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1979 SB Vert Pan off rebuild: Forrest, Forrest Gump
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Dodgy
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PostPosted: Thu Jan 22, 2015 1:03 am    Post subject: Reply with quote

Weezle wrote:

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I think I can just patch this. Maybe some puddle welds to the supports behind and then reattach the strut support


Exactly that. Just drill some holes in the patch that line up with these flanges, make sure the flanges butt up tight to the patch (or vice-versa, I guess) and puddle weld through.
Maintaining these structural connections helps keep the body rigid as VW intended. Especially important in this area of a Super, supporting the front suspension and steering loads.
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toddb_67
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PostPosted: Thu Jan 22, 2015 7:33 am    Post subject: Reply with quote

Weezle, don't get discouraged! That is a fairly simple patch you are looking at there. My advice is to keep plugging away at the welding and patching, then turn the car over to the body/ paint shop after you are satisfied with all of your patching. That is the route I took and it can be the difference between paying $10K for paint and body versus the $1600 that I am paying for a complete respray.
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1971 Super Beetle Convertible (sold) http://www.thesamba.com/vw/forum/viewtopic.php?t=582365&highlight=
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Weezle
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PostPosted: Thu Jan 22, 2015 8:29 am    Post subject: Reply with quote

toddb_67 wrote:
Weezle, don't get discouraged! That is a fairly simple patch you are looking at there. My advice is to keep plugging away at the welding and patching, then turn the car over to the body/ paint shop after you are satisfied with all of your patching. That is the route I took and it can be the difference between paying $10K for paint and body versus the $1600 that I am paying for a complete respray.


I know! I am attempting to go this route but even after I fix the last two holes I made, I'm probably about 20% done Sad so much rust! 20% estimate is based upon what I can see. Once I start digging it, I'll probably have more than I currently think I have.
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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Weezle
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PostPosted: Thu Jan 22, 2015 12:25 pm    Post subject: need some advice Reply with quote

regarding this hole which involved the back of the front wheel well and part of the heater channel:

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Do I need to make a small square patch for the heater channel, or can I just put the inner wheel well patch on there?

This one is harder:
lots of rust in heater channel, rear of wheel well plus pretty moth eaten convertible support rail:

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also remember on this (the left side) I have that issue where the firewall bolts down to the napoleans hat thingy on the pan:

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Any suggestions on how to proceed here? What is the "order of operations?" I am having trouble envisioning how to support the body while removing the entire conv. support rail. Maybe I should bolt the body back onto the pan to do this part??? any suggestions greatly appreciated.
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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ToughBug
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PostPosted: Thu Jan 22, 2015 2:11 pm    Post subject: Reply with quote

I had the same question about the heater channel! Ended up fixing the inside tube thinking that would keep the new moving forward like it should. I could be wrong about that though because I think the area I fixed is actually not the "tube" but a space behnd where the tube enters from inside/under the cabin. Anyway it was my best welding, which no one will see!

My rust made me think about finding a cleaner body somewhere out west, just to have something solid to attach stuff to. Just kept finding more rust. The bolts are crumbling, and that's distressing. But I haven't hit on a better body from a model year that will fit all my windows and dash components yet, so I keep welding!

Don't get too discouraged. I figure this is the hardest part.....

(If I decide to head out west I'll come back with a truck of no rust bodies for the east coast!)
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Weezle
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PostPosted: Sun Jan 25, 2015 9:30 pm    Post subject: Reply with quote

Working on the strut mount area.

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To be continued.
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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Weezle
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PostPosted: Mon Jan 26, 2015 1:15 pm    Post subject: rear part of wheelhouse Reply with quote

got more done this weekend than in the last month Shocked

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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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Weezle
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PostPosted: Fri Jan 30, 2015 1:50 pm    Post subject: final pics of rust repair Reply with quote

Here's whats completed so far:

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_________________
I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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Weezle
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PostPosted: Fri Jan 30, 2015 1:56 pm    Post subject: the horror....the horror Reply with quote

ok, anyway I still have all this mess left to do:

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I'm just not sure if I'm up to this job. I think what's left is about 3x whats already done if not more. I could trailer the car to a VW specialist and have the heater channel and convertible support rail put on. I may attempt the firewall repair myself. Assuming my rinky dink rotisserrie will actually flip the car on its side safely. Any suggestions here greatly appreciated! Especially any suggestions for people who can do this job correctly around Orlando. Thanks.
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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ToughBug
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PostPosted: Sat Jan 31, 2015 7:10 am    Post subject: Reply with quote

I feel your pain. You're making good progress and bringing her back from the dead. But sometimes it's hard to find something non-rusty to build out from.

Haven't been able to get into the garage lately but I've been scanning other regions for some type of non-rusty body shell that would magically fit my chassis. It seems like out west they sell super beetle body shells or old cars with good shells for pretty cheap! (Actually, it is a little frustrating to see the difference.) But then there is the $1200 transport fee. Ugh. I found a 73 SB project that someone was giving up on *in my town!* but of course it had all the same rust spots as mine. A twin, apparently. Found 71s and 72s but I'd like to use my new lowering struts, dash items, and glass, and they won't fit those. And I've had the same thought you had: maybe a little professional help would go a long way. No shame in that. I've thought that maybe I'll have my engine done by someone else while I weld.

I have to decide before attempting the front quarter panel replacement - that's my biggest job on the shell. And will require a few new tools.

I did some looking in your area but did not find anything close to your model year that looked like it would be cheap but with a good shell. Maybe a wanted ad here on The Samba?
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Weezle
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PostPosted: Sat Jan 31, 2015 9:24 am    Post subject: Reply with quote

Actually I don't think Forrest is too rusty for an East coast car. Only needing to do one heater channel and the floorboards already replaced by PO makes it worth saving. I already got a lot of time/money in this body, so I will finish fixing it. But if I ever buy another VW I'm flying to the west coast to find one Laughing
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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Weezle
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PostPosted: Mon Feb 02, 2015 5:20 pm    Post subject: right rear heater channel cap Reply with quote

This is where the back end of the heater channel is spot welded to the body cross member. The hole was within the spot weld arc so I cut my patch to fill that area, not messing with the spot welds at all. After removing the undercoating, I noted a tiny hole through the raised portion next to my job. So a coin sized patch welded in there (you can kind of see the outline in the filler to the left and up a bit from the main patch.

Also finally found a setting that makes nice small welds instead of the mondo blobby welds I've been doing so far. Much easier.

I'm in the habit of putting some metal to metal over my patches to make sure they are water tight and sanding that down to fill in any imperfections, then a little skim of rage which I sand too. It ends up feeling smooth and hopefully will hide the welds better. Then again, every single weld I'm doing is going to be hidden anyway Shocked

after media blasting and priming:
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after wire wheeling the factory seam sealer/undercoat off.....I drilled out these spot welds on the right and peeled back that metal. I slid my patch behind there and puddle welded the section together. The patch was cut from a patch panel for this area so it had the right contour to tuck it under that piece.

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final appearance
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I know, where's the pic of the oustanding welds themselves? Doh. I forgot to take a pic of that.
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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Weezle
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PostPosted: Mon Feb 02, 2015 5:30 pm    Post subject: Reply with quote

next up:

planning to roll the car on its side and work on the firewall/nut plate/body mount area in the LEFT front wheel well. Then...I went and ordered the heater channel for that side. Its a bit intimidating but I just keep watching the bug me vid again and again until I get it. Just like studying for a test back in school days. Looking at what I've done so far having zero experience, I think I can do it. We will soon see.
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=


Last edited by Weezle on Tue Feb 03, 2015 4:34 am; edited 1 time in total
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VWCOOL
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PostPosted: Tue Feb 03, 2015 4:32 am    Post subject: Reply with quote

well you've done OK so far Cool
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Weezle
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PostPosted: Tue Feb 03, 2015 4:56 am    Post subject: Reply with quote

Thanks Laughing Check your PM. Had some ?'s about Bosch EFI. Thanks.
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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ToughBug
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PostPosted: Tue Feb 03, 2015 4:18 pm    Post subject: Reply with quote

Nice progress. You mentioned media blasting part of the body. What equipment do you use for that? I could use something to clear off areas I'm patching. Too many small spaces for the grinder.
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Weezle
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PostPosted: Tue Feb 03, 2015 4:54 pm    Post subject: Reply with quote

No I just paid a company to do it. It's not cheap. If your neighbors don't give a crap just soda blast in your driveway with some cheap harbor freight disposatool. I'm on HF angle grinder number 2 already. But for the price can't complain.
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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Dodgy
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PostPosted: Thu Feb 05, 2015 8:52 am    Post subject: Reply with quote

Not sure if you've seen this, from another thread?

http://superbeetlesolutions.com/front-firewall-reinforcement-brackets

Hurrah! Very Happy
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Weezle
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PostPosted: Thu Feb 05, 2015 9:52 am    Post subject: Reply with quote

no dodgy, thanks.

I got a used one that someone kind of sawz alled out of a firewall. I'll have to carefully extract it, but it should work fine. If I saw those new ones I'd probably have grabbed them but the used one was cheaper. I guess if I bugger it up I know where to get another one Laughing
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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Weezle
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PostPosted: Wed Feb 11, 2015 12:35 pm    Post subject: Front Firewall Reinforcement Bracket transplant aka "nu Reply with quote

Swapping out a rusty nutbox for a solid one on the left at the wheelwell. I'm in the process of dissecting out the old nutbox while trying to disturb as little good OG steel as possible. There are at least three areas of rust:

1. the nutbox itself
2. the firewall in front of and to a lesser degree behind and to an unknown degree under the nutbox
3. the wheel well panel

Not sure yet about the support member in front of the nutbox, I think I see some rust, but I plan to flip the car for better access to this area before the weekend. Need to feed pizza to son's friends to make that happen.

Here's some pics, I carefully tried to preserve the lip on the rear firewall that weld that part of the firewall to everything.

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donor:
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the three layers from top to bottom:
nutbox, firewall bottom panel, heater channel
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I got a fever, and the only prescription is more beetles!

http://www.thesamba.com/vw/forum/viewtopic.php?t=604918&postdays=0&postorder=asc&start=0

https://www.thesamba.com/vw/forum/viewtopic.php?t=759868&highlight=
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