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1958 De Luxe Beetle from Morocco
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flyboy161
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PostPosted: Mon Feb 10, 2020 4:39 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Itís 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 voilŗ
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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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My father's 1970 Beetle-
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flyboy161
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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, itís all good. I know, itís better off than some. Iím actually pleased with the amount of good metal this car still has.
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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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flyboy161
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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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Itís not. Itís a fine layer of surface rust with some minor pitting.
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My father's 1970 Beetle-
http://www.thesamba.com/vw/forum/viewtopic.php?t=603879

The 1964...Diamond in the rough
http://www.thesamba.com/vw/forum/viewtopic.php?t=612776

My 1958 Morocco Bug-
http://www.thesamba.com/vw/forum/viewtopic.php?t=611483
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flyboy161
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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 fatherís 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 thatís left after the razor work, and that vanishes quickly once sanded.
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The 1964...Diamond in the rough
http://www.thesamba.com/vw/forum/viewtopic.php?t=612776

My 1958 Morocco Bug-
http://www.thesamba.com/vw/forum/viewtopic.php?t=611483
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flyboy161
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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.
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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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My father's 1970 Beetle-
http://www.thesamba.com/vw/forum/viewtopic.php?t=603879

The 1964...Diamond in the rough
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My 1958 Morocco Bug-
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flyboy161
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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 havenít run across anything awful yet.
When the car was repainted, they sanded the Capri pretty well, so itís kind of leopard skin pattern under all the other layers. But they left all the original primer. At this rate Iíll be ready to paint in a couple of years, lol
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The 1964...Diamond in the rough
http://www.thesamba.com/vw/forum/viewtopic.php?t=612776

My 1958 Morocco Bug-
http://www.thesamba.com/vw/forum/viewtopic.php?t=611483
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flyboy161
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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.
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Passenger side. Not terrible. Helps to able to see where the spot welds are hiding
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Drivers side and package trays werenít 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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The 1964...Diamond in the rough
http://www.thesamba.com/vw/forum/viewtopic.php?t=612776

My 1958 Morocco Bug-
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flyboy161
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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. Iím exhausted just thinking about whatís 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.

Iím 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. Iíll start de-painting and removing seam sealer this week.
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The 1964...Diamond in the rough
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wcfvw69
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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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flyboy161
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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. Youíve 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 Iíve collected over the years. Iíll be ordering Klassic Fab heater channels and a couple of odds and ends. Iíll 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 itíll be a good opportunity to fix it right.
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My father's 1970 Beetle-
http://www.thesamba.com/vw/forum/viewtopic.php?t=603879

The 1964...Diamond in the rough
http://www.thesamba.com/vw/forum/viewtopic.php?t=612776

My 1958 Morocco Bug-
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flyboy161
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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 didnít 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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The 1964...Diamond in the rough
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flyboy161
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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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My father's 1970 Beetle-
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The 1964...Diamond in the rough
http://www.thesamba.com/vw/forum/viewtopic.php?t=612776

My 1958 Morocco Bug-
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flyboy161
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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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The 1964...Diamond in the rough
http://www.thesamba.com/vw/forum/viewtopic.php?t=612776

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flyboy161
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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 1.2Ē x 3.5Ē 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 Iíll 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. Iím sitting on the fence on this one. I donít want to replace a heater channel.
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If I end up patching that tube Iím going to have to cut into the channel skin to fully treat it. Ugh!

On a happy note, I did find a body shop thatíll spray the car when Iím ready.
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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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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: Sun Dec 29, 2019 10:09 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Looking fantastic. Thanks for the updates!
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flyboy161
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PostPosted: Sun Dec 29, 2019 5:54 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Sunday was a productive day for me.
Finished the passenger quarter a finding some areas that needed a little finesse
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Patched the remaining rust holes around the back window
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And around the windshield as well
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Now to drill and retap those four pesky pan bolts.
A little interior clean up and then Iíll be ready to paint the interior and mate the pan with the body.
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My father's 1970 Beetle-
http://www.thesamba.com/vw/forum/viewtopic.php?t=603879

The 1964...Diamond in the rough
http://www.thesamba.com/vw/forum/viewtopic.php?t=612776

My 1958 Morocco Bug-
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flyboy161
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PostPosted: Sat Dec 28, 2019 12:38 pm    Post subject: Re: 1958 De Luxe Beetle from Morocco Reply with quote

Interior paint is about 7 days out. I decided to work on some sculpting today to finish out the right front quarter panel. As a refresher, this car had been hit on the right front corner and repairs on it were shoddy to say the least. That and rust formed as a result of metal fatigue and crap-tasting repair job, somebody did.
This was from March 2018, after I hammered a bit trying to retrieve the basic shapes pressed into the panel.
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Rough. But better. I ended up replacing the bumper mount area entirely.
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The after shot
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Yesterday, I started hammering again. And then today I was ready for some filler.
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Two thin layers and itís primed
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My father's 1970 Beetle-
http://www.thesamba.com/vw/forum/viewtopic.php?t=603879

The 1964...Diamond in the rough
http://www.thesamba.com/vw/forum/viewtopic.php?t=612776

My 1958 Morocco Bug-
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