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Wed Jan 11, 2006 3:00 am

I was talking to a body guy in regards to a planned restoration. My car though has had two small sections cut out of the rear apron to fit a 36hp muffler. This will need to be fixed so that the apron is flush, straight accross.

It probably could be done so that just looking at the car no one would ever be able to tell, but as soon as someone looks under the apron, they would notice the factory "curl" and stamping is missing. I've resigned myself to the fact that I more than likely won't be finding another pre 54 apron ea$ily, if at all. Besides, other than the cutouts, mine is in great condition.

So, what is my second option? Any advice? Has anyone solved this delema before? Can anyone out there replicate this bottom edge to be grafted into my exsisting apron? As aways any help would be much appreciated.

Wed Jan 11, 2006 6:30 am

Quote: It probably could be done so that just looking at the car no one would ever be able to tell, but as soon as someone looks under the apron, they would notice the factory "curl" and stamping is missing.

When they get down to look, just accidently step on their fingers :twisted:

Someone put up a thread about aprons about 4 months ago with good pics to show the small rectangular stampings under the edge. Lots of work to make a real good fake, and it would be hard to hide the seam. That's a tough part to repro without expensive metal shaping tools...and lots of talent.

Wed Jan 11, 2006 6:59 am

Matt, 13 years ago I had a Zwitter on which a PO had installed a '63-era rear apron (accident repair) which of course had the factory exhaust cutouts. Somewhere before that time I read (HotVWs??) that you can get a close match to the rolled-under bottom edge by cutting out a matching section from a trashed original German fender. Use paper to trace the size you need by holding the paper to each of your car's cutouts. I did this and it worked very well. But my car was otherwise a mutt of later body parts so I was certainly not interested to retrofit an H apron. The "solid" rear apron appearance with the closed decklid was all that I wanted.

Wed Jan 11, 2006 7:32 am

Its actually not that hard to repair and make look like original IF it is taken off the car.

There is a heat shield under there as well to keep the muffler heat from baking the paint on the apron.

Wed Jan 11, 2006 7:46 am

I remember a thread here last week I think it was that had a video link to a shop in the UK (I think it was the UK) that showed them making a replacement apron. I can't remember the name of the thread, but will try to find it. Maybe if someone else remembers it they can help me out.

Wed Jan 11, 2006 9:59 am

wolfs rings a bell but i'm not positive

Wed Jan 11, 2006 10:05 am

johnshenry wrote: Its actually not that hard to repair and make look like original IF it is taken off the car.

There is a heat shield under there as well to keep the muffler heat from baking the paint on the apron.

I'm totally willing to take it off of the car. I figure if someone is able to repair it right, they can put it back as well.

Wed Jan 11, 2006 10:08 am

bugman55 wrote: I remember a thread here last week I think it was that had a video link to a shop in the UK (I think it was the UK) that showed them making a replacement apron. I can't remember the name of the thread, but will try to find it. Maybe if someone else remembers it they can help me out.

A video would be great, because whoever I have fix it, would be able to see exactly what needs to be done. Especially since the body guy I have been talking to is very talented, but not an early VW expert. He'd probably jus fix it they way I want, but it is hard to describe to him a factory stamping and have him reproduce it.

Wed Jan 11, 2006 10:15 am

Here is the thread.

http://www.thesamba.com/vw/forum/viewtopic.php?t=148484&highlight=

Good Luck!

Wed Jan 11, 2006 11:44 am

Cut an orignal 56+ donor apron's sections off to the outside of the cut outs and use those sections to weld into your apron.

Wed Jan 11, 2006 12:15 pm

That might work. Would the stampings match up though? Somewhere I remember a thread (as mentioned above) with pictures and comparisions of stampings on thes bottom edge of the apron. I can't find it though after a thurough search. anyone know extly where this thread is?

Wed Jan 11, 2006 12:59 pm

johnshenry wrote: Its actually not that hard to repair and make look like original IF it is taken off the car.

There is a heat shield under there as well to keep the muffler heat from baking the paint on the apron.

If it is a OG split apron it doesn't have the heatshield just the cutouts.. If it is a complete replacement apron it might have the heatshield.

Post-55 don't have the stampings do they?

Here you go:
Rear apron thread in Oval-window section.

Wed Jan 11, 2006 1:37 pm

Quote: If it is a OG split apron it doesn't have the heatshield just the cutouts.. If it is a complete replacement apron it might have the heatshield. I've only one pre 56 here, and it has no shield.

Quote: Post-55 don't have the stampings do they?

Post 55 does not have those rectangular stampings.

P/S I did what Darby describes, on a 56-60 h apron. On those years you almost can't get enough donor metal from a later apron. That's because you need to cut more metal out of a factory twin cutout apron, that if you were fixing the apron at top of thread. So, I'll guess either Darby's idea or What Rome said about fender metal would work good on this particular repair. I ended up with some extra drainholes from using the donor apron pieces.

Can't you make tools to make those rectangles??? I would try a die, made from flat stock. Then weld 4 strips about 1/8" thick to make a shallow box. Then make the male die a little smaller depending on how sharp of an edge you want on the rectangles. How to press them together is something you need to work out. Maybe welded dies on heavy duty visegrips?
EDIT: I just looked at the thread that Hebster put up; those stampings would be tougher to do than I thought. Because they are on a bent edge. I doubt a homemade die would work, it would kink.

Wed Jan 11, 2006 3:01 pm

Man, this is not going to be an easy fabrication job. First there are the stampings, plus the curl and then a bow or arc as well. It sounds like there isn't suppose to be a heat shield though. (?—will have to look at my car if it has one) Can there be a consensus to agree on that? That could make things easier as far as fixing it I would think…

The pictures on the forum that Hebster52 linked to a couple post up will help a lot. Thanks for that Heb. I can at least show those to whom ever can fix my apron.

Wed Jan 11, 2006 4:31 pm

A good experienced metal master should be able to handle exactly what you need. Hot VWs magazine had a '67 rear apron that was filled, all with mwetal and it was very well done. If you've got a few hundred $$$s to spend, give Danny Gabbard (Gab Fab) a call.

Fri Jan 13, 2006 7:55 am

I stand corrected, there is no heatsheild on the eary aprons. Those dimples wouldn't be that hard to do. You could either make a hinged die, or a punched die with the base section curved.

The cutouts can be easily filled with patches, MIG'ed on both sides and ground down on both side so the reapir is undectable. I actually have an apron I need to do this too, I'll post some pics when I do.

Fri Jan 13, 2006 8:33 am

Why restore such a nice looking car at all?...
Just drive and enjoy would be my suggestion. Once you take it apart
it loses its history (which the "cut out" is a part off).
Just my two cents.

:)

Fri Jan 13, 2006 8:34 am

Why restore such a nice looking car at all?...
Just drive and enjoy would be my suggestion. Once you take it apart
it loses its history (which the "cut out" is a part off).
Just my two cents.

:)

Fri Jan 13, 2006 9:57 am

Jonas Burman2 wrote: Why restore such a nice looking car at all?...
Just drive and enjoy would be my suggestion. Once you take it apart
it loses its history (which the "cut out" is a part off).
Just my two cents.

:)

I totally agree.

Fri Jan 13, 2006 10:28 am

steven wood wrote: Jonas Burman2 wrote: Why restore such a nice looking car at all?...
Just drive and enjoy would be my suggestion. Once you take it apart
it loses its history (which the "cut out" is a part off).
Just my two cents.

:)

I totally agree.

Thanks for the nice words and good advice on my car. I struggle with that all the time and I probably will leave it "as is" for a while. The history is important to me and once I start a restore, I'll never be abe to go back. It is probably also true that I won't be able to enjoy the car as easily once I put a bunch of money into it. Nevertheless, I prepare everyday for when I do decide it is time (collecting parts, information, etc.). Thats part of the fun.

:D :D :D