Thuis.	Forum.	Contact en Links.
Daf Albums.	Andere Albums.	Evenementen.

	Terug.	Naar Deel 4.

Project Kikker.

Part 3.

It is still 2009.

It's time to do something about the rotted edges on the trunk lid. Three of the edges have to be repaired.

Replacing the rot with new strip of metal.

A new edge ready for paint.

The trunk lid finished and mounted (temporarily) to get the hinges lined up.

Bottom of the Driver's door is pretty well rotted around the drain holes and edges have seperated from the outer skin. Something will need to be done here.

The door repairs are coming along nicely. A little more welding and it should be ready to finish off.

The new strips of steel are welded in, the welds have been smoothed out and now it's time for a skim coat of filler.

The driver's door inside face is now ready. The only thing left to do is drill three drain holes in the new steel plate.

A little (a lot) of Bondo filler was needed on the outside Driver's door.

Driver's side door about finished, including the drain holes, and ready for paint.

The Passenger side door is in perfect condition (this came out of California so no rust out).
I just purchased new window guides and vent window rubber from J.C. Whitney and those will go in after the paint.

On to the Hood...OMG, what a mess! The Hood has five metal tears caused by flexing (opening and closing).

Re-enforcing metal strips were added to both sides inside the Hood lid.

The new strips were blended in with body filler.

The nose of the Hood was also re-enforced because that's where the Hood prop rod mounts.

Front nose has also been filled and is super strong. No more flexing when the hood is propped open.

The remade hood was test fitted and it was a perfect match. No more waves, flexing or cracking. My new welder and electric metal shears are coming in very handy lately.

It's the small details that stands out like a sore thumb. After removing the door I discovered that these corners had been fabricated square...all wrong!
The trim piece is curved (see it on the right?) so this corner needs a curve.

The first piece of metal welded in place to create the curve.

The passenger side also done in the same manner.

The inner plate now in with a first layer of Bondo.

The outside curve all done and it looks good.

Time for a little more welding for authenticity. The fender edges are missing on both door frames, so I need to fabricate a new ones.

After tracing the curve a 1" wide piece of sheet metal was cut and test fitted.

The new door edge in place with a first layer of Bondo.

Front fender repairs are just about completed now and they are starting to look new again.

The Driver's side edge is also missing. Time for a little more welding and fabricating.

Driver's door edge now also done.

I am starting to refurbish the doors, which need serious help. The old window guide channel is so far gone that it will be thrown away and replaced.

Today I installed the door glass. I found the perfect replacement for the window track rubber at (of all places) J.C. Whitney. A perfect fit.

In order to get the door glass in you must loosen the top of each door. They are held on by 6 screws and it's the only way to get the glass in.

Here are the door internal guts. Window crank mechanism on top & door lever mechanism on the bottom. Each is held on with screws so they come out easy.

Driver's window in place and inside panel has been sprayed with finish "Kikker" green.

Final Step on the door, addition of plastic to insulate againts drafts. This door is ready for finishing.

Time to start putting back some glass while I wait for the painter. Side windows in first, they are easy.

Driver's side glass all in except for the vent window.

Outside handles installed.

Since I now have new rear window rubber (Thanks to Danny) now is a good time to get it together. A good layer of window Butyl was applied first to seal it tight.

With some careful fitting the rear window was installed with new rubber. DCA decal followed soon after.

I made a slight change to the original design. Instead of trying to make rubber seals I choose to seal the door gaps with seam sealer and they just paint them.
The original rubber is not available, trying to make it is almost impossible and won't seal properly.

Vent windows going in. New Rubber from J.C. Whitney (VW Beetle), a perfect fit with a few small modifications of course.

After a little cutting and fitting the window rubber is now all set. Vent window pivot is screwed together and new pillar rubber seal is also in place.

I also installed the new interior & exterior window weatherstrips I got from Danny.

Busy day today installing the front headlights...and they work!

I can't wait for the paint so am also installing the Front Windshield glass using new rubber from Danny.

After shaping the rubber around glass I attached the locking trim starting at the bottom.

With careful fitting, pulling and prying rubber over the inside edge it was seated with a rubber mallet.
A thin layer of window seal was applied around glass and outside edge to weatherproof it.

Front Windshield now also in place. "Kikker" is begining to look like a real car again. Just waiting for the painter now...but where is he?

It's time to get serious with the Solex Carb. I've ordered the rebuild kits so now to clean them up. I have 7 of these little French nighmares...luckily only 3 need help.

Solex Carb is half way to being rebuilt. You can see the discarded parts in the top left corner.

All finished. This Solex 34 PBI carb should now be good for many years to come (as long as I keep changing the fuel filters).

Newly rebuilt Solex mounted back on the intake.

Decided to rebuild my fuel pump as well since fuel flow was very weak.

All rebuilt and ready to go back in. This pump only puts out 2 psi so finding a replacement will be hard...
Although with an adjustable pressure reducer valve I should be able to find a replacement, if needed

Rebuilt fuel pump all bolted down & hooked up.

Thinking maybe I had a bad Distributor/Fuel Pump drive I decided to replace it as well as the Distributor.

I pulled the old headliner out of "Red Baron" to have it duplicated locally.

© www.SITEJE.com