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    Thread: Cabrio project for the wifey... build thread

    1. Member
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      18 Atlas SEL:::13 GTI:::93 Cabriolet:::2009 Silverado
      10-09-2019 09:56 AM #601
      Decided I needed to paint the area inside below the rear window and the B pillar so they will match the front doors.

      Welded up the coat hook holes, and did a quick bit of filler on the spot welds.



      Primed



      With that done it was time to get them painted along with the radiator support / front end. So of course, masking....





      I did the front clip with Upol Guard 10



      Sealed and base







      And cleared





      And with a little added light - this color really pops in the light









      Dan

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    3. Member
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      10-09-2019 10:42 AM #602
      With that done it was time to mask, again, and get the last bit of primer on the cowl, windshield frame, door jambs and the quarter that I had to do a little more filler work on.











      Some people have been asking about the paint and color, here it is.



      Dan

    4. Senior Member briano1234's Avatar
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      10-09-2019 12:18 PM #603
      Been wondering when you were gonna update the thread, and the wait was worth it. Great work, good look Sire Cab-a-lot. nice, and sure it's for the "WIFEY", but that is your story and you are sticking to it .

    5. Member
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      10-14-2019 03:28 PM #604
      Epic milestone reached this weekend. The chassis is painted.

      Finished blocking out the primer with 320 and 400 dry.





      Spent like 8 hours masking the car and the booth.





      Sealer. Had a little issue here. My stupid tack rag left a few drag marks. Luckily I was able to wet sand them out quickly with 1000 grit after freaking out for a few mins.



      Three coats of base which turned out perfect. There was just one tiny spot of trash near the wiper cowl, i was shocked.





      Three coats of clear. This is where it went a little wrong. While Ive had great luck on the small parts doing these large panels was a bit more of a challenge. I ended up with a variety of results. Some huge runs (not shown), a lot of orange peel, and a few spots that were near perfect. Im going to pick up a different gun before I clear the next parts as technically im using the wrong size tip.

      Overall though, for a first time paint job in my garage, Im pretty happy. I definitely have a lot of wetsanding and buffing in my future, but I think its gona look amazing.

















      Dan

    6. Member Schumo's Avatar
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      10-14-2019 06:51 PM #605
      Looking good, but what is going on with the dings on the rear arch?
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    7. Member
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      10-14-2019 09:04 PM #606
      Quote Originally Posted by Schumo View Post
      Looking good, but what is going on with the dings on the rear arch?
      Those are factory. They get covered by the fender flares.

    8. Senior Member briano1234's Avatar
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      10-15-2019 12:14 AM #607
      Salivation, I can only imagine your wanting to "Finish" the finish and start the re-assembly.

    9. Member
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      10-15-2019 11:52 AM #608
      Quote Originally Posted by briano1234 View Post
      Salivation, I can only imagine your wanting to "Finish" the finish and start the re-assembly.
      I actually started assembly last night.

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      10-16-2019 03:23 PM #609

    11. 10-18-2019 03:46 PM #610
      The project looks amazing, looks like you'll have a perfect cabby - as though it just rolled off the assembly line - probably better!

      I too have a 1989 cabby which we've owned now since new for 30 years. Never winter driven and barely seen any rain. Back 6 years ago we had the car stripped and re-painted back to to original, just to bring it back up to perfect (I had a door dent or two and a couple of chips in the hood) so thought lets do it right. However, since, I've been looking for side trim molding that runs the length of the car, as what I have (albeit pretty good) they don't look as new as the rest of the bodywork.

      What plans do you have to obtain new side body molding? The original factory parts are no longer available from VW in North America or elsewhere (I've tried Europe, South Africa and the UK without success). And from what I've seen there are no third party sources available either.

      Interested in hearing how you'll handle parts like that. Keep up the amazing post - and once complete, please advise if you'll be taking the car to any VW car shows. I'd love to see it in person and have a good chat with you.

    12. Member
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      10-18-2019 03:53 PM #611
      Started assembly while Im waiting for clear to cure.

      So far:

      - insulated exhaust tunnel
      - installed shifter (the gold box) which still needs cables
      - rear brake line
      - fuel hard lines
      - parking brake cables
      - gas tank
      - rear exhaust section
      - painted and set the rack in place, Im missing the 12pt nuts I need to install it fully right now







      Used this stuff on the tunnel.



      Fuel line clips







      Dan

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      10-18-2019 03:54 PM #612
      Quote Originally Posted by jamesjuhasz View Post
      The project looks amazing, looks like you'll have a perfect cabby - as though it just rolled off the assembly line - probably better!

      I too have a 1989 cabby which we've owned now since new for 30 years. Never winter driven and barely seen any rain. Back 6 years ago we had the car stripped and re-painted back to to original, just to bring it back up to perfect (I had a door dent or two and a couple of chips in the hood) so thought lets do it right. However, since, I've been looking for side trim molding that runs the length of the car, as what I have (albeit pretty good) they don't look as new as the rest of the bodywork.

      What plans do you have to obtain new side body molding? The original factory parts are no longer available from VW in North America or elsewhere (I've tried Europe, South Africa and the UK without success). And from what I've seen there are no third party sources available either.

      Interested in hearing how you'll handle parts like that. Keep up the amazing post - and once complete, please advise if you'll be taking the car to any VW car shows. I'd love to see it in person and have a good chat with you.
      I have all the body side molding pieces. Most were intact when I bought the car, and the rest I obtained used. Of course this was almost 10 years ago so perhaps more were available back then.

      You should be able to refinish them. A little SEM Trim Black paint can go a long way.

      Dan

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      10-21-2019 02:45 PM #613
      Started wet sanding and buffing this weekend.

      The clear was pretty thin on the rear part of the pass quarter (just shy of sanding through) and there is a decent tiger stripe in the color, so at least this top section will need to be resprayed.

      Overall though Im very happy how its turning out. So far Im doing a quick sand with 1000, then finishing the leveling with 1500, and finally going over it with 2000. Then Im using Megs 105 on a orange foam pad and 205 on a black foam pad using a Rupes 21 d/a buffer.









      This is the spot I was talking about. Its very hard to get a pic of.



      This area is where I had a huge run (of many). You def cant see it now.



      The drivers side turned out much better. I think I figured out to do less sanding with the 1000 grit, and more with 1500.








      I picked up the mini Flex rotary and some 1 and 2" pads to do the small flat areas, jambs etc. So far I just used it on the top lip of the quarter, seemed to work well.





      Dan

    15. Member madone's Avatar
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      10-29-2019 09:15 AM #614
      as always outstanding work, this is going to be one amazing vw cab once done.

    16. Member
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      10-29-2019 11:25 AM #615
      Did some more sanding and polishing. The drivers side is about 98% there. I have the pass side fully wet sanded to 3000. I think I may end up respraying the whole pass side so Ive decided not to buff it for now.

      So a few more boring pics of that progress









      Giant run previously mentioned. oops



      And mostly sanded out. I dont have any pics of the pass side all sanded out, but whatever



      Took a break from sanding to get the motor and trans mated.

      First, since I A. couldnt find a decent dust sheild, and B. I hated its mult-ipiece design I made my own from 0.030" stainless.

      Made a template using poster board. I find the edges by rubbing a piece of aluminum bar stock around the trans with the posterbaord taped in place in a few spots. Its quite accurate.



      And used the billet rear main seal carrier to mark the location of the cutout once I found the center of the bell housing.



      Fast forward thru the cutting and sanding and here it is in place along with a new rear main seal.



      And then the freshly resurfaced flywheel and new bolts.



      Stock VR6 clutch



      And mated up. The dust shield fit perfectly.







      And here is the whole package ready for install.










      Dan

    17. Member flying_oliver's Avatar
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      11-05-2019 10:50 PM #616
      Man, I haven't been on the vortex in a while and am so happy to see how far this has come.

      Keep up the amazing work!!

    18. Senior Member briano1234's Avatar
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      11-06-2019 09:21 AM #617
      Dan, I like the tranny cover plate, never been a fan of the old ones..... Can we get a collective WOW.

    19. Member DUTCHswift's Avatar
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      11-06-2019 11:34 AM #618
      Quote Originally Posted by briano1234 View Post
      Can we get a collective WOW.

    20. Member madone's Avatar
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      11-08-2019 01:33 PM #619
      the big question is now this has been so many years in the making, will this still be the wifey car or more of family weekend/show car?

    21. Member
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      11-11-2019 03:39 PM #620
      Quote Originally Posted by madone View Post
      the big question is now this has been so many years in the making, will this still be the wifey car or more of family weekend/show car?
      Its going to be her nice day car and of course a weekend / show car as well. IF and when we have time.

      Dan

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      11-21-2019 04:50 PM #621
      Decided to extend the drivers rear brake hard line vs using a longer flex line.





      Added some shaft collars to the exhaust hangers. I had cut off the stops b/c they were rusty underneath. This was the cleanest solution to keep things in place
      Of course I had to swap the bolts out for stainless







      For fun I set a control arm / knuckle / brake in place.



      And then decided I wanted to re-route the front hard brake lines around the firewall vs through the frame rail as originally planned. because reasons.
      Utilized the hole in the firewall that I didnt shave for the one to pass through. Added another hole for the pass side and a nutsert to mount a little ss plate I cut out.









      Had to space out the one fuel line mount 3/8" for clearance. Worked well.



      With that done it was back to painting. Decided to tackle the hood and trunk.

      Final blocking.





      Seam sealed



      Picked up a new spray gun.



      Hood in sealer



      Inside of trunk painted. clear right off the gun.











      I wasnt happy with the hood. It had more tiger stripes than I found acceptable so I didnt clear it. Its now color sanded and ready for another coat. My paint buddy is going to stop down soon to give me a lesson on how to not F it up again. haha.



      Finally sanded out the huge runs in the brake booster and gave it a fresh coat of matte silver single stage.





      Dan

    23. Senior Member briano1234's Avatar
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      11-21-2019 08:36 PM #622
      Been Panting for an update but only 2 pictures?

      Ok it took about 5 minutes to download the photos.....Nice......Panting arrested.

    24. Member
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      11-22-2019 10:38 AM #623
      Quote Originally Posted by briano1234 View Post
      Been Panting for an update but only 2 pictures?

      Ok it took about 5 minutes to download the photos.....Nice......Panting arrested.
      Odd. Oh well, at least they are still working. I was having an issue with my host for a bit, they kept updating the version of PHP to something newer than my site can handle.

      Hoping to have some more updates before thanksgiving, but we'll see.


      Dan

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