Replacing a roof...car rolled over

grandpa pete · Last edited by grandpa pete on Sat May 11, 2013 12:55 pm; edited 1 time in total

This thread will be a how to for anyone who needs to do this in the future...the owner was driving in the rain;slid sideways on a curve and rolled the bug on it's side and top...A local body shop straightened the roof structure and doorframe and abandoned the project ....I took this on as a to-do project on my time schedule and the owner covering costs,( I like challenges;especially when someone else is paying)..I will be separating the outer roof from the inner structure and grafting a "new " undented replacement;see roof in background ...the severe damage to the driprail and some of the inside structure made replacement easier than trying to straighten everything out....today I installed an outside fan in my work area and took some "before photos" .

Image may have been reduced in size. Click image to view fullscreen.

I will be adding photos and commentary along the way
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63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

EilatBug · Posted: Fri May 10, 2013 9:21 am Post subject:

Good luck and respect its aint going to be easy if it was me i use roof from another beetle

slalombuggy · Posted: Fri May 10, 2013 9:29 am Post subject:

I would cut it at the pillars and put an entirely new roof on it, far to much damage to the inner structure, but that's me.

Good luck, looking forward to watching this one.

brad

mrmarcdude · Posted: Fri May 10, 2013 1:48 pm Post subject:

I've cut a roof off, but never put on back on... good luck! Popcorn

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- Marc M.
-65 Beetle -1600dp-

grandpa pete · Posted: Sat May 11, 2013 12:41 pm Post subject:

Today we started by protecting the interior from cutting and welding sparks

The tools necessary Mini grinder,cutting wheels,protective face shield. a spray bottle of water for when the inside roof padding catches fire....also recomended are heavy gloves and a long sleeve COTTON shirt

Cut twice;measure once...The pink string is tied to the dome light wire... Very Happy

I hope the sharpie marker doesn't ruin the paint Rolling Eyes

Rough cut to remove the bulk of the damage

There is an inner metal structure around the front and rear windows that will remain intact.I will be drilling out the welds and removing the outer metal
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63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

demon1018 · Posted: Sat May 11, 2013 2:56 pm Post subject:

HELL YEA! NO FEAR! Cool

the only thing i would have done different is pulled the interior . how do you plan on welding without anything coming down and burning something? tig welding? even then your taking a chance and the time you would save not dealing with all that inside . but thats just me. at least you had the balls to even fix it! looks awesome so far. im sure it will be great when its done

Longrifle · Posted: Sat May 11, 2013 5:43 pm Post subject:

HaHa...you're half way there, make it a Vert.
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Longrifle

67’ sedan
66’ SO-42

jjohnson67 · Posted: Sat May 11, 2013 6:48 pm Post subject:

Am i the first? First pics i saw a padded dash. 2nd set... wrong section. Still curious as hell. Sorry 2 be a dick. Laughing

grandpa pete · Posted: Sat May 11, 2013 7:04 pm Post subject:

Your point Dick?...same car same yard;different angle
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63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

Boom · Posted: Sat May 11, 2013 9:09 pm Post subject:

jjohnson67 · Posted: Sun May 12, 2013 9:57 pm Post subject:

Sorry grampa... ambitious project. Looks good Rolling Eyes

6Kabrio7 · Posted: Sun May 12, 2013 10:22 pm Post subject:

Nothing personal Pete I applaud your ambition but post 67 project bugs are a dime a dozen really. I would have just bought a nice roller and swtiched everything over.
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67 Convertible July 67 Yukon Yellow
67 Sedan May 67 Zenith blue

grandpa pete · Posted: Mon May 13, 2013 4:23 pm Post subject:

not my car ..not my choice.....remember; a challenge and someone else is paying to entertain me....Semi retired,lots of time,if i wasn't doing this i might be home bored watching TV...6 days work this month Shocked

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63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

Culito · Posted: Mon May 13, 2013 5:53 pm Post subject:

rgdedge · Posted: Mon May 13, 2013 7:19 pm Post subject:

Glad to see you save it for some one. Not "A dime a dozen" around here. A nice bug any year bring good $. I like all,bugs all years.
Tim
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youngnstudly · Posted: Mon May 13, 2013 11:10 pm Post subject:

You're a brave soul tackling that job. After watching my father perform rust and collision repair for many years, I've learned one thing from it all...Don't get involved with heavy projects like the one you're doing, especially if you are getting paid very little to do the work. If the owner (who obviously has trouble keeping control of their car while driving) has another accident and your repair work fails (even a simple weld breaking), they will blame you and possibly sue the pants off of you. Even if nothing you did fails, they'll drag you into their mess if they think it will get them ahead or out of a jam.

It's all cool when you're working on their car (after every body shop in town laughed them out the front door), and doing the work cheap, but if the worst should happen, they will never bring up the fact you got paid peanuts and did decent repairs on their car...they'll leave that part out and instead tell a story of how they thought you were a licensed shop and they paid you top dollar to do the repairs. My father never got involved doing this sort of work to customer cars (he only did repairs of this nature to personal cars he would build for my mother or himself), but he knew of a few "hacks" who did this sort of work on a regular basis, and it came back to bite them in the rear later on.

Anyways, keep up the good work, and keep the photos coming. I didn't mean to rain on anyone's parade, just pointing out the obvious. It's always nice to see different methods of repair work being done. Your method looks to be one of the better approaches. It always astounds me with these cars how many spot welds the factory uses, and some of the awkward places they put them. Good luck!

Andy
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The economy is in a state of disaster, we have NO time for common sense!

grandpa pete · Posted: Tue May 14, 2013 8:58 am Post subject:

Youngstudly, please correct Very Happy

.........WANTED...Good Woman...must be able to cook , sew , set points , change condensers and spark plugs......Must own old Volkswagen and a complete set of tools.....PLEASE SEND PICTURE OF OLD VOLKSWAGEN AND TOOLS....... Very Happy

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63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

grandpa pete · Posted: Tue May 14, 2013 12:07 pm Post subject:

FEEL THE SAMBA LOVE !! Very Happy

THANKS EVERETT!! Very Happy

Got a pm asking if i wanted a roof with a lot more rear window edge than I had !!! SCORE!!! Local and FREE !!! ( in the photo the darker roof in the background is what I was going to fit. It will be easier to line up the peices with the extra metal in rear )

_________________
63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

grandpa pete · Posted: Tue May 14, 2013 12:14 pm Post subject:

Read about this tool on samba ( I read build threads during the commercials on TV )....Can't wait to try it....$15 for tool $15 more for extra bitts

_________________
63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

Lidpainter · Posted: Tue May 14, 2013 12:46 pm Post subject:


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