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flyboy161
Samba Member
Joined: December 26, 2009
Posts: 2091
Location: Perry, GA
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Zundfolge1432 
Samba Member
Joined: June 13, 2004
Posts: 12468
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 Posted: Sat Nov 16, 2019 7:30 pm Post subject: Re: Hole cut in tunnel |
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Agreed it’s still a great car with potential and as noted it hasn’t folded up yet. I once looked at a race car that had multiple lightning holes in the pan. These cars are stronger than you think and over built. Ever seen one folded up? I haven’t either unless it hit a tree.
Always if necessary to access the tunnel use a hole saw but drill at angle about 270 degrees creating a flap which you can open then close when done. Take a look at these photos of a well known shop that used to convert Autostik cars to 4 speeds. They had it down to a science and it will be perceived as sacrilegious to Autostik people but if you must make a hole this is well thought out. I apologize in advance the pic is a copy of a copy VW trends 1990 how to article.
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EVfun
Samba Member
Joined: April 01, 2012
Posts: 5481
Location: Seattle
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| Posted: Sun Nov 17, 2019 12:48 pm Post subject: Re: Hole cut in tunnel |
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While you have that hole I would check everything inside the tunnel. The shift rod bushing and hanger, the clutch cable tube at each attachment point, and do a pressure test on the fuel line too.
I would finish cutting that out so it is easier to align. I would sand the faces near the cuts for a good clean weld. I would hold it in place with magnets and tack it generously every couple inches working from side to side, including the extended cuts. Then I would finish welding it up.
Some painting on the outside and rust protection on the inside would be a good idea too.
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scrivyscriv
Samba Electrician
Joined: October 04, 2011
Posts: 2922
Location: Memphis
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| Posted: Wed Nov 20, 2019 8:28 pm Post subject: Re: Hole cut in tunnel |
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I’ve been searching topics and going through my blue Bentley but I can’t figure out how to get the rear seat back carpet loose from the carpet rail. Can anyone shed some light on it? Maybe my backseat material is just stuck in there tight?
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help. |
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slalombuggy
Samba Member
Joined: July 17, 2010
Posts: 9147
Location: Canada
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| Posted: Wed Nov 20, 2019 8:38 pm Post subject: Re: Hole cut in tunnel |
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It's been a long time but I think I remember folding the back down about half way to gain access and then using a hook tool to pry one end out and work the hook across the rail gradually working the carpet free
brad |
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scrivyscriv
Samba Electrician
Joined: October 04, 2011
Posts: 2922
Location: Memphis
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| Posted: Sun Nov 24, 2019 7:20 pm Post subject: Re: Hole cut in tunnel |
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I just got my shift rod bushings in this week, along with a YOM tennessee tag to register it!
To be honest I've been mentally going back and forth on totally disassembling the chassis to get it sandblasted, after I replace the pans. I still haven't made up my mind how far I want to go, but the goal is to epoxy it, possibly body color topcoat, and finish with the Wurth Stoneguard.
Probably just going to weld the tunnel damage up after I replace the shifter bushing, instead of making an access hole. I can't really picture the need to get back in this area for maintenance or repair in my lifetime.
 So far the engine looks good too - even has the thermostat and flaps, and all the tin! At this point, why not split the case and check everything inside, too? If the case is really worn I don't plan on putting much time or money in to it... don't most people say the "H" cases aren't good to modify much beyond stock?
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help. |
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 12860
Location: North Carolina
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| Posted: Fri Jan 03, 2020 1:02 pm Post subject: Re: Hole cut in tunnel |
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| flyboy161 wrote: |
| TDCTDI wrote: |
| Zundfolge1432 wrote: |
You’d be real surprised with the amount of damage that gets repaired and returned to service. If it’s not covered with a standard repair it goes to engineering for an approved fix. Very little gets wasted, problems are solved and it puts bread on the table.
Once a 727 wingtip cut a gash 15 feet long into fuselage of MD80. The mad dog was less than a year old. At first it appeared to be impossible to repair. It was shored up and all three angles shot in with laser, reskinned and stringers spliced. Entire frames replaced and 3 months later returned to service. Cost millions but it got done. See em land wheels up, fixed that. Landed short hitting trees, fixed that. Where there’s a will there’s a way. |
I realize that lots of stuff gets repaired but none of your examples are the same type of thing that we're discussing here. Show me one example of a structural component that had 1/3 of it's cross section cut, broken, damaged, fatigued or what not, repaired by a doubler & rivets.
I'm pretty sure that you wouldn't sign your name on something like what you're suggesting the OP do on his car. |
Actually, I would. I’ve been doing aircraft crash recovery and repair for the last 30 years. What I described is standard repair at depot level. If it was a field repair I’d do a scab patch. But I was describing a permanent repair. The owner has a great deal of aircraft experience also. Clearly Zundfolge4321 does too. Your concerns are valid, but done right, this repair would be just as strong as welding. And you are able to access the area in the future. |
Alright, I'll take y'alls word for it. As it turns out, my clutch tube just broke free also, here's how I tackled it.
For several months, I have been getting a creaking from the tunnel when I depress the clutch. Well today, the clutch got rather weird & wouldn't completely disengage. I removed the pedal assembly & the clutch cable to find that both were fine. Dammit, the clutch tube broke. So I went to hacking the tunnel open.
I started by finding a piece of scrap the same thickness as the tunnel (Which so happens that I had some left over from the torsion housing truss project.).
I then drilled a couple of pilot holes in it.
I then laid that over the tunnel & transferred the holes into the tunnel.
After that, I took the 3" hole saw & drilled into the tunnel at a 45* angle so that I only cut the outer radii.
And then made cuts to remove the center section.
Once done, I bent the doubler plate to match the contour of the new access door & then I cut out the center of the doubler plate, except with a 2.5" hole saw.
I then slipped the doubler plate into the tunnel and, after drilling several holes around the perimeter, I plug welded the doubler plate into the tunnel.
After repairing the clutch tube, I set the access door back into place, now I just need to finish the mounting points.
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Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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scrivyscriv
Samba Electrician
Joined: October 04, 2011
Posts: 2922
Location: Memphis
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| Posted: Wed Nov 04, 2020 6:44 pm Post subject: Re: Hole cut in tunnel |
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Hey TDCTDI. How’d you finish out the access panel?
I’m about ready to start cutting and welding on my pan and I’ve been back and forth on carbon steel rivnuts, clip on nut plates, or just welding everything back shut.
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help. |
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scrivyscriv
Samba Electrician
Joined: October 04, 2011
Posts: 2922
Location: Memphis
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| Posted: Mon Nov 15, 2021 11:05 pm Post subject: Re: Hole cut in tunnel |
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Well guys I figured I would post here and wrap this whole thing up.. I debated on an access door for a while, and finally realized I was overthinking the entire process and needed to just weld it up and keep moving.
Since the gap was so large I had to weld in a flange all the way around. Zoom in on the pic and you’ll notice I stop drilled and radiused the ends and edges of the cut lines.
I used my Horrible Fright 240V spot welder and it did pretty well. Would have been impossible to use after the pans were installed.
Honestly would have preferred to put a small access panel there especially now that I’m getting ready to install a solid bronze shifter bushing. But I don’t for a minute regret welding it up instead, because I closed that chapter, welded the pans in, and just got the chassis back from powder coat last week.
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
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ZENVWDRIVER
Samba Member
Joined: November 07, 2008
Posts: 3340
Location: N.E. Oklahoma
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| Posted: Tue Nov 16, 2021 10:47 am Post subject: Re: Hole cut in tunnel |
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| AZOffTheWall wrote: |
| That hole is there because the shift rod bushing bracket broke and needed to be replaced, it's pretty common, usually guys do a little cleaner work but I've seen much worse. Replace the bushing before you weld it up. |
I would not weld it closed - i've just taped the cuts so, 50 years, from now, the next guy won't have to cut - your gift to him/her - z
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otis64
Samba Member
Joined: April 11, 2017
Posts: 32
Location: 32174
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| Posted: Sun Nov 21, 2021 4:12 pm Post subject: Re: Hole cut in tunnel |
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I'm currently in the process of welding up a hole in my tunnel that i found when replacing my clutch cable. I'm going to leave a small access opening with a hinge /door type latch, so i can replace cables when needed. I know it sucks when you find hack jobs like that, but it makes it more enjoyable to be able to fix it correctly and know that you saved a possible devastating blow to your ride.
Stay aircooled! |
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