Rear crossmember advice please

[Fenian]

Are these worth patching or replacing?

I’m a novice welder 😱

Thanks!

Fenian

[VW_Jimbo]

Replace them, both. You will need to replace some of the inner fender as well.

Are those your welds along the heater channel. They look bulky, too thick. Either turn up the heat, or turn down the wire feed, or pull the puddle faster. I always turn up the heat!

That is a tricky spot to weld in. It is called the Lower Luggage Shelf. It welds to the Luggage Shelf, the Inner Fender Well and the Rear Quarter Panel. Be really patient, as buckling the Quarter Panel is really easy to do!
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[Fenian]

Thanks for the advice! No these are the previous owner’s welds. I only just got her. I agree it looks a bit botchy 🤭.

[beetlenut]

You'll need to drill out the spot welds for that panel, and unbolt it from the outriggers of the floor pan. If you lightly sand the areas where the spotwelds are, they will reveal themselves so you can drill them out. Then use a flat putty knife and hammer to separate the two sections. The panel is called a rear cross member. There's one for the right and left. You'll also have to patch parts of the body where that panel attaches to.

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scrapyards are for quitters
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[Fenian]

Thanks for your the images! Very helpful!

As the metal guy s so thin on top, would it not be better to just cut the panel along where the spot welds attach and use the remaining metal as an additional strengthening element?

I’m assuming I’ll need to fabricate the patches for the area at the ends of the heater channels.

Thanks for your help!

Fen

[VW_Jimbo]

You will find a lot of rust that has started in between the spot welds. If you disassemble the seam, you will have access to clean and treat that area before welding in the new panels. If not, you may run the risk of crappy holding welds and failure down the road.

I always like to get to good steel! Worth it every time!
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[Fenian]

Thanks, Jimbo! Guess I'd best get drilling then

[VW_Jimbo]

[beetlenut]

[Fenian]

Thanks for the picture - very helpful for me.

I'm having some issues finding the spot welds - whoever did them must've been drunk - 'cos they are not in a straight line... and I don't want to grid that top piece of steel too thin in order to find them, as I'll have nothing to weld the cross members to I may have to add another section of steel to reinforce it...

Any chance you have a picture from the wheel well side of things? I'd love to see how the heater channel is supposed to be covered. At the moment it is just open to the air (and moisture).

Thanks again for your help!

Fen

[Q-Dog]

Don't use a grinder to find the spot welds, use a wire wheel to remove the paint and not damage the metal.

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Brian

'69 Dune Buggy
'69 Beetle Convertible
'70 Beetle

[beetlenut]

[Fenian]

Thanks, guys!

I have some 1mm sheet metal that i can hammer into submission for the rear-end splash panels. I should probably do those before the rear cross members to ensure I have good welds.

Cheers!

Fen