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1958 De Luxe Beetle from Morocco
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flyboy161
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PostPosted: Sun Dec 29, 2019 11:46 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Well, thank you, Mr. Mike!
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PostPosted: Mon Dec 30, 2019 4:30 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Nice job on that quarter. I've got to address around the back window myself.
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PostPosted: Sun Jan 12, 2020 10:50 am    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

I puttered around this weekend addressing some of the uglier rust on the car. The passenger door had some rust through spots at the back lower corner. I cut out a 1.2” x 3.5” area and welded in a patch.
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There was also some rust that turned into a hole at the bottom of the B pillar once I tapped on it with a hammer. I cut it out. But I’ll need to square it up before I start fabricating a patch. I also need to decide the best course of action for the next issue before I continue.
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Finally the heater tube where it enters the heater channel is just yuck. I’m sitting on the fence on this one. I don’t want to replace a heater channel.
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If I end up patching that tube I’m going to have to cut into the channel skin to fully treat it. Ugh!

On a happy note, I did find a body shop that’ll spray the car when I’m ready.
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PostPosted: Sun Jan 12, 2020 11:13 am    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

The underseat heater tube cover on the passenger side is also in pretty sad shape.
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Replacement is on the way
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PostPosted: Wed Jan 15, 2020 10:09 am    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Now starts the paint removal. At an hour a day, I should be ready to smooth and prime this door by Saturday 🙄

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PostPosted: Sat Jan 18, 2020 1:09 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Well, 4 days later...
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Not really. I didn’t touch it after the first day. The rest of the door was sanded this afternoon. I needed a bigger sander. Laughing
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PostPosted: Mon Jan 20, 2020 10:20 am    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Unfortunately, rust has reared its ugly head again. This time at the A pillar passenger side. Also in the heater tube on the drivers side. You’ve already seen the heater tube and B pillar on the passenger side.
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The passenger B pillar.
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The bottom of the passenger heater tube
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The passenger A pillar. This was one teeny little hole that opened up with some scribe work
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The underside of the drivers heater tube.
Nothing to do but replace heater channels. Ugh!
First step was to get the door out of the way.
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Surprisingly, all the door screws came out with an impact screwdriver with the exception of one at the lower right outboard position. Drilled it out and then retapped the hole. Fortunately I have a fair stash of hardware I’ve collected over the years. I’ll be ordering Klassic Fab heater channels and a couple of odds and ends. I’ll finish stripping the door while waiting for those to arrive. Collect up some bracing and begin uncovering spot welds. I really did not want to end up doing heater channels, but it’ll be a good opportunity to fix it right.
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PostPosted: Mon Jan 20, 2020 11:02 am    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Jeez, I'm exhausted looking at all that work you're doing. Laughing

As my Dad would say when I was a kid "God damn it, if you can't do it right the first time, don't do it at all!"
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PostPosted: Mon Jan 20, 2020 11:27 am    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Thanks Bill. I’m exhausted just thinking about what’s coming. I will reinstall the door prior to removing the heater channel. I just wanted it out of the way to thoroughly evaluate the rust damage and to depaint the area.

I’m thinking of transitioning away from the wire feed welder for this job as I am a much better oxy-acetylene type of guy. Better for me.

Anyhoo, this promises to be a very slow process with not a lot of frequent updates. I’ll start de-painting and removing seam sealer this week.
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PostPosted: Mon Jan 20, 2020 2:07 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Well, I decided to get started cleaning up the interior for the upcoming mayhem. Still had a lot of tar paper to scrape out plus 62 year old body seam sealant.
Image may have been reduced in size. Click image to view fullscreen.

Passenger side. Not terrible. Helps to able to see where the spot welds are hiding
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Drivers side and package trays weren’t hiding anything awful
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While removing body sealant up front I did find something on the passenger side
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Again, not awful, but will need to be repaired
Something about the passenger side of this car Confused
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PostPosted: Wed Jan 22, 2020 9:06 am    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Yesterday, I took a break. Today I can only give her an hour and a half, but I made some progress.
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At the bottom of the quarter panels...
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5 little pin holes

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Only 5 layers of paint to go through Shocked
The purple, a yellow white primer
A rust colored primer
The Capri blue
And the original primer.
Ugh! On the bright side, I haven’t run across anything awful yet.
When the car was repainted, they sanded the Capri pretty well, so it’s kind of leopard skin pattern under all the other layers. But they left all the original primer. At this rate I’ll be ready to paint in a couple of years, lol
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PostPosted: Sat Jan 25, 2020 1:15 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Today was sanding with a purpose. Uncover all the spot welds needed to remove the heater channel.
Image may have been reduced in size. Click image to view fullscreen.

The long view
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Happy to see no rot here
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Bottom of the rear quarter panel
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Inside under the back seat
Base of the B pillar
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Bottom of the A pillar
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At the front bulkhead
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And finally the front quarter panel. Double row of spot welds...ugh
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PostPosted: Sun Jan 26, 2020 1:05 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Work smarter, not harder: My father’s mantra
Today a little heat and razor blade work made short work out of stripping the rest of the rear quarter panel.
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This definitely sped up the process. A little primer residue is all that’s left after the razor work, and that vanishes quickly once sanded.
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PostPosted: Sun Jan 26, 2020 1:50 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

And finally for today, my ugly lesson learned...what lurks under pretty paint is not always golden.
So, continuing the razor blade heat trick, I found a large area of what looked to be rust colored primer on the front quarter panel
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It’s not. It’s a fine layer of surface rust with some minor pitting.
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PostPosted: Sun Jan 26, 2020 2:26 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Hey Brother of the same name. Life's not over!
Based on what I have seen from the last few posts. Your car looks better than most from the region lately.
Clean up the rust a little and treat it with Ospho. And move on with the repairs.

Good Luck.
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PostPosted: Sun Jan 26, 2020 3:04 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Nah, it’s all good. I know, it’s better off than some. I’m actually pleased with the amount of good metal this car still has.
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PostPosted: Mon Feb 10, 2020 4:39 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

It’s about to get scary for me😂
Step 1: re-orient the pan under the body the correct direction front to rear
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Step 2: receive 2 boxes from Bogota, Columbia
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Step 3: open said packages and voilà
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One heater channel
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One A pillar base
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And one rear quarter section
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Step 4: test fit the heater channel to the pan....
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Perfect fit. I mean absolutely perfect. Gerson makes great parts. I mean these things are heavy gauge steel, for sure. Not flimsy in any way shape or form.
Now, the real fun begins...
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PostPosted: Sat Apr 25, 2020 8:24 am    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Kind like watchin paint dry, but this week I got back on it.
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Welded in a box frame to hold everything together
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Cut out the back 1/2 from the A pillar to the aft bulkhead
This was last weekend. This week...
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The front 1/2 was cut out
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Just have to clean up the last 1” at the front bulkhead.
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This lower quarter panel is going to get a lot of attention and so is the front quarter and A pillar.
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PostPosted: Wed May 06, 2020 7:36 am    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Test fit number 2. I really don’t like being in a hurry, so I just don’t hurry. First test fit was a bust. I had to remover the lower heater muffler, notch the front and rear crossmembers to accept the flanges on the channel and trim 1/4” of the rear crossmember so the channel would slide up past it. It was just residual metal from the old channel. So, Gerson makes great channels! This thing fits like a glove. I’m going to leave it up for a few days while I go to work. Then it will come down for cleanup prior to welding. I’ll tack it in place and then I’ll start replacing the rusty areas on the quarter panels and finish weld. I guess the biggest hurdle has just been confidence but by walking away, breathing, contemplating navel lint, etc., I gain a little confidence and whittle away at it.
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It’s a tight fit at the rear crossmember.
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And at the front
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It warms the heart to see metal under the door again
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The front quarter panel section pulls in nicely too
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The two clamps are just more for peace of mind. I honestly don’t think it would fall out at this point, the channel fits that tight.
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PostPosted: Fri May 29, 2020 7:58 am    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Other priorities, other projects...but, today is the last test fit. It took a little grinding to remove remnants of old defrost hose and old heater channel. Everything lines up and is clamped in place.
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They weld the defrost hose to the car Shocked
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I did not end up re-using this. VW switched to paper hoses is 1960, so did I

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

Clamped in place! Paint is removed from the areas to be welded and I don’t feel like welding today. Gotta get ready for work. Tomorrow? We’ll see Wink
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