How would YOU fix this rust?

///Mink · Posted: Sat Nov 24, 2007 3:36 pm Post subject: How would YOU fix this rust?

OK, I'm back to work on my '74 coupe. I'm nearly done with the bodywork, and plan to spray it in the next month or so. The last bit of bodywork I need to do is to fix the rot in the lower corners of the front windshield frame.

Ideally, I'd section in pieces from a donor car, but I don't have one. So I thought of a couple of options:

1. Cut separate pieces for the channel and the cowl and weld them together where they meet. In other words, the bend between the cowl and channel would actually be a welded seam.

2. Bend a hunk of metal in a brake and then make a series of relief cuts in it so I can bend it to match the curvature of the frame.

3. Some other idea I'm not thinking of (this is where you come in).

Currently, I'm leaning toward #2, but if you've done this before, please chime in...

Image may have been reduced in size. Click image to view fullscreen.

blarneyman · Posted: Sat Nov 24, 2007 5:52 pm Post subject:

I would go with #2. I did the same thing on my 70 but in a different area. worked out pretty good, just time consuming.
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69 Beetle
70 Ghia(resto)

70 140 · Posted: Sat Nov 24, 2007 5:58 pm Post subject:

Is it to thin to build up and close with a welder? It looks pretty thin.

I vote for option two. The more relief cuts you make the less the gaps will be between cuts = easy to close up with some welds.

I would also coat the area under the seal with POR silver (metal strengthener) I have had great luck with this stuff.

westcoast-paul · Posted: Sat Nov 24, 2007 6:11 pm Post subject:

why not find a section from a donor car on the net?

ICY has a crap load of extra ghias.
_________________
- Paul

wcfvw69 · Posted: Sat Nov 24, 2007 6:16 pm Post subject:

I will drill out the spot welds along the rusted part and cut out the entire rusted piece. If you can't buy it aftermarket you can certainly buy that piece from a donor.
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rumplestilskin · Posted: Sun Nov 25, 2007 8:29 am Post subject:

umm i don't think that last poster noticed that is a pic of a windshield frame. and this is a ghia (1 giant hunk of steel).

lay a piece of card stock over the piece u will be cutting and cut and trim and bend until u get it how u want, than fab the piece . when your fabbing is perfect than cut the body
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currently 71 super auto-stick, 73 ghia, 71 yellow ghia , a 68 square w71 fi, a 77 bus station wagon deluxe. and finaly finaly a 74 riveria with volvo pawer .ITS AN ADDICTION!!!

wcfvw69 · Posted: Sun Nov 25, 2007 8:48 am Post subject:

OTO X58 · 10.10.84 - 12.25.09

rumplestilskin · Posted: Sun Nov 25, 2007 10:54 am Post subject:

repairs like this. i wish we could use photoshop in real life.
_________________
currently 71 super auto-stick, 73 ghia, 71 yellow ghia , a 68 square w71 fi, a 77 bus station wagon deluxe. and finaly finaly a 74 riveria with volvo pawer .ITS AN ADDICTION!!!

///Mink · Posted: Sun Nov 25, 2007 12:35 pm Post subject:

OK, it's official...I'm a dimwit. After posting this thread, scrounging the classifieds, and asking a few friends, I looked up and realized I had this hanging on my garage wall...

(and it appears that there's enough metal left on it for the sections I need.) Woohoo!

I'll post a few pics of the repairs.

70 140 · Posted: Sun Nov 25, 2007 12:38 pm Post subject:

So you aren't going to use kitty hair? Wink

rumplestilskin · Posted: Sun Nov 25, 2007 4:02 pm Post subject:

what a dork.

just do what i do. say u were drunk at the time.... it works every time!
_________________
currently 71 super auto-stick, 73 ghia, 71 yellow ghia , a 68 square w71 fi, a 77 bus station wagon deluxe. and finaly finaly a 74 riveria with volvo pawer .ITS AN ADDICTION!!!

///Mink · Posted: Sun Nov 25, 2007 6:43 pm Post subject:

Well, having the right parts certainly made this job a whole lot easier!!

First, I positioned the piece I cut from the donor using the wiper pivot as a reference point - this ensured that I matched the curvature correctly.

Then I marked and cut the donor piece off so that all the rust was covered.

Then I cut out the rotten area on the lines and cleaned it up:

Quick test fit of the donor bit:

Donor bit tacked in:

Welded in and cleaned up:

wcfvw69 · Posted: Sun Nov 25, 2007 6:51 pm Post subject:

Damn! Nice work!
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc

Decades of VW and VW parts restoration experience.
The Samba member since 2004.

**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours**

70 140 · Posted: Sun Nov 25, 2007 8:05 pm Post subject:

It looks like the car has been a few colors in its life.

///Mink · Posted: Sun Nov 25, 2007 8:09 pm Post subject:

OTO X58 · Posted: Sun Nov 25, 2007 10:01 pm Post subject:

Nice job!!
_________________
-Thomas

RIP HBB 10.10.84 - 12.25.09
1958 Ragtop Bug Build - Subaru Swap!
1957 Gazelle Beige Ghia FOR SALE
1957 Dove Blue Kombi field find

Gary · Posted: Mon Nov 26, 2007 6:49 am Post subject:

Nice work, Tom. Looking good and I'm glad you didn't scrap the fattie!
_________________
West Virginia State Board of Education v. Barnette, 319 U.S. 624 (1943)

grelland · Posted: Mon Nov 26, 2007 4:15 pm Post subject:

Nice work.

Just a tip, though, the welds get a lot nicer if you grind away the paint before you weld. Actually the welding itself becomes much easier.


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