Beetle frame head replacement

[davidpot53]

Hi Everyone

I have found a lot of good information on this forum and i am sure someone will be able to help me, having issue to align my new frame head, it's out by at least 10 mm while positioned in the same jig as the old one came out.
Brand IGP

i think i might end up cutting the good tunnel side of the old one and make the new one fit or find a second hand head which is pretty hard.

What are your though folks ?

Thanks

[BuggyFaron]

I'm having the very same problem, what did you end up doing?

[Goshen]

I am replacing my Frame head about 6" from the tunnel to the front where the beam mounts...

Here is the Ugly rot

Now comes the fun part to measure to know where to cut and then install new piece or rather weld it.

_________________
My '64 Pan Meyers Manx Dune Buggy "Lady in Red"
https://www.thesamba.com/vw/forum/viewtopic.php?t=659260

My '67 Split Window Bus project :
http://www.thesamba.com/vw/forum/viewtopic.php?t=634144

My '67 Maserati Blue Oceano Bug Build:
https://www.thesamba.com/vw/forum/viewtopic.php?t=541870

[Goshen]

Chronological sequence ... No captions.

Measured the distance from the Shift lever cutout to the edge of the Frame head and I got 32.5"
I made all the markings and used the Sawzall to cut the bad rusty frame head off:

I secured the sides with two visegrips one for each side and made my first weld on top to secure it.

Marking the yellow tape as to where the plug welds will go.

Went to town on fusing the replacement frame head and the original tunnel.

Now to secure the Napoleon Hat

All done

Now to fill the underside where most of the rot was ..

_________________
My '64 Pan Meyers Manx Dune Buggy "Lady in Red"
https://www.thesamba.com/vw/forum/viewtopic.php?t=659260

My '67 Split Window Bus project :
http://www.thesamba.com/vw/forum/viewtopic.php?t=634144

My '67 Maserati Blue Oceano Bug Build:
https://www.thesamba.com/vw/forum/viewtopic.php?t=541870