin and first door fully welded up! Just need to dress the welds and it’s done. All the hours on the door finally paid off.

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A spot of neptune blue. The insides of our doors now look better than the outsides used to!

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Door skins and frames epoxy mastic’d. All worth it in the end!

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O/S Cab Door Frame Complete

I’ve made a big push this week to get the door frame on the O/S complete.

My repair piece for the door bottom tacked in:

And ground flush. It came out pretty well.

Style line curve closed up at last:

Repairs made to the bottom corner:

And more repairs to the seal channel:

Started stripping the bottom half to bare metal:

And a little while later, the bottom half all zinc primed.

 Hoping to get everything prepped and epoxied over the next few days so I can get the skins on and have the doors done.

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Made up another big repair panel for my door. Hoping to get the frame finished this weekend.

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Final repair for the door card style line and curved corner section welded in. Started making up a template for the previously badly repaired door bottom.

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