For Kernowjon01 : Behind this pretty exterior lies a very hot secret.

I thought that you would like to see these photos Jon. It belongs to one of my customers who bought it in 2014 but it kept overheating and it was eventually decided that it needed another Cylinder Head which I duly supplied for £75, and it sorted the problem. But that was not the hot secret. Feast your eyes on these photos. I will probably have to send them one or two at a time as my Tablet keeps telling me that I don't have enough storage space to send the pictures. I have 14gb spare on the Tablet never mind the 64 GB SD Card. Anyway I will send this message first followed by the pictures.

I will feast my eyes when the pics appear. Jon

The Oven in the back is the Hot Secret and the Fridge I suppose has to be the Cool Secret.

Forgot to mention that a big VW Badge covers the access hole for the radiator cap.

Is that one of the GRP front ends?
Is it one of or ex Pasty Van?
If you notice my grill has a wider V and the rad cap is level with the top of it - I need a funnel and length of hose to easily fill but nothing dramatic.
Jon

Yes it is a Giber Flass Front Jon which when I saw yours I assumed that yours was too.
Your chap has certainly made a superb job of doing that in steel. I wish I had those skills and the equipment to do that sort of metal work.

I am very fortunate having a well equipped workshop at home but more for the Woodwork sort of stuff and car mechanics, Welding etc.

I would love to have a super Workshop that Logi has got or a huge one that D1noh has. But I get by working outside in the fresh air and natural light.

Hope you have removed that film on the helmet visor before you have done any welding If not may explain any difficulties you may have had!

The amazing thing is he did not have any really special equipment - I'll see if the pictures I took will go on the forum without me reducing the size. He carried the plan in his head - measured around the van from door to door where the top of the lights are. Then marked it out on a sheet of 1mm steel. He had 2 wooden formers 1 to make the headlight fairings the other to form the grill frame.
Of course first have to put pics on photo bucket.
Jon

Don’t bother with photo bucket just host them on the platform used by the forum when you upload the photos on here, serving.com

I'll try later Raggy meanwhile Woodie check your emails 3 of them
Jon

These are pics of the process start to finish of Steve fabricating my front end. Jon

And there are more

Thanks very much Jon. I don't know why Drive was saying that they are " Invalid Files". I have just had two Drive files through from my Doctors and they are OK. It's just me that's not.

Your friend is certainly a very clever chap. How did he weld the front on without melting or setting fire to the Dashboard or loom?? Even by plug or spotwelding can be a tricky process. And time consuming going back and forth with spotting so as not to distort the metals. Very nice job indeed.

I would have covered the windscreen and the Fibreglass as filings from the Angle Grinder wrecks a screen and can make a right mess of the Fibreglass too.

Final set

and a few more something funny happening

There you are Woody only basic tools MIG Welder, hammer, compressor and spray gun, a wooden former to shape headlight fairing, wooden former for the radiator grill surround.

Lights are standard 7 inch - indicators LED units sold for LandRovers etc

As I said anyone wants to have this done contact Steve Deacon he does a great job and not too pricey.

Jon

Certainly a very talented man Jon. Lucky to have found him I would say.

Woodie - strikes me this thread needs to be renamed if that is possible - extreme customising - or something like that.
Jon