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1979 SB Vert Pan off rebuild: Forrest, Forrest Gump
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Weezle
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PostPosted: Wed Feb 11, 2015 6:23 pm    Post subject: Hester channel question Reply with quote

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This is the better one not Klokkerkrap. I believe the primer is electrostaticly applied in and out. Should I spray the Eastwood frame paint inside there anyway?

Does that coating need to be wheeled or sanded off the outside to bare metal and epoxy Prime it or just scuff and prime?

The carpet clamp is different vs the convertible. I'm guessing I need to drill out the spot welds on the old one and weld it onto the new channel: yes?

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

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Dodgy
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PostPosted: Thu Feb 12, 2015 1:16 am    Post subject: Reply with quote

I don't think (thankfully) the really crap heater channels are sold anymore.

Check out this thread
http://www.thesamba.com/vw/forum/viewtopic.php?t=503306&highlight=heater+channel

The heater channel I bought looked the same as yours and was labelled Klokkercrap - but was the better quality of the two shown in the thread. 'Who made what' is always hard to establish with pattern parts.
This panel seemed to fit OK. Possibly the curvature towards the front is different to original panel, which will leave a void that will have to be filled with seam sealer or similar. It's hard for me to tell as I've had to replace all the surrounding metalwork too.

Unless you are prepared to spend BIG bucks on a really nice part...
http://csplink.de/qRHwnAATR2
... there are a few things you may need to do to prep the panel
• OE panel had a couple of holes towards the front (I assume for venting, reduce static air & condensation) which are missing from the pattern part. Up to you if you think it's important to reinstate them, and possibly they are covered by the additional convertible metal
• Front air tube (inside A-pillar) is loose and will need fixing to stop it rattling. It won't be accessible when fitted. Just do one tack weld as you may need to adjust position when installed
• The front section that fits under the bulkhead is too short, you will need to either flatten it and extend the bolt holes, or (better) cut it off and add an extension piece to restore alignment.
• Some people have found that the welded flanges are much wider than the OE panel and can contact the seat mount, causing interference when fitting the body to the pan, so it's worth grinding these back a bit. Same goes for the heater pipe under the rear seat part.
• Not sure about the carpet strip, looks like it might work for the sedan

I assume you are content with the dent towards the rear of your heater channel by the air tube? This is where it fits to the rear quarter inner panel, so you will need to get it reasonably straight to get a good fit.
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'72 Squareback - full resto completed 2008 - now sold
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Weezle
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PostPosted: Thu Feb 12, 2015 1:57 am    Post subject: Reply with quote

Hey Dodgy. Thanks for that info. Th part I got was the heavier one in the thread you linked to.

First noted that dent in the pic I posted. I think it will be hidden inside the quarter panel. I'll line it up against the car and double check.

I always appreciate you info here. If mine is the one with the electrostatic coating can just scuff and prime? Anyone?
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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

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Weezle
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PostPosted: Sat Feb 14, 2015 12:55 pm    Post subject: Firewall battle plan Reply with quote

My kids attempted to turn the car on this "rotisserie wanna-be" it tipped fine but wouldn't stay, the weight was wrong. I could put some 2x4 under the raised end or heavy weights on the other end. but I decided to just crank up one side on the trailer jacks as far as possible and this is what I got:

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If I can manage the firewall repair like this, then I will but I don't relish welding from a laying position.
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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 16, 2015 12:33 pm    Post subject: nutbox extraction Reply with quote

Ok, so got that damn nutbox out of my car. Cut a chunk of rusty firewall out as well. I'm thinking to cut the repair piece out of the firewall I bought, then flange it and tuck it insite the OG metal. Water dripping down will roll off the junction. Maybe puddle weld and seam sealer or a couple of lines of welds along the junction.

I have to make a piece, or cut off the donor a "spacer" that sits between the nutbox and the inner wheel well.

And I have yet to extract the donor nutbox from the chunk I bought in the classifieds. These are really heavy duty spot welds, very hard to remove.

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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: Sun Feb 22, 2015 6:48 pm    Post subject: Will get back to welding in a minute but for now... Reply with quote

Got this 5" dual voice coil speaker for the dash but the factory speaker is 4"x6". So how to fit a square peg into a rectangular hole? I made a Masonite piece to make sure the foam edge had clearance to move. Then added foam soundproofing to the edges and using a coat hanger made a new mounting spring to hold it in place. Now I have to wait to see if it will fit with the air ducts behind it.

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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 23, 2015 9:25 am    Post subject: Vert buttresses Reply with quote

Getting these convertible support buttresses off was a freaking chore. So many welds. I still have the heater channels to look forward to Sad

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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: Tue Feb 24, 2015 3:06 pm    Post subject: Reply with quote

Firewall patch panel

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Donor nut box in place

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New heater channel welded to convertible support rail. Installing this intimidates me but it needs to be done

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I plan to get the welding done within the next 3-4 weeks then off to paint! Smile
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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

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Dodgy
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PostPosted: Wed Feb 25, 2015 12:54 am    Post subject: Reply with quote

Weezle wrote:
Firewall patch panel

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Donor nut box in place

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Bet it feels good to see all this in place, rather than the big rusty hole that was there before!

Did you weld the nut box to the front panel of the firewall - and hence to the heavy reinforcement bracket? That's how it was done originally, for maximum strength in this area (heavy bracket won't do much if only attached to the thin firewall panel)
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'72 Squareback - full resto completed 2008 - now sold
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Weezle
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PostPosted: Wed Feb 25, 2015 3:13 am    Post subject: Reply with quote

Yes Dodgy I welded right through the five holes in the beefy bracket. I drilled the same holes into the firewall patch panel and placed the mother of all puddle welds there. Just didn't photo that yet. Also welded the side of the nut box to the flange on the back wall of the firewall where it meets the inner wheel well. Once the front flange of the heater channel is welded to the back of the firewall that will make the whole area one solid connection.

Can you look at the heater channel/vert reinforcement and let me know if I put enough welds there? I put 2" beads between every bolt hole. I put the support rail as far outboard as the nuts would allow so that it would almost certainly clear the lip of the pan. And I welded the defroster hose connection which was loose as you mentioned previously. Lastly should I add drain holes to the vert reinforcement rails? In not why not. I plan to fill them with waxoil. Thanks for your help.
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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

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Dodgy
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PostPosted: Wed Feb 25, 2015 4:15 am    Post subject: Reply with quote

I've never worked on a convertible, so I'm not familiar with the differences to sedan structure. But if you follow what the factory did for welds, drain holes etc, you can't go wrong really.

Injecting waxoyl or cavity spray is a good idea, so consider access for this. This may mean holes that need sealing later.

Factory holes at rear end of heater channels are a good example of this - see recess in body section photo below. There is a flat steel plug over the hole glued / covered with sealer, following the primer bath at the factory, before exterior paint.

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(thanks for the photo cj2a)
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Weezle
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PostPosted: Wed Feb 25, 2015 6:11 pm    Post subject: Colors being considered Reply with quote

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Florida blue - river blue - raveena green - viper green

Liking river blue more and more. It's the original color and it has a touch of turquoise.

Interior and top will be off white.
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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

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Weezle
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PostPosted: Thu Feb 26, 2015 4:46 pm    Post subject: Reply with quote

Applied gravigard stone chip textured coating to rickers and support rails:
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Applied 3m paintable rubberized undercoat to wheel wells. These will be painted body color

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Dynatron Seam sealer

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Just tying these things out. Waiting until the weekend to do that 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

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Weezle
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PostPosted: Sat Feb 28, 2015 5:18 pm    Post subject: Reply with quote

Holy weld removal Batman:

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Removing it was a three hour adventure.
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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

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PostPosted: Sun Mar 01, 2015 4:16 pm    Post subject: Reply with quote

Working on wheelhouse. 5 beefy spot welds tie wheel well to the body mount "nut box" and the flange on the rear panel of the firewall. Later the new heater channel will be welded to the same area on the firewall making a strong enough structure for the body mount and shock tower stresses.

Got halfway done and ran out of gas (again).

Have to clean up where the heater channel attaches then tack it in. Remate the body to the pan and repair the A pillar before welding the heater channel completely in place.


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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

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PostPosted: Mon Mar 02, 2015 3:55 pm    Post subject: Moment of truth Reply with quote

Today I repaired the panel at the rear of the heater channel and finished welding in the wheelhouse. Then with a bit of finagling got the heater channel in place. All measurements are good. Next weld that sucker in and fix the A pillar.

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One of these at each end should help when dropping the body onto the pan

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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

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PostPosted: Tue Mar 03, 2015 5:24 pm    Post subject: Reply with quote

using two cherry pickers i loaded the body onto the pan and bolted the heater channel on so I could weld it in properly.

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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

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PostPosted: Thu Mar 12, 2015 1:16 pm    Post subject: Reply with quote

Hey. Looks like GREAT progress!
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PostPosted: Sat Mar 14, 2015 5:13 pm    Post subject: Reply with quote

Body is done. Welded and primed. Taking to paint a week from Monday.

Was gonna put engine tins on today but decided to play around with this 924 steering wheel I got on eBay. Put a Wolfsburg emblem in its and leather wheel skin.

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My interior and top had also arrived;

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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

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Weezle
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PostPosted: Sun Mar 15, 2015 8:11 am    Post subject: Reply with quote

some last pics of the final rust repairs

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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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