Aircooled VW South Africa

Hi If this was my screen I would fill the cavity with about a third of sikaflex (stuff used to glue in windscreens in modern cars)press the glass in while the sikaflex is wet and adjust once this is dry I will fill any remaining cavities with the same stuff and smooth off this way the shield is mated to the frame with no tension as the sikaflex will confirm to any slight mismatch.
Armand

Thanks Armand. Do you suggest I don't fit with the rubber at all?, Only use Sikaflex?

I have never done a speedster windscreen with the stuff before but at worked in a similar situation on my puma. I would first try to bend the frame to fit evenly around the screen and then glue it in obviously this only applies for the frame to window and not across the body to shield interface I would also mask the windshield except where I am glueing as that stuff is a Bi#$h to get off glass once cured
Armand

If the windscreen Sika is the same as the Sika I use, then it hardens to a hard rubber.
To remove it from a hard smooth surface like glass, cut it with a stanley blade along the window frame and roll it off using your thumb. Then clean off the last bits with a window scraper.
Masking is easier and much quicker
Do not underestimate the strength of this stuff!

Cool, Am getting new Windscreen on Tuesday I think. Will then use this method. Any specific "Sika number product"? eg: 256 or whatever?

I use their general adhesive, but if you go to glassfit or similar I am sure they can tell you which one they use for windscreens

As the right stuff is very expensive,

I normally go to my local PG Glass and buy off them a half used tube,

as they would need to dump it if it gets old,

and I do not need a full tube.

Herman

Thanks guys,
I'll be collecting tomorrow. My idea is to probably put 4 pieces of the Profiled rubber in the frame, 2 on the very edges, and two on the top, simply to "hole" or "center" the glass in the frame. Then I'll be filling the rest of the cavity with Sikaflex and let dry. Should be solid, and strong, with no reason to "flex" the glass at all.

So in prep for getting the Speedster home on a couple of days time, I've actually be pretty busy preparing for the rebuild. Can only go easier if everything's on hand, and ready to go, so to speak.

It also helps to have any idea beforehand of where you want to end up. I did this with the Bikes I restored, and the finish was close enough, and it helps to keep you on track.

My Aim. (The Beige Top.)
The finished look will be my Newly painted Rich Red, with Tan Interior, Beige top like this, and with the white wall inserts on. that should be just perfect.


The Interior (I mirrored this to emulate right hand drive..)
The interior can take quite a bit to get right. I've made up some knobs, sourced the gauges, and am customizing them for my use and to look right. The new dash will also feature the dash panel, proper grab handle, the Instrument shade, and so on.


The Motor (With my linkage system)
I'm not wanting huge HP like other guys here. Maybe I've just matured more, days of hair on fire speed are past, but make no mistake, I still want the car to run decently, so I intend doing some basic headwork with another airhead guru here in Cape Town, but the finish must be clean, basic, and functional.. No fancy bits and pieces.. That just gives more room for failure.


So, in prep, I managed to re-pop some Resin Knobs, which will help to give the car it's period correct look.


As pictured earlier, the dash will only have 3 gauges, with 3 knobs, Headlight, Hazards and Windscreen wipers. And I'll probably mount the remote ignition as well.

The bodywork will have a lush new paintjob on it, all cracks and surface\pressure cracks are removed, and it should look smooth and perfect. I've made my own scripts, which will be Gold Plated to stand off against the red body.


To get everything evenly balance, so chrome is the same all round, I got the window frame chromed up, new front and rear tail lights with new Chrome Bezels, new Mirrors, and all my old bodywork I've been polishing up and ready to be re-mounted. Also bought a Upward facing numberplate light which will be fitted on the tail.


Thanks to my good friend Manny, I've got all the correct mounting reference points as to where everything must go back on the car correctly, as well as an excellent reference book I bought, the 356 Speedster, a restorer's guide to Authenticity. Astounding reading about the fine difference between each year, and each model..

Hey, mine's a bloody replica, but it's going to look near perfect as far as I'm concerned.

So the plan of attack when the car get's home. First is to make some profile changes on the interior chassis, channels, tunnel, and kick panels. Then install some Dynamat. Cut all new holes in Dash for new Gauges. build correct dash with Instrument Shade cover (or eyebrow), I'm re-doing the door panels again. Then will hopefully get the Carpeting done. Then get the outside bits all re-fitted, mount the new roof to the Bow and hoops, and get that to fit, mount all new tenax fittings for both roof and tonneu cover.

Lastly I'll remove the motor and redo all the rubber surrounds, clean up and repaint the tin, hopefully fit the new smaller Shroud and relocate Coil and other bits to helop clean up engine bay.

Will post again when I've got the car.

nice writeup, hope it all goes according to plan
enjoy it

Shot man, When's your return date?
Not sure if I'll be "on the road" by then, but it'll also be mid-winter, and I doubt I'll be out and about in the Speedster. At least I have a few months to work on the car, even if it is in a cramped single garage.

I spent years working out of a single garage, anything is possible.
I'll be home around 15 July.

Just remember when putting it together. You dont have to finish it by a deadline. So if you get frustrated or confused, take a step back, have a cup of coffee or sleep on it. It will be much easier on a clear mind when you are in the mood for it.

Hey Alan, you mention that you made your own scripts, how ? Engineering shop ? Water jet ? And are you allowed to do that ?

Hi,
Yep, similar to waterjet, but routered or cnc cut by one of my Service Providers. I'm now going to get them Gold "chrome" plated, so we'll see what the finish looks like.
Why would I not be allowed to make my own badges for my replica? I'm not selling them to anyone, shouldn't be a problem.

Looking good, I am impressed with the scripts, cant wait to see the gold plating on it.

Thanks buddy. Pics will follow.

I stopped in at the Bodyshop this morning to drop off the dash brow, which needs some bolts glassed in to hold it on the dash. Holy shit I'm so excited now.. The Red they have used is PERFECT, it just looks brand spanking new.. No holes anywhere on the body, so, it's like starting for fresh again. So if all goes according to plan, I should get it home this weekend. Intend to take missus and kid, and they can lead and follow with me inbetween.. Car's DEF not roadworthy, but it's "down the road" so will take a chance to drive it home.

I need an 'excited" icon here..