TheSamba.com :: View topic

Fri Sep 05, 2025 10:53 am

First post, been lurking since last year. Thanks for all the great advice I've read so far! Trying to put a 1970 Bug sedan back on the road. Was my daughter's first car, but it's been sitting many, many years (20+?).

I'm starting by trying to rebuild the front end with all new components and do a disc brake conversion while it's all apart. Of course I found the front firewall rusted through on the passenger side. (that's why the carpet used to always be wet!).. I found it stuffed with caulk, body filler, and newspaper!

So... is there a method of repairing this without removing the body from the chassis? Can I just make a patch panel and weld it in? On the inside and outside? It looks like this is where the body rests on the "Napoleon Hat" and there is a rubber seal between. The seal is there although not in perfect condition. I would not want to weld the two together so the body could not be lifted in the future.

Bottom line: how can I seal these holes to prevent water from entering the passenger compartment?

I'm not restoring this car - I just want to drive it. I'd like to do it as close to the "right" way as I can. I just don't have the means to remove the body at the moment..

Thanks for your patience and thanks in advance for any suggestions!

Fri Sep 05, 2025 12:10 pm

That is a very common rust area. For a quick repair you could weld or rivet in some patch panels and cover them with seam sealer to keep water out. Years ago on long Island when my bugs were daily drivers I would put screening over the rotted area in the wheelhouse and cover with several layers of roofing tar. It kept the water out.