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///Mink Samba Member
Joined: May 03, 2000 Posts: 5051 Location: Fair Oaks, CA
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Posted: Sat Nov 24, 2007 3:36 pm Post subject: How would YOU fix this rust? |
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OK, I'm back to work on my '74 coupe. I'm nearly done with the bodywork, and plan to spray it in the next month or so. The last bit of bodywork I need to do is to fix the rot in the lower corners of the front windshield frame.
Ideally, I'd section in pieces from a donor car, but I don't have one. So I thought of a couple of options:
1. Cut separate pieces for the channel and the cowl and weld them together where they meet. In other words, the bend between the cowl and channel would actually be a welded seam.
2. Bend a hunk of metal in a brake and then make a series of relief cuts in it so I can bend it to match the curvature of the frame.
3. Some other idea I'm not thinking of (this is where you come in).
Currently, I'm leaning toward #2, but if you've done this before, please chime in...
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blarneyman Samba Member
Joined: February 06, 2005 Posts: 1622 Location: Everson/Bellingham, WA
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Posted: Sat Nov 24, 2007 5:52 pm Post subject: |
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I would go with #2. I did the same thing on my 70 but in a different area. worked out pretty good, just time consuming. _________________ 69 Beetle
70 Ghia(resto) |
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70 140 Samba Member
Joined: September 22, 2002 Posts: 8471 Location: Ontario Canada
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Posted: Sat Nov 24, 2007 5:58 pm Post subject: |
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Is it to thin to build up and close with a welder? It looks pretty thin.
I vote for option two. The more relief cuts you make the less the gaps will be between cuts = easy to close up with some welds.
I would also coat the area under the seal with POR silver (metal strengthener) I have had great luck with this stuff. |
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westcoast-paul Samba Member
Joined: January 31, 2006 Posts: 822 Location: CanadaYaHoser
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Posted: Sat Nov 24, 2007 6:11 pm Post subject: |
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why not find a section from a donor car on the net?
ICY has a crap load of extra ghias. _________________ - Paul |
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wcfvw69 Samba Purist
Joined: June 10, 2004 Posts: 13389 Location: Arizona
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Posted: Sat Nov 24, 2007 6:16 pm Post subject: |
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I will drill out the spot welds along the rusted part and cut out the entire rusted piece. If you can't buy it aftermarket you can certainly buy that piece from a donor. _________________ Contact me at [email protected]
Follow me on instagram @sparxwerksllc
Decades of VW and VW parts restoration experience.
The Samba member since 2004.
**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours** |
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rumplestilskin Samba Member
Joined: January 13, 2007 Posts: 963 Location: los banos,CA
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Posted: Sun Nov 25, 2007 8:29 am Post subject: |
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umm i don't think that last poster noticed that is a pic of a windshield frame. and this is a ghia (1 giant hunk of steel).
lay a piece of card stock over the piece u will be cutting and cut and trim and bend until u get it how u want, than fab the piece . when your fabbing is perfect than cut the body _________________ currently 71 super auto-stick, 73 ghia, 71 yellow ghia , a 68 square w71 fi, a 77 bus station wagon deluxe. and finaly finaly a 74 riveria with volvo pawer .ITS AN ADDICTION!!! |
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wcfvw69 Samba Purist
Joined: June 10, 2004 Posts: 13389 Location: Arizona
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Posted: Sun Nov 25, 2007 8:48 am Post subject: |
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rumplestilskin wrote: |
umm i don't think that last poster noticed that is a pic of a windshield frame. and this is a ghia (1 giant hunk of steel).
lay a piece of card stock over the piece u will be cutting and cut and trim and bend until u get it how u want, than fab the piece . when your fabbing is perfect than cut the body |
Actually I did. That top piece (that's rusted) is spot welded (or sandwiched) to the bottom of the windshield piece. You should drill out the spot welds then use a pattern like you discribed. _________________ Contact me at [email protected]
Follow me on instagram @sparxwerksllc
Decades of VW and VW parts restoration experience.
The Samba member since 2004.
**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours** |
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OTO X58 Samba Member
Joined: March 27, 2004 Posts: 3101 Location: Santa Cruz, CA
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Posted: Sun Nov 25, 2007 9:23 am Post subject: |
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wcfvw69 wrote: |
rumplestilskin wrote: |
umm i don't think that last poster noticed that is a pic of a windshield frame. and this is a ghia (1 giant hunk of steel).
lay a piece of card stock over the piece u will be cutting and cut and trim and bend until u get it how u want, than fab the piece . when your fabbing is perfect than cut the body |
Actually I did. That top piece (that's rusted) is spot welded (or sandwiched) to the bottom of the windshield piece. You should drill out the spot welds then use a pattern like you discribed. |
HAHA, did you really think that someone pounded out the Ghia body out of one sheet of metal? If I were you I would cut a piece out of a donor car. _________________ -Thomas
RIP HBB 10.10.84 - 12.25.09
1958 Ragtop Bug Build - Subaru Swap!
1957 Gazelle Beige Ghia FOR SALE
1957 Dove Blue Kombi field find |
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rumplestilskin Samba Member
Joined: January 13, 2007 Posts: 963 Location: los banos,CA
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Posted: Sun Nov 25, 2007 10:54 am Post subject: |
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repairs like this. i wish we could use photoshop in real life. _________________ currently 71 super auto-stick, 73 ghia, 71 yellow ghia , a 68 square w71 fi, a 77 bus station wagon deluxe. and finaly finaly a 74 riveria with volvo pawer .ITS AN ADDICTION!!! |
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///Mink Samba Member
Joined: May 03, 2000 Posts: 5051 Location: Fair Oaks, CA
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Posted: Sun Nov 25, 2007 12:35 pm Post subject: |
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OK, it's official...I'm a dimwit. After posting this thread, scrounging the classifieds, and asking a few friends, I looked up and realized I had this hanging on my garage wall...
(and it appears that there's enough metal left on it for the sections I need.) Woohoo!
I'll post a few pics of the repairs. |
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70 140 Samba Member
Joined: September 22, 2002 Posts: 8471 Location: Ontario Canada
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Posted: Sun Nov 25, 2007 12:38 pm Post subject: |
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So you aren't going to use kitty hair? |
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rumplestilskin Samba Member
Joined: January 13, 2007 Posts: 963 Location: los banos,CA
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Posted: Sun Nov 25, 2007 4:02 pm Post subject: |
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what a dork.
just do what i do. say u were drunk at the time.... it works every time! _________________ currently 71 super auto-stick, 73 ghia, 71 yellow ghia , a 68 square w71 fi, a 77 bus station wagon deluxe. and finaly finaly a 74 riveria with volvo pawer .ITS AN ADDICTION!!! |
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///Mink Samba Member
Joined: May 03, 2000 Posts: 5051 Location: Fair Oaks, CA
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Posted: Sun Nov 25, 2007 6:43 pm Post subject: |
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Well, having the right parts certainly made this job a whole lot easier!!
First, I positioned the piece I cut from the donor using the wiper pivot as a reference point - this ensured that I matched the curvature correctly.
Then I marked and cut the donor piece off so that all the rust was covered.
Then I cut out the rotten area on the lines and cleaned it up:
Quick test fit of the donor bit:
Donor bit tacked in:
Welded in and cleaned up:
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wcfvw69 Samba Purist
Joined: June 10, 2004 Posts: 13389 Location: Arizona
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Posted: Sun Nov 25, 2007 6:51 pm Post subject: |
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Damn! Nice work! _________________ Contact me at [email protected]
Follow me on instagram @sparxwerksllc
Decades of VW and VW parts restoration experience.
The Samba member since 2004.
**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours** |
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70 140 Samba Member
Joined: September 22, 2002 Posts: 8471 Location: Ontario Canada
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Posted: Sun Nov 25, 2007 8:05 pm Post subject: |
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It looks like the car has been a few colors in its life. |
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///Mink Samba Member
Joined: May 03, 2000 Posts: 5051 Location: Fair Oaks, CA
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Posted: Sun Nov 25, 2007 8:09 pm Post subject: |
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70 140 wrote: |
It looks like the car has been a few colors in its life. |
Tell me about it. It makes feathering the edges of the paint a total bitch. By my count, there are about 4 colors on top of the original. |
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OTO X58 Samba Member
Joined: March 27, 2004 Posts: 3101 Location: Santa Cruz, CA
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Gary Person of Interest
Joined: November 01, 2002 Posts: 17069 Location: 127.0.0.1
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Posted: Mon Nov 26, 2007 6:49 am Post subject: |
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Nice work, Tom. Looking good and I'm glad you didn't scrap the fattie! _________________ West Virginia State Board of Education v. Barnette, 319 U.S. 624 (1943) |
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grelland Samba Member
Joined: January 26, 2006 Posts: 540 Location: Norway
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Posted: Mon Nov 26, 2007 4:15 pm Post subject: |
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Nice work.
Just a tip, though, the welds get a lot nicer if you grind away the paint before you weld. Actually the welding itself becomes much easier. |
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