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VWTortuga336
Samba Member
Joined: December 01, 2013
Posts: 125
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 Posted: Tue Jul 31, 2018 2:35 pm Post subject: How to: Tail Light Conversion - Late to Early |
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I couldn't find a detailed how to guide when I did my tail light conversion on my 72, so I wanted to provide a step by step write up. Overall, it wasn't a difficult process, but it can be nerve wracking cutting up a "perfectly good" fender. I figured this post would help others not feel so anxious about doing it. It took me about 3 hours per side (not including filler and body work). You can probably get it done in less time if you are better at panel fitting and welding than I am (not hard to be better than I am  ).
One of the first things to note is that the curve from the tail light to the engine compartment is different on later cars, so I had to be careful to cut out the entire transition.
Since you now need to maintain the stock transition area, make sure you cut out as little as possible from the old tail light.
From here, test fit your new piece and put a level across the vertical points. Mark on the fender where the level point is.
Cut the fender, test fit again, weld in place.
Now make a patch panel for the inside section.
Finished!
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kiwighia68
Samba Member
Joined: October 20, 2013
Posts: 2932
Location: Auckland, New Zealand
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| Posted: Tue Jul 31, 2018 3:26 pm Post subject: Re: How to: Tail Light Conversion - Late to Early |
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An expert can make anything look easy and you've just proved that.
Great tutorial.
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djkeev
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Joined: September 30, 2007
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Location: Reading Pennsylvania
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sputnick60
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art_lessing
Samba Member
Joined: February 20, 2014
Posts: 157
Location: Sacramento
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| Posted: Tue Jul 31, 2018 5:12 pm Post subject: Re: How to: Tail Light Conversion - Late to Early |
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this is awesome...can you please document your battery tray fix as well? I want to copy all the steps. My tray is rotted out exactly where yours is...especially where the b-tray meets the rear tray....
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Thanks in advance
DQ |
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VWTortuga336
Samba Member
Joined: December 01, 2013
Posts: 125
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| Posted: Tue Jul 31, 2018 5:21 pm Post subject: Re: How to: Tail Light Conversion - Late to Early |
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| djkeev wrote: |
Thanks for the tutorial!
I must ask though, would it be prudent to measure how far rearward the tail light is before welding it?
What point would you measure from? I'd guess the top of the door opening?
This would be the same distance on the Coupe and on the Convertible.
Dave |
I just used where the fender and the bottom of the tail light section meet as a reference point. It pivots from here when you test fit to get it level.
Circled here.
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djkeev
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VWTortuga336
Samba Member
Joined: December 01, 2013
Posts: 125
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| Posted: Tue Jul 31, 2018 5:36 pm Post subject: Re: How to: Tail Light Conversion - Late to Early |
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| art_lessing wrote: |
this is awesome...can you please document your battery tray fix as well? I want to copy all the steps. My tray is rotted out exactly where yours is...especially where the b-tray meets the rear tray....
.
Thanks in advance
DQ |
Sure, no problem
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Mellow Yellow 74
Samba Member
Joined: October 14, 2014
Posts: 1615
Location: Sydney, Australia
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| Posted: Wed Aug 01, 2018 2:15 pm Post subject: Re: How to: Tail Light Conversion - Late to Early |
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| VWTortuga336 wrote: |
| From here, test fit your new piece and put a level across the vertical points. Mark on the fender where the level point is. |
It is worth pointing out that before you use the level to check panels you need to check that the body and dolly are level both lengthways and sideways.
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TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 13289
Location: North Carolina
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| Posted: Wed Aug 01, 2018 3:04 pm Post subject: Re: How to: Tail Light Conversion - Late to Early |
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It would appear that to conform to the later model fender structure that the new hybrid tail light protrudes rearward another 1"-2", that's really gonna screw with folks later on.
Are you going to fill the bumper reliefs?
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djkeev
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Joined: September 30, 2007
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Location: Reading Pennsylvania
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VWTortuga336
Samba Member
Joined: December 01, 2013
Posts: 125
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| Posted: Wed Aug 01, 2018 4:00 pm Post subject: Re: How to: Tail Light Conversion - Late to Early |
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| TDCTDI wrote: |
It would appear that to conform to the later model fender structure that the new hybrid tail light protrudes rearward another 1"-2", that's really gonna screw with folks later on.
Are you going to fill the bumper reliefs? |
I filled the bumper refliefs, not the best pic but you get the idea.
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c21darrel
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