'77 95 V4 van conversion by melle

4 minute(s) of a 19 minute read

The new panel is aligned and exactly mirrors the opposite side. I used the body measurements table from the factory shop manual and straight edges, cords and finally the panels and the bonnet to check the job.

I've been stupid enough though not to remove the spring before starting to cut the panel... Luckily I got the tip through the Dutch forum to remove the spring in order to stop it from distorting the panel even more. Did that yesterday morning before I went home:

Back in Denmark now, but hopefully Easter will give me some time off to at least complete the welding on the front wing!

8-5-2012

Holiday update!

Wing now fully welded:

The bent support bar already suggested further damage to the front:

I fortunately have a workshop manual with a body measurements table, a 96 for comparison and professional alignment tools (the car stands levelled on supports):

I've cut the bar, aligned the wing and the tower and welded it back together. The nose is now completely back on track, in the front area there's only some minor welding work left on the corners of the front valance. Around the suspension towers there's nearly no rust. Next year I'm going to replace the rotten rear floor and there's a small hole left where the floor meets the firewall under the clutch pedal (that's to the left. ). Hopefully next summer all welding will be done.

When I got bored with panel welding, I've proceeded with the interior. I've decided to create a third (foldaway) seat behind the passenger seat. A part of the cargo floor folds up and is secured with a metal safety support. There will also be a two point safety belt for this seat. I've made sure the seat meets all RDW (Dutch VOSA) safety rules for its model year. The window next to the extra seat will be kept.

Then I've made a start on scrap ply moulds for the wall panelling. The final interior panels will be done with new plywood.

I've welded a tip-up crate rack for the left side wall. If the rack is folded away, the room between the wheel housings will be free from floor to roof (for example to transport an engine on a pallet). On the left hand side wheel housing a 12V>230V inverter and 12V and 230V sockets will be installed. The car will also have a second battery.

Last but not least I've dropped off some metal at the zinc coater's. Job, as ever, very well done: