TheSamba.com :: View topic - Northeast fatty rustback- Noobie 'How To' time

Wed Mar 26, 2008 1:35 pm

RafCarre12 wrote:
I also cut off a little more of the rusted out pieces. Rough shaped the hole up some too. I think I am going to need to box in underneath where the new to me pieces and the existing part of the car is going to meet... that would make me feel better about the work.

Oh and if anyone can help me fill these holes, it would really be appreciated. I don't think this hatch is original to the car so I'm not exactly sure what part number I should be looking for.

I think I'd rebuild /remake the lip for the "new" pan section to join into, along the edges were part of it rusted away (wheel well s, and the front edge). For the area nearest the carbs, I'd add a lip to use as a ledge (maybe shaped like a piece of angle, for stiffness), and use / do it as a seamed joint. That way you can grind it flush, and hide most of that joint. It would probably be the cleanest way to do it. I'd also epoxy prime, or use some POR 15 on the area you've currently got exposed, as this is the best time to seal it, and help keep future rust at bay. Maybe even do the repair patch as well, since once it's welded in, you won't be able to get at it again.

As for the deckid, you just need to hunt up a standard VOLKSWAGEN script (same part as a bug), as that was what normally went there. Or you could take a copper block, and plug weld them closed from the inside. You'll have to paint those spots though, as they'll start to rust in 12 hours(if it's as humid there as it is here). I hope this helps.

Wed Mar 26, 2008 2:04 pm

That's exactly the plan with adding extra angle supports... the only difference is that I am going to be flanging and well welding the joints as they did in the factory. Thanks for the tips!

Stay tuned! I'm hoping to be doing the test fit this weekend. :-k

Here is what I got done today...

The "Shop"

Took the underbelly pieces off

Cleaned up the top end some too. Its getting a little closer to the shape I need to fit into the car. :)

Saving all the scraps for the support angles I'll need to make

And the trusty assistant ever so photogenic

Thu Mar 27, 2008 1:12 pm

RafCarre12 wrote: That's exactly the plan with adding extra angle supports... the only difference is that I am going to be flanging and well welding the joints as they did in the factory. Thanks for the tips!

Stay tuned! I'm hoping to be doing the test fit this weekend. :-k

Here is what I got done today...

The "Shop"

Took the underbelly pieces off

Cleaned up the top end some too. Its getting a little closer to the shape I need to fit into the car. :)

Saving all the scraps for the support angles I'll need to make

And the trusty assistant ever so photogenic

Mine needs the exact same treatment. If anyone else has a good donor section like this HELP ME OUT!!!

Thu Mar 27, 2008 1:59 pm

I know there is someone in the classifieds selling the same area off of a part out.

Thu Mar 27, 2008 3:31 pm

You're ambitious with the rust repair! When you get the header, you'll really like the exhaust note. You MUST fit some Beetle fresh air hoses to blow from the fan outlet necks into the top of the heater boxes. MUST. Unless you remove the HB's which I would not suggest. Attach the hoses using clamps to the outlets, then using a Beetle stock muffler metal collar that you SCREW into the HB. Then fasten the fresh air hose to that. On my car with a similar header, one of the fresh air hoses came off the HB, and after about 1/2 hr fast highway speeds, the heat inside the HB from the exhaust overheated the cylinder and piston directly above it. Got the car home on a tow hook... :oops: :x

Fri Mar 28, 2008 5:27 am

This might sound abit strange but i have soldered up small holes on my vw like that on your hatch. Just make sure you wash the area afterwards well.

Sat Mar 29, 2008 12:04 pm

I'm actually working on the rear floor pan right now but this came in the mail and just had to post a picture of it. THREE WHEELIN!!!!

Sat Mar 29, 2008 2:21 pm

Okay, this is what I accomplished today. I removed the plate that would regularly face the engine (what a pain in the ass!!!). I also trimmed some of the bits off of the "horns" and ground down some of the spot welds both on the donor piece and in the car.

This is a better shot, you get a really good idea of the piece that is going to line up with the engine cover surround...

The pile of "scrap" is getting bigger and bigger...

And the obligatory assistant shot sniffing the fattie...

Sun Mar 30, 2008 12:18 pm

So it being Sunday, I didn't really feel like cutting any metal. Frankly, I'm getting kind of bored with grinding down the donor piece so no progress there. I did change the oil of the Jetta this morning and cleaned up around the house... this was until about noon or so. It was nice out and I wanted to do something so I decided to tackle the one piece glass.

So I get myself organized and start by removing the door panel. I fully expected to see a finely hacked inner door... I wasn't wrong...

After looking at that picture, I'm sure most of you that have opened a door panel in the past are asking yourselves... is that an F'in piece of wood! To answer your question...

Ingenious, it was used to stabilize the bottom of the single piece rails or whatever that would be called.

Not to be downplayed, notice the craftsmanship when attaching the door handle mechanism...

Does anyone want to buy a single piece kit? I'll include the wood block at no extra charge. :D

Now that the 1 piecer was out of the car, I went ahead and installed the outer and inner scrappers. Although frustrating at first, I figured out that it worked well if, while sitting in the car, I held onto the scrapper with my right hand above the door while using my left hand to push the clips in by running it inside and up to the window sill.

They aren't by ANY means mint but I can take care of that in the near future.... or not. :D

After that, I slipped on the wing glass, slipped in the new to me main glass piece and attached the regulator. Once that was done, I cleaned it up a bit and that was that.

Not too terrible for about 2 1/2 to 3 hours work for never having done it before. \:D/ I left the door panel off the car so I can fix some of badness and to rustproof/reinforce the hacked up metal at the same time I treat the floors, which should be within the next couple of weeks.

OH and if anyone has a good source of the channel liner felt stuff that goes on the in the upper part of the scrapper, please let me know.

Sun Mar 30, 2008 2:19 pm

man, I am impressed. I had my ass handed to me by window scrapers, so it's encouraging to know that it can be done. a little humiliating, perhaps, but encouraging... and they were repro.

which felts are you talking about - the one that runs in the channel that's part of the vent window or the one that runs around the rest of the window? I think both are available from West Coast Metric or anyone who resells their stuff. I got some of the vent window based one at Bughaus here locally.

Sun Mar 30, 2008 4:21 pm

I have some of that felt channel, but will need it myself. It has parts tags on it from West Coast Metric. You might check there.

Sun Mar 30, 2008 7:46 pm

I got mine thru CIP, and it was also from west Coast Metric. Might try looking at some of the bigger local VW shops in your area, as they might have it in stock. By the way, it's called glass run channel.

Mon Mar 31, 2008 12:40 pm

Back on the Sunvisor question??? Are the beetle sunvisors the same??? I finally found the aus. ebay store but it is hard to read. Although I found the rear window blinds

Mon Mar 31, 2008 12:55 pm

67stang302 wrote: Back on the Sunvisor question??? Are the beetle sunvisors the same??? I finally found the aus. ebay store but it is hard to read. Although I found the rear window blinds

Talk to Vic. He is where I got it. Here is a link to his member profile thing:
http://www.thesamba.com/vw/forum/profile.php?mode=viewprofile&u=27124

And thanks guys for the tip on the window bits. I just ordered a set.

Mon Mar 31, 2008 5:58 pm

Small update today: The tires arrived!

Here is a pic of the fronts which are going to be going on the 16x7" wheels.

And the rear which are going to be mounted on the 16x8" wheels. The fenders may need to be rolled a bit so the roller is standing by. I may also need to shave down the upper bracket for the bumpstop but that is okay too.

And last but not least, I purposely ordered these so there would be some difference in tire wall sizes between front and back. Hard to believe but that is only a 2" difference.

And a picture of the tread pattern

The wheels are being stripped and polished as we speak. I'm hoping they are done by next Thursday (the 10th).

Tue Apr 01, 2008 8:32 am

RafCarre12 wrote: I know there is someone in the classifieds selling the same area off of a part out. Good 67 deck section for $80 parts & LABOR! :wink:

Wed Apr 02, 2008 8:36 am

The air flange/punch tool just came in! I'm picking it up after work!!!

Wed Apr 02, 2008 8:45 am

I'm await seeing those tires mounted. 8)

Wed Apr 02, 2008 3:51 pm

Air-Cooled Head wrote: I'm await seeing those tires mounted. 8)

Same here. :lol:

On other news...

Damn flange/punch tool finally arrived! Hopefully, I'll be able to "dry fit" the replacement rear floor panel this weekend.

And the exhaust is scheduled to be delivered tomorrow. Things are coming together!!!

Thu Apr 03, 2008 10:50 am

:D :D :D