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Discussion Starter · #1 ·
Back from the dead... the RotisseRabbit

Hey all,
Some of you may remember... I'm restoring a rusty '77, small-tail german rabbit.

So far, the biggest part of the project had actually been building a rotisserie from scratch
to mount the car... (see my previous posts) but it's done, and works GREAT!

The other battle has been finding parts... I've managed to source the following new, OE (VAG):
- small-tail rear panel

- rear frame rail / inner rocker
- front inner rocker
- front o/s inner fender
- front apron / rad support x2

And I've just received my shipment of aftermarket (Klokkerholm) panels for the parts I couldn't find OE:
- FULL floors, front to back
- outer rockers
- d/s inner fender

And for some of the smaller, unseen patches, I'm making my own patch panels.

I've also just finished building my own full-size sandblaster. So it looks like it's time to get down to business!
I'll try to post updates as I get stuck in... anyone who's particularly interested, get a hold of me here, or MSN (chester_field)
-Duncan
Ottawa
'78 MG Midget
'77 RotisseRabbit


Modified by tosoutherncars at 6:26 AM 7-23-2006
 

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Re: Back from the dead... the RotisseRabbit (tosoutherncars)

wow..... thats a lot of parts !
i bet ya the parts cost more than the actual rabbit.....
http://****************.com/smile/emthup.gif
 

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Discussion Starter · #3 ·
Re: Back from the dead... the RotisseRabbit ([smeg0r])

Hehe, definitely... but once I decided to do a FULL resto, I chose to replace entire panels... I don't want rust coming back two or three years after I've done it all! And I don't trust any other method of stopping it...
 

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Re: Back from the dead... the RotisseRabbit (tosoutherncars)

where'd you find those full floor panels? sweet .. pulling up another chair to wach this one .. http://****************.com/smile/emthup.gif
 

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Re: Back from the dead... the RotisseRabbit (drchron)

Looks quite ambitios http://****************.com/smile/emthup.gif
maybe I can take a day trip down and lend a hand? or just have a look?

Let me know if you need any parts
 

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Re: Back from the dead... the RotisseRabbit (tosoutherncars)

Was wondering where and how you got your aftermarket panels. I see you have Klokkerholm as the brand, but it seems they don't sell to individuals. How did you buy them?
If you don't want to share your secrets with all, please PM me.
 

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Re: Back from the dead... the RotisseRabbit (Cynical 1)

Dude...as if you are in Ottawa! Have you checked out Ottawa-Vdubbing yet? We've had a sudden influx of MkIs lately :mrgreen:.
Nice project!
 

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Re: Back from the dead... the RotisseRabbit (B4S)

Klokkerholm is the shiz! I bet you had them through Fender Factory in Ottawa, right?
They didn't have Mk2 panels though, so I had them imported from Norway. I have one on my Mk2 GTI and it's spot on.
BTW, is you car a 4-door by any chance? My parents used to have a '78 Panama Brown like this, in Ottawa too. http://****************.com/smile/emthup.gif


Modified by Bakounine at 3:37 AM 7-24-2006
 

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Discussion Starter · #11 ·
Re: Back from the dead... the RotisseRabbit (Bakounine)

Burn_your_money... come on down man, I need all the help I can get with this thing! lol...
As to buying the panels, it wasn't easy! Cross Canada Parts is the national reseller (Canada) for Klokkerholm, but they don't sell to individuals. And, their local resellers couldn't / wouldn't special-order parts that aren't in the CCP catalogue.
Thankfully, my buddy owns a chain of service stations, so I was able to order directly from CCP. The floors + rockers came to a little over $500, but well worth it now that I know there isn't any rust lurking anywhere!
Update for the day... took the front of the car off the rotisserie (since it uses the bumper mounts) so I could finally remove the front apron and start cleaning & prepping the engine bay.


For those that have never done this type of thing... those pics show I've drilled a small hole through each spot weld, then gone in with a much bigger bit on the side I *won't* be keeping, to open it up... at which point the two parts can be split apart with a cold chisel. I have a few spot weld drill bits, but I can't say that I think much of them.

You can see what a rust trap that bottom corner is.
I have to do:
- spot rust removal
- patch panels to replace the front inner rocker, both sides
- new front apron (lower only)


I also have to remove, clean up, and reinstall the passenger-side motor mount on the firewall; it looks like it was put on by someone on the Popcorn Welding crew! (you guys out there?)
-Duncan


Modified by tosoutherncars at 5:31 AM 7-24-2006
 

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Discussion Starter · #13 ·
Re: Back from the dead... the RotisseRabbit

DAILY UPDATE: Cleaned up the engine bay a little more, and got to work on the driver-side inner fender. I have an aftermarket patch that's quite well-made.

I got brave and decided to butt-weld it, rather than overlapping it and seam- or plug-welding. It's neater, and I don't want either (a) a visible seam in the engine bay, or (b) a rust trap in the wheelwell.
So I had to measure. and fit. and adjust. and bend. and measure. and re-fit...

...until I finally got the thing to sit right. Then I cut out the old fender with a zip disc. You'll notice that I didn't use the whole panel, and that there are several angles to the seam; it was easier to line up when the joint followed flat portions of the panel.
I should have been a little more precise when cutting it out; the gap is slightly uneven, which made it harder to weld without going through.

Still, on setting 2 (of 4) on my 110 gas MIG, it's not too bad.

And once those are joined up, ground down and covered in rocker-guard, it'll be invisible from the wheelwell side. http://****************.com/smile/emthup.gif
Even better, the engine bay side won't show at all after a sand & a VERY thin skim of filler.

So that's it for the night; I'm very happy with the first panel to go back on... Nice to be adding on, instead of ripping off, for a change!!
http://****************.com/smile/emthup.gif

-D
 

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Discussion Starter · #14 ·
Re: Back from the dead... the RotisseRabbit (tosoutherncars)

...and another glorious update! http://****************.com/smile/emthup.gif
Gotta love bodywork... it's such a glory job.

Finished joining together all 2.5 million spotwelds, and grinding down a little. The patch panel had the faintest hints of rust in a couple of spots, so... 1851 stripper it is!

There was definitely some rust lurking there! Applied a couple of coats of rust-converter... I'll let that sit overnight, and prime tomorrow.

Have to remember to pick up some seam sealant. I'm not particularly worried about the joint(s) being visible... but I'd like them to be as neat as possible, and protected from corrosion!
I have a larger, VAG panel for the same spot on the other side, so that will be going on next I think. And hopefully, by the weekend, I'll be ready to sandblast and prep the whole engine bay.
Ooh, this is the sandblaster I build myself.

It runs off my 5-7HP 80gal compressor, and can take 100 lbs of sand at a time. Works great, but what an air hog! Here's a shot of my control arm, before & after...

Not to be an attention whore...
but is this kind of stuff useful / interesting to you guys?
-D
 

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Re: Back from the dead... the RotisseRabbit (tosoutherncars)

If you do this every day I may have to give up porn. http://****************.com/smile/emthup.gif
 

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Re: Back from the dead... the RotisseRabbit (Cynical 1)

Quote, originally posted by Cynical 1 »
Was wondering where and how you got your aftermarket panels. I see you have Klokkerholm as the brand, but it seems they don't sell to individuals. How did you buy them?
If you don't want to share your secrets with all, please PM me.

Rabbitparts.com out of NJ has some good stuff.
 

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Re: Back from the dead... the RotisseRabbit (tosoutherncars)

Quote, originally posted by tosoutherncars »

Not to be an attention whore...
but is this kind of stuff useful / interesting to you guys?
-D

this is great, Luv the backyard blasting pot..

I dip all the parts I can in a hot caustic tank, removes the paint /plating /rust from everywhere, then blast for good paint adhesion. Zinc electroplate most stuff before painting to give the component the best chance of survival... even here where it takes 25 years for ya car to rust anyway..

Keep the progress piccies coming.. http://****************.com/smile/emthup.gif
 
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