904-068 / 904-090
November 17, 2007
is over. It was a long hard 2 years. Some got done, some didn't.
That's just the way it works out sometimes.
Anyway, enough of the sermon. Here are pictures of 068 and 090.
We are now on a mission to get these cars done and get them
to their patient owners.
back to the doors...068 had a new set of doors, which were made
of fiberglass roving material. This is a woven mat, not like
cloth at all. It's stronger and lighter than a chopper gun,
but not as light as a cloth door. When the car was purchased
from Vasek Polak, these two lightweight doors were included.
090 had original doors, which were chopper gun material made
doors. Tons of detail still have to go into the doors to make
them ready for texture and paint. These doors were pretty rough,
even when installed new on the cars. It's hard to leave all
the very bad workmanship patina!
doors are primed and then textured on the inside.
I am applying the texture and because this stuff dries so fast,
you have to pull the tape (that keeps the undercoating off the
outside surface) off immediately. If the texture dries, it will
harden the edge of the masking tape and you will not be able
to pull off a straight detailed line. The texture ends right
at the inside of the door edge.
is a third 904 that got re-done while nobody was looking. So,
if you see pictures with 6 doors, you'll know why. Here Bill
block sands the final door so I can prime today. The doors were
primed with duratec months ago and now we're just doing the
final blocking to make sure they are perfectly fit.
I am glassing the edge of the 090 hood. When the hood was re-fit
to the body, the gaps were a little off, so I re-glassed the
edge to make them fit better. Sometimes these hoods fit perfect,
and sometimes through accidents and time, they don't fit so
perfect. We haven't done one yet that didn't need some sort
of adjustment. You can see the glass straps laid out on the
hood which will be used for the outside edges.
doors are in the booth and ready for primer. You can see the
polyester filler on the edges of the doors. This is done to
insure a nice flush fit between the door and the surrounding
area of the cockpit. Urethane primer is now applied. The doors
will be final fit and painted in the dolphin gray primer, which
is the base for the silver.
We have the column switches for only one of these 904's (090),
so we are making two sets - one for 068 and one for my car,
Andy lays the harness out on a bench and measures every wire
and also indexes the color codes.
housings are the same as a middle series (circa 1960-1966) VW
bus. This is fortunate for us because with a few adjustments,
we can make the exact housing for the switches. The switches
are VW also, but we have to modify them to make them as close
as original to the 904 switches.
Andy is cutting holes in the 068 dash for the switches. The
wires have already been connected under the dash and now Andy
will connect the gauges and the switches to all the wires.
is already done in this department, so it is easy for Andy to
refer to either 904-090 or the secret car, 904-040.
is the layout and mounting brackets for the electrical relays.
is what they look like when they are mounted. Andy has been
under the dash of 068 for almost a week.
wipers get rebuilt the easy way...new paint and hardware. We're
still missing a motor for 068.
will work on the pedal assemblies for both 904's next week and
after Thanksgiving. I will be applying final paint on the doors
and hoods next week. We will update these 904's at least once
a week until Sharon leaves for our daughter's wedding.
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