My new 1965 Java Green survivor

[edgood1]

I had some bug time over the weekend. I replaced the temporary fuel line with a proper line through the tunnel. I took out the gas tank and everything under it to clean things up a bit.
I took out the interior and did some poking and there was some rust under the tar board floor insulation. The driver's side was worse than the passenger side but not terrible, easy to patch n place. I started with the passenger side.



fishing the new gas line through the tunnel:

Front floor pans are solid.

The driver side rear has some rust through and will need to be cut out and replaced.

The passenger side is much better.

after some grinding and wire wheeling I found a small area in the battery tray that needed patching

A little zip and zap

I prepped and sprayed some epoxy primer.

I ordered a patch panel for the driver's side replacement but I might get impatient waiting for it and make my own we'll see.

Like every old vw, the more you dig the more work you uncover.
_________________
'87 Syncro :: Subaru eng
'63 Samba Conversion ::(photo album)
'65 Westfalia
'65 Bug

[Bobs67vwagen]

That doesn't look too bad, I think I probably would have fiberglassed that with some mat and painted it up and called it a day. Your brake pedal looks like it may be creeping to the rear. Adjust the brakes and check the manual for proper freeplay on the brake pedal and adjust the bracket on the floor accordingly. Nice work on the pans.

[edgood1]

I got some time to work on the bug between other projects.


I cut out the rusty part of the pan

.

The replacement I ordered seems to be a "universal" replacement pan, not correct for a '65 but I modified it to work.

old vs new:

here it is welded in:

Then I tackled the rusty door sill. The heater channel was fine underneath. I cleaned it up and painted it.
First I cut out the rust:

then made a new piece:

and welded it in

then ground the welds smooth.

Next up is the door "A" pillar. Mice made a nest in there and mouse pee rusted it from the inside out, thats why there's weird rust holes all the way up it.
_________________
'87 Syncro :: Subaru eng
'63 Samba Conversion ::(photo album)
'65 Westfalia
'65 Bug

[Bobs67vwagen]

Nice welding and grinding work. What type welder are you using?

[edgood1]

[edgood1]

I welded in the lower pillar section this morning

And cleaned it up

I cut out some more metal above this area that I'll need to replace next
_________________
'87 Syncro :: Subaru eng
'63 Samba Conversion ::(photo album)
'65 Westfalia
'65 Bug

[sportin-wood]

Nice work! How difficult was replacing the fuel line through the tunnel? I noticed you clamped it off where it exits using a piece of rubber to grip it with. Good idea!
_________________
Dave

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1966 Bug project
1973 Thing project
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"Relax, all right? My old man is a television repairman. He's got this ultimate set of tools. I can fix it." --- Jeff Spicoli

[edgood1]

[edgood1]

I patched all the rust holes in the pillar caused by the mice. It would have been easier to just replace this whole section but I didn't want to find donor metal so I just welded in several patches

I cleaned , prepped and painted it

I also painted the floors but I somehow lost the pictures

While I had the door off I color sanded and polished it on a workbench

I've done a ton of other little repairs like changing the axle boots that were leaking, replacing all the fuel lines and brake lines, completely rebuilding the pedal assembly an extended clutch shaft. I hope to get it on the road soon and enjoy it.
_________________
'87 Syncro :: Subaru eng
'63 Samba Conversion ::(photo album)
'65 Westfalia
'65 Bug

[Bobs67vwagen]

Nice work I hope you get to use it a little before the weather shuts you down.