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Mellow Yellow 74
Samba Member
Joined: October 14, 2014
Posts: 1615
Location: Sydney, Australia
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 Posted: Thu Apr 16, 2015 3:36 am Post subject: Door Rust Questions |
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I am embarking on a resto of my RHD 1962 KG and have removed the doors and door cards. I was expecting to find rust in the bottom and they were ok apart from one very dodgy previous patch that will need to be repaired. However, I did find rust at the top on the inside and in the sheet metal bracket on the inside of the door handle as per the photos below:
I have a few questions, as follows:
- Is rust at the top like this unusual and what can I do to prevent this in future?
- Instead of making a weld repair at the top on the inside in an area you don't see and doesn't seem to do much, would there be any issues in just cutting this rust out and dressing it back so it is tidy (I understand the purists will not like this idea)?
- The bracket on the inside of the door handle is different on each side. On one side it goes back around to behind the other rusty area but on the other side it doesn't. Are these meant to be different on each side?
- What is the bracket on the inside of the door handle called and where do I buy new ones (I can't find them on the web)?
Any advice appreciated.
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1962 Karmann Ghia
1974 Deluxe Microbus
1985 Caravelle (Vanagon) |
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TheFop
Samba Member
Joined: February 03, 2014
Posts: 302
Location: Auckland - New Zealand
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| Posted: Thu Apr 16, 2015 3:43 am Post subject: |
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I'll be watching this as I have the same sort of issues with my doors.
Correct me if I'm wrong but from the picture I'd guess the plate over the handle is an anti theft bracket to try and stop people sliding a piece of flat down into the door to pop the lock. I should see if mine has this as its only 1 year earlier.
It may be worth contact Vinco at Vics Autobahn as he's in your neck of the woods.
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Rusty 61 RHD Karmann Ghia Coupe - Resto in progress....slowly
Stock 69 LHD Karmann Ghia Coupe - Driver
67 New Zealand Spec Beetle - Being rebuilt
63 New Zealand Spec Beetle - Going Baja!
86 T25 Westfalia - Family Fun car |
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c21darrel
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Joined: January 22, 2009
Posts: 8211
Location: San Dimas
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SoCalJes
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Joined: November 02, 2011
Posts: 1093
Location: Broward, FL
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| Posted: Thu Apr 16, 2015 11:44 am Post subject: |
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As long as you remove the rust, prime and paint so you do not loose any more metal you will be fine. Rust can start with a scratch exposing bare metal, feed it moisture and it will eat the rest of the car. 
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Jesse
71 Ghia
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Just because it didn't come that way, doesn't mean it shouldn't have. |
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c21darrel
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Joined: January 22, 2009
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Location: San Dimas
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SoCalJes
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Joined: November 02, 2011
Posts: 1093
Location: Broward, FL
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| Posted: Thu Apr 16, 2015 1:50 pm Post subject: |
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| c21darrel wrote: |
^^car was probably just stored upside downunder.  |
Sounds like something Mark would say 
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Jesse
71 Ghia
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Just because it didn't come that way, doesn't mean it shouldn't have. |
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c21darrel
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Joined: January 22, 2009
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Location: San Dimas
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Loren
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Joined: January 10, 2004
Posts: 1701
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| Posted: Thu Apr 16, 2015 6:03 pm Post subject: |
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| Instead of cutting out the rust and leaving it, you might want to weld in new metal and make it like it was originally. The extra metal will help the interior of the door from flexing and causing stress cracks. |
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Mellow Yellow 74
Samba Member
Joined: October 14, 2014
Posts: 1615
Location: Sydney, Australia
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| Posted: Sat Apr 18, 2015 3:14 am Post subject: |
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| Loren wrote: |
| Instead of cutting out the rust and leaving it, you might want to weld in new metal and make it like it was originally. The extra metal will help the interior of the door from flexing and causing stress cracks. |
Yeah, you are right so I have cut the rusty bits out and will get some sheet metal folded up and weld it in.
I have also removed the brackets behind the door handles and they were welded to the door skin but only around the rear bolt hole. I will get some sheet metal folded up to replace these as well.
Also I have cut out the old repair patch and it had been welded on top of another patch that had rusted out. It was a mess so I cut it all out and will have to fix it properly.
I will start a resto thread and post more photos of these repairs.
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1962 Karmann Ghia
1974 Deluxe Microbus
1985 Caravelle (Vanagon) |
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Matanin
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Joined: March 15, 2015
Posts: 11
Location: Simi Valley, Ca.
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| Posted: Sun Apr 19, 2015 7:07 am Post subject: |
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| Por 15 is the best rust inhibitor, use both the cleaner and prep. |
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