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Old 12-18-2018, 04:59 AM
Bruno Bruno is offline
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Default Porsche 356 Karmann body floor plugs

Hi
I made floor plugs for my karmann hatchback BT6. The floor plugs in the rear seat pan was badly repaired and I did not know about the rust beetween the foldings.



So I decided to remove they. I searched a wile for spare parts with no succsess.
Here is my way how I made it.
Idea Karmann body floor plugs

Idea:



Some time ago I built a little press. Now I need some dies to press a round blank into it.

1. Blank and first lower die to press the cup









Cup



2. Upper die to press the cone





3. press the flange (Upper die missing in the Picture)



The yield could be improved.


And folded into a test piece with a 50mm hole

Inside:



Outside:



I am satisfied with the result. It was not a 5 minutes Job. For more parts, the process must be saver. My experience with this little project is:
- The blank must be perfectly round and must have a smooth edge. Otherwise it creats folds on the flange.
- The diameter for this application allowed no reserve. 2mm more and after the first step (cup) you have a wavi flange.
- Whe you press the cone, all parts (Upper, lower dies and part) must be precise and fix in line. Otherwise you will have to much scrap like me.

Bruno
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Old 12-18-2018, 06:31 AM
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MP&C MP&C is offline
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Nice job!!!!
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Old 12-18-2018, 06:57 AM
cliffrod cliffrod is offline
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Those do look good. What gauge and kind of metal did you use, simple cold rolled steel or ?
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Old 12-18-2018, 09:36 AM
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Kerry Pinkerton Kerry Pinkerton is offline
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Nice work Bruno. Thanks for documenting the process.


I'd think there is a market for these. VW's are really hot these days.
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Old 12-18-2018, 09:50 AM
Bruno Bruno is offline
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Quote:
Originally Posted by MP&C View Post
Nice job!!!!
Thank you.

Simple cold rolled steel 0.75mm (between 21 and 20 gauge?!).

Bruno
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Old 12-18-2018, 09:58 AM
galooph galooph is offline
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Good skills, Bruno! Very creative!
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Old 12-18-2018, 10:05 AM
Bruno Bruno is offline
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Quote:
Originally Posted by Kerry Pinkerton View Post
Nice work Bruno. Thanks for documenting the process.


I'd think there is a market for these. VW's are really hot these days.
Thanks Kerry

As I wrote, my process for delivering to a market is not really effective. Calculation with a Swiss price per hour, they would be very expensive.

And they are not for a VW. They are for the Porsche 356 with bodys who are built by Karmann. But maybe the Karmann VW have the same..

Bruno
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Old 12-18-2018, 10:07 AM
Bruno Bruno is offline
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Nice job!!!!
Thank you!
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Old 12-18-2018, 06:14 PM
Jaroslav Jaroslav is offline
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Nice work and good result. How much do you have the Karmans?
I would use a lathe for those two eyelids. In a rotating way - the spinner makes it easier to make. No special preparations. Ball bearing on tool tool point.
But a good example thank you for sharing.
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Old 12-19-2018, 06:03 AM
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very nice bruno
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