Roman’s Rust Bucket ('67 Beetle)

[rstrobel]

Thanks! It may take a little longer, but it should be worth it in the end!
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1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[rstrobel]

In order to replace the body mount area, I first took a few reference pictures.

Then, I cut out a big chunk, so that I am able to better access and remove the rest of the metal.

There it is...the death foam!!

I began to pick the foam out with a pry bar, but I noticed that it was quite rusty up there. As such, I decided that I need to cut out a piece of metal in the inside, so that I am able to completely remove the foam and sandblast everything.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[Rome]

Careful with the test-fitting of the rear body mount repair panel: There should be a rubber pad in between the underside of the body mount bracket and the top of the frame casting, though that won't influence the alignment of the mount panel on the rear quarter panel. The pad is there for reducing transmitting frame vibrations from road bumps to the body.

[rstrobel]

[rstrobel]

After cutting the area out, I was able to remove most of the foam. I then sandblasted the whole area and painted it with Eastwood's "Internal Frame Coating."

Once it was painted and dry, I welded the panel back in place.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[Dibaltic]

Nice work and very detail orientated !

[Chickensoup]

[rstrobel]

[rstrobel]

I taped a straight piece of wood along the bottom of the door, in order to ensure that the quarter panel is in line with the door.

Then, I cut through both the original quarter panel and the aftermarket one.

Once the quarter panel was cut, I removed it and put seam sealer in all of the necessary locations. Man, that was a messy job...

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[rstrobel]

Due to the poor quality of the klokkerholm cross members, I had to extend part of the quarter panel so that it fits underneath the cross member (it was about 1cm too low).

After a little bit of cutting, bending, and preparation, I was able to weld the extension piece on.

Then I test fit the bottom part and welded it on.

This is the final product. Not the best, but it'll do.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[rstrobel]

I bolted the fender onto the car, so that I was able to determine where I needed to weld the nut.

As you can see, the fender will need some work due to previous repairs that were poorly done.

Since I wanted to keep the indentations that are around the fender nuts, I cut it out of the extra piece of quarter panel and welded it into the new quarter panel.

After a little bit of grinding...

Next, it was time to fill in the hole that was there for the stud.

Now that everything was welded in place, it was time to grind it down.

I didn't really grind the back down, as no one will ever see it...and it allows for a little more strength.

I also went ahead and seam sealed the other body mount metal and quarter panel area.

Before welding the quarter panel in, I had to do a little bit of fitting.

Since the rear portion of the quarter panel was too far back, I decided to cut it right where the curved metal stopped. This allowed me to move the metal without creating too much extra work.

Then, I started to weld the quarter panel in.

I made sure to always check the angle with a straight edge. It's not perfect, but that's because the quarter panel did not have the correct curvature.

Once it was welded in, I ground it down and painted it.

Next, it was time to weld the wheel well in.

I first tacked it onto the original wheel well, and then I cut through both sheets of metal, to ensure proper fitment.

Once it was cut, it was time to slowly weld it in...always making sure that it still fit as I wanted it to.

By shining a flashlight on the backside of the weld, I found a couple of holes that I needed to weld.

Next, I moved to the driver-side quarter panel. Same process...tape jig onto door and cut through both quarter panels.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[viiking]

Awesome work! I'm particularly impressed with the sandblasting.

Are you using a pressure pot or something else? I have seen the normal venturi gun type blaster that you just stick the suction hose into a bucket or the pressure pot type.

I only have small sections that I need to blast so don't want to clutter up the garage any more than I need to. I already have a sandblasting cabinet for detachable items.

Appreciate your advice.
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1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[matthew henricks]

Nice work. Love reading the metal replacement process. Every car is different and every builder does it different. I learn sooo much that way. Good work.
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1964 Original Owner build Thread. https://www.thesamba.com/vw/forum/viewtopic.php?t=702135&highlight=

Ambulance Fan's. https://www.thesamba.com/vw/forum/viewtopic.php?t=627707&highlight=

Parts i am looking for:
64 bug nice used front/rear Black LHD floor mat.

[rstrobel]

[rstrobel]

[rstrobel]

I took a small break from the driver side and continued on passenger side. I had to make a custom piece for the lower corner of the wheel well. The first time that I tried to make the piece, I simply used a vise and bent it in the correct locations. However, that proved to be rather difficult, as the vise would crease the corners too much. As a result, I used some scrap tubing to get the correct shape...and instead of using one piece, I made it out of two.

I was able to use a part of the donor bug to ensure that the angles are correct.

Before sandblasting:

After sandblasting:

The first bend...

The second bend...

The finished product...

Once that was done, it was time to repeat the whole process on the other side.

First, I cut out a majority of the wheel well. I kept the spot welds on the lower part of the wheel well, so that the panel does not shift like last time.

Then, I cut out the inner part, so that I could remove the foam.

Once the foam was removed, I sandblasted the entire area and used internal frame coating to paint it. Then, it was time to weld the panel back in, grind the welds down, and paint it inside and out.

Since I accidentally cut the driver side quarter panel too low, I had to purchase a new one.

I also tested out the Rust Oleum Aircraft stripper...it's okay. It was able to remove the single stage with one coat.

However, it was not able to remove the primer with a second coat (after removing the bubbled single stage coat.

After cutting the quarter panel in the correct location, I was able to weld it in...always making sure that it is straight with a straight edge.

I then cut part of the inner door jamb out, as it was very thin.

Next, I tackled the lower wheel well area.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[rstrobel]

Time to update this thread...

I made sure that all of the curves lined up and that the curvature was correct.

Once the rear corner was welded in and ground down, I cut out a square, so that I could weld the nut in. The reason why I wanted to use the KlassicFab nut is because I wanted to to keep the factory indentation.

Once the nut fit, I painted the the metal behind it.

Time to weld it in...

The fender still fit as expected

Here it is fully welded in.

I am glad that I removed this metal piece and sandblasted behind it...there was a lot of rust lurking behind it.

Then, I trimmed the wheel well area and welded it in.

For some reason the corner didn't fit, so we had to use the Oxyacetylene torch to bend it into place.

Here it is fully welded in.

While the torch is out, I decided to remove the rear clip by melting the brazing.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[scrivyscriv]

Your welds look pretty good.
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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.

[rstrobel]

[Chickensoup]

very nice work!
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-'85 c10 5.3 LS, 222 cam, long tubes, x pipe, 3 inch spin tech's
-'05 B5.5 TDI Wagon 17in sport rims ;EGR + BSM + ASV Delete, Stage-2 Tune, straight pipe
'65 Tourist Delivery Build
'66 RIP
'69 RIP
Hosea 4:6 "My people are destroyed for lack of knowledge"