Windshield Lip Repair Help *FINISHED!*

dreadnotmusic · Last edited by dreadnotmusic on Sun Oct 26, 2008 5:47 pm; edited 1 time in total

So I've taken the plunge and decided to fix my rusty lip the correct way. I've got the bus depot replacement lip on hand and have made a nice cut along the front of the rusty section.

There seem to be spot welds holding the rearmost section of the lip to the back panel. Can anyone offer advice on separating the two lips?

Thanks!

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66 Riviera

VDubTech · Posted: Sat Oct 11, 2008 12:40 pm Post subject:

Get a spot weld cutter. Drill them out.

dreadnotmusic · Posted: Sat Oct 11, 2008 12:53 pm Post subject:

Thanks VDubTech...

Any chance Kragen or PepBoys carries these? Ace Hardware perhaps?
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66 Riviera

Bleyseng · Posted: Sat Oct 11, 2008 1:08 pm Post subject:

A FLAPS might or should but a auto paint store will have good ones with replacable teeth. Drill only thru the first layer of metal!!!! split the pieces with a sharp flat tool.

My trick when installing new metal is too lay it over the spot its going, tack it in at the lip and then using a dremmel cutting tool, cut along the edge of the new piece using it as a guide to fit it to the old. Then you have only a small 1/16th gap to weld and fill.
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gmag69 · Posted: Sat Oct 11, 2008 3:19 pm Post subject:

dreadnotmusic · Posted: Sat Oct 11, 2008 3:35 pm Post subject:

Thanks guys, great tip on fitting the new one. I got the spot weld drills from a local auto body supply shop. Nice and easy, though I went deep in a couple spots.

Here is my progress so far. I'm going to have to fill a couple gaps, but not bad for a first timer!

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66 Riviera

Bleyseng · Posted: Sat Oct 11, 2008 5:11 pm Post subject:

looks good just keep fitting it til its really close as its hard to fill with the welder. Even with a MIG with gas its hard. I hope you are using a wire feed MIG with gas as thats pretty damn easy to weld lite gauge metal with.
_________________
70 Ghia Black convert-9/69 build date-stock w/133k 1600 SP-barn find now with a rebuilt tranny and engine
77 Westy 2.0L w/Ljet, Camper Special engine-95hp and with LSD!(sold)
76 Porsche 914 2.1L L20c, 120hp Djet (sold)
87 Syncro Westy Titan Red 2.1L 2 knob 100k miles

dreadnotmusic · Posted: Sat Oct 11, 2008 5:15 pm Post subject:

I'm using a Miller-Matic portable welder with .035 wire. The shielding gas for this unit is CO2 only due to the size of the bottles. I hope it's not too dirty.

I'm a bit worried about filling gaps. I don't know if the nose skin has relaxed and opened up the gap because there's much more of one than I measured for. I might have to cut some filler metal from some sheets that I have.

Oh,,,,this is my first weld job. I borrowed the unit from my work. I've never worked metal before. Shocked

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66 Riviera

busdaddy · Posted: Sat Oct 11, 2008 5:27 pm Post subject:

OOooohhh.... this should be interesting, take lots of pics as you learn Wink

Start by welding the outer edges, as things shrink the middle gap may close up.

Nothing wrong with Co2 but you really should get to know the welder on the scrap parts first, a W/S lip repair can go sideways really fast if you're a noob.
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Paul D · Posted: Sun Oct 12, 2008 5:36 am Post subject:

More pictures please!

I need some inspiration to see if I can do it myself, keep it up.
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KantDriveFast wrote:

2VWs1BMW · Posted: Sun Oct 12, 2008 6:28 am Post subject:

Dread,
Don't worry about the nose skin so much. Get a bunch of small vice grips and clamp the repair pieces to the inner support and then trim the panel to fit to the nose. This took several iterations on mine, but the end results were perfect.
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gmag69 · Posted: Sun Oct 12, 2008 8:51 am Post subject:

If you drilled through both panels with the spot weld cutter here's what you do. This goes for any place there is a gap you need to fill as long as you can get behind it. Get yourself a piece of copper pipe big enough to to cover the hole. Now smash one end of it flat leaving the other end open to use as handle. Now hold the flat part to the back of the hole and weld the hole closed. The weld will not stick to the copper and helps keep you from burning through the metal. Just a FYI. Keep up the good work. Cool

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http://www.thesamba.com/vw/forum/viewtopic.php?t=230285

dreadnotmusic · Posted: Sun Oct 12, 2008 8:55 am Post subject:

Good tip Geno, thanks. I'm probably going to wait on the welding until a co-worker comes over to assist. He does this for a living, and I don't want to screw it up. I bought a sheet of 22ga weldable steel because the replacement piece doesn't fully cover the section I had to cut out. I might have to fit a couple small strips in there to close the gap.

I've ground down all the rust on the inner lip and plan to spend the day laying a nice coat of silver POR15 on there. I don't want to do this again.

Thanks for the tips so far. My wife can't believe I cut a bit hole in our bus. Shocked

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66 Riviera

PicklePickle · Posted: Sun Oct 12, 2008 11:36 am Post subject:

Joey · Posted: Sun Oct 12, 2008 12:03 pm Post subject:

dreadnotmusic · Posted: Mon Oct 13, 2008 6:37 pm Post subject:

Lot's of progress today! Thanks to a fellow VW enthusiast and welder from the local VW group "NAG" www.norcalaircooledgroup.org , I'm miles ahead of where I was yesterday. It's a tribute to the VW community that he was more than willing to drive 30 miles to my house and complete this job with no compensation. I objected, of course, on the compensation part. Laughing

I can't thank him enough!

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66 Riviera

gmag69 · Posted: Tue Oct 14, 2008 3:26 am Post subject:

Sweet. Glad to hear you got it fixed. It is cool someone was willing to come help ya out too. I guess VWs bring out the best in people. Cool

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Check out my Westy resto. thread.
http://www.thesamba.com/vw/forum/viewtopic.php?t=230285

dreadnotmusic · Posted: Wed Oct 22, 2008 3:45 pm Post subject:

Alright, several folks asked for a follow up on this so here's where I'm at. Here's a shot of the repair just after the welds were all ground down and a nice coat of POR15 was added and then sanded.

Here she is rolled outside to check the sanding and filler work I did. Not much filler used at all. Everglass filler went on first to smooth things out and then a light skim of Metal Glaze to cover the pin holes.

Here's how it sits now, with a nice coat of Epoxy primer. I'm waiting on a painter to come over and give me a quote on spraying the front panel. I want my bus back on the road!

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66 Riviera

gmag69 · Posted: Wed Oct 22, 2008 7:25 pm Post subject:

Lookin good man. Can't wait to see it all painted with the windshield in. Cool

_________________
Check out my Westy resto. thread.
http://www.thesamba.com/vw/forum/viewtopic.php?t=230285

Patrick199 · Posted: Wed Oct 22, 2008 7:43 pm Post subject:


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