TheSamba.com :: View topic

Mon Apr 16, 2012 9:06 am

I found rust in my Napolian Hat (front Cross Member) where the bolts go through the pan and into the heater channels. Now I dont want to replace the entire hat but I wasnt sure the best way to attack this. maybe just replace the end pieces??
thanks timmyz

[/img]

Mon Apr 16, 2012 10:07 am

You are the Engineer on your build. Cut it to your specifications, but First use your wire wheel on it to bare metal back to where the metal is suitable for welding. Buy a replacement section and cut it to fit/weld with Panel Clamps from Harbor Freight.

Mon Apr 16, 2012 6:03 pm

The ends of my Nap hat were totally gone. I cut off the ends until I got back to solid steel. Then I bought the replacement nap hat piece and cut off the corresponding ends and welded them on.

Mon Apr 16, 2012 8:25 pm

I don't like to buy anything
fab it back together !

Tue Apr 17, 2012 6:30 am

JerryMCarter1 wrote: I don't like to buy anything
fab it back together !

Come on Jerry, you really going to fab up the complex curves of that Napolian Hat? That's some thick metal to form. I have enough work to do without reinventing the wheel. I appreciate preformed pieces that make doing a job easier! And even those need to be massaged to get them to fit right.

Tue Apr 17, 2012 8:42 am

Each to his own
Less than two hours there and they would be done !

Tue Apr 17, 2012 4:58 pm

Take several measurements and make an alignment jig of sorts and remove and install a new one. Easy fix.

Tue Apr 17, 2012 6:16 pm

Check out vosaclub.org, based out of San Antonio. Lots of folks on there know people who can help. Hardknockscustoms does a lot of VW stuff for the San Antonio and Austin VW owners.

Wed Apr 18, 2012 3:57 am

I restored my Napoleons hat using bits of metal laying around. As long as the surrounding metal is thick it is pretty easy to weld. You can even use a regular stick welder (I did).
The main concern is how much rust there is on the inside...

Wed Apr 18, 2012 10:16 am

Here's how I did mine. hope it helps you.

First take a look inside and to do that you'll have to cut into it and clean it up.

Cut out what is needed.

The lower steel is heavy stuff so you need to line up some flat stock for this piece and cut to size and cut the oval holes.

Then weld it in and clean it up with your grinder.

I have a lot of respect for someone that can shape metal into this shape but I'm not nearly that good so I bought one.
Line it up, mark it, then cut to fit.

Clamp it in place, make sure everything is all good.

Then weld it in and clean it all up with your grinder.

Easy Peasy! Good Luck and I hope this helped!

Jim

Wed Apr 18, 2012 10:42 am

nice work
nice doggy !

Wed Apr 18, 2012 11:42 am

JerryMCarter1 wrote: nice work
nice doggy !
Thanks Jerry!

Gotta have the shop dogs for entertainment!
And they let you know when it's getting late.

Jim

Wed Apr 18, 2012 11:43 am

Nice clean steel! Such a beautiful thing, kinda brings a tear to my eye! :D

Wed Apr 18, 2012 11:57 am

beetlenut wrote: Nice clean steel! Such a beautiful thing, kinda brings a tear to my eye! :D

Ha! Ha! Yeah, This one wasn't too bad at all. But it's the photo's I have.

If you wan't to see some sheet metal repacement photo's go to beetlenut's photo's!

Dude, you are a madman! I would have never taken on that project!

Kudo's to you!

Jim

Wed Apr 18, 2012 2:12 pm

you made my Day

I miss my doggies!

Jerry

Wed Apr 18, 2012 7:38 pm

BXRJIM wrote: beetlenut wrote: Nice clean steel! Such a beautiful thing, kinda brings a tear to my eye! :D

Ha! Ha! Yeah, This one wasn't too bad at all. But it's the photo's I have.

If you wan't to see some sheet metal repacement photo's go to beetlenut's photo's!

Dude, you are a madman! I would have never taken on that project!

Kudo's to you!

Jim

Thanks...
I would never have taken on that project either if I knew what I know now! Eventually I'll run out of car to fix!. The front firewall is proving to be the biggest challenge so far.

Wed Apr 18, 2012 8:41 pm

piece of cake for you beetle nut
Never second guess yourself

Thu Apr 19, 2012 6:06 am

Awesome thanks for all the Tips and Tricks. I took the advise and purchased the "Nap" Hat and now waiting for it to show up. I busted out my sandblaster and cleaner the pan up real nice, then covered it with a primer for now. as soon as the hat shows up I will take a bunch of pictures and post up my work.
:D

Thu Apr 19, 2012 7:40 am

JerryMCarter1 wrote: piece of cake for you beetle nut
Never second guess yourself

Why thanks Jerry. It never seems that way going in, but always works out once you rip it apart and see what's what.

Thu Apr 19, 2012 7:45 am

timmyz wrote: Awesome thanks for all the Tips and Tricks. I took the advise and purchased the "Nap" Hat and now waiting for it to show up. I busted out my sandblaster and cleaner the pan up real nice, then covered it with a primer for now. as soon as the hat shows up I will take a bunch of pictures and post up my work.
:D

It will be easy and obvious with the pan separate like it is. Just be happy you're not going at it with the body on. I would however make some cardboard templates of the two bolt holes in each end with respect to someplace on the pan, so you can line up the new piece(s).