Hello Everyone!
First time posting on here.
Now weather is improving I am going to soon start on my project.
I've cut bolts so body can be removed, wasn't sure how to disconnect steering column?
I did buy the expensive floor pans but they was too short so got the basic pans, I'm going to cut down and join behind the front seats, is there any recommendations on overlapping or angles I need to cut at to make as strong as possible?
Any tips on cleaning out old petrol tank?
I work in building so have very little knowledge, but been a petrol head my whole life.

It`s a Hi from me...

Hello and welcome.

I cut in a chevron, it gives a longer stronger weld and leaves the visible weld on the side rail at the back so more discreet.

I generally overlap the join by about an inch and weld each side.

As for cleaning the tank, try putting some diesel and a length of chain in in, block the inlet and outlet then tie it across the front of a concrete mixer and let the chain rattle around for half an hour.

Quote from: Manxdavid on March 28, 2021, 12:20:46 PM
Hello and welcome.

I cut in a chevron, it gives a longer stronger weld and leaves the visible weld on the side rail at the back so more discreet.

I generally overlap the join by about an inch and weld each side.

As for cleaning the tank, try putting some diesel and a length of chain in in, block the inlet and outlet then tie it across the front of a concrete mixer and let the chain rattle around for half an hour.

Many thanks 
I will give that a go 👍🏻👍🏻

Quote from: Paul1953 on March 28, 2021, 12:05:52 PM
It`s a Hi from me...

You can put box section around the lip for strengthening it also means rivnuts can go in the top to bolt the body to but roll bar needs it drilling through with tubes fitted for bolts and nuts

Quote from: snoopy on March 28, 2021, 05:21:14 PM
You can put box section around the lip for strengthening it also means rivnuts can go in the top to bolt the body to but roll bar needs it drilling through with tubes fitted for bolts and nuts

Hello, thanks for tip! You make it look easy 😂. I'll make a tread on here with pics and progress.
This forum is brilliant btw 👍🏻

Welcome aboard - Looking forward to your Build thread 

I used the chevron cut method as well. Remember that when you bring the two halves back together they will not fit exactly correctly together so some hammering, nip & tuck, is inevitable. There is a method, as issued by VW themselves, whereby the cut is a bit more complicated but it does appear to get the two halves to meet with minimal extra work.

Quote from: Dave DND on March 28, 2021, 06:37:54 PM
Welcome aboard - Looking forward to your Build thread 

 

Quote from: Paul1953 on March 28, 2021, 06:39:06 PM
I used the chevron cut method as well. Remember that when you bring the two halves back together they will not fit exactly correctly together so some hammering, nip & tuck, is inevitable. There is a method, as issued by VW themselves, whereby the cut is a bit more complicated but it does appear to get the two halves to meet with minimal extra work.

That's interesting, being a carpenter I'm use to scribing and making joins, so I will look into that, I'm not too bad with a angle grinder and plan on holding onto buggy so be nice to make as nice as possible!👍🏻

Make sure you have a nice big pile of 1mm thick cutting discs for your grinder. You will use these over and over during your build. Just like using a saw keep the disc vertical to what you cut and eye protection essential.

(Also plenty of elastoplasts or electricians tape for when you cut through your hands, fingers and so on  )

If you're just replacing the floors you won't need that many discs but you'll find a cup wire brush for your grinder really useful for cleaning the crud off, plus a litre of red oxide paint for when you're finished welding.

You've already discovered that a Hustler is about 3 or 4 inches longer than most short buggies so if you find out that a new body (£1200 ish in nice shiney coloured gel coat) will work out cheaper than restoring and painting your old one (often the case) then the swb Jas body is the same length.

Agreed re- not many needed to cut floor pans but I find I use loads for cutting plate, tube, bar, bolts etc. 

Quote from: Paul1953 on March 29, 2021, 08:05:47 AM
Make sure you have a nice big pile of 1mm thick cutting discs for your grinder. You will use these over and over during your build. Just like using a saw keep the disc vertical to what you cut and eye protection essential.

(Also plenty of elastoplasts or electricians tape for when you cut through your hands, fingers and so on  )

Haha, some handy tips 😁😁, I don't normally wear safety glasses but I will take your advice 👍🏻 Plenty of electrical tape at the ready 😂