Death foam replacement

[Synchromesh]

Long story short, my '72 Super exhibited rust in the usual places. I bondoed the bejeezus out of it couple of times but it kept coming back. Instead of doing in the third time I realized I should just get it properly repaired at the body shop. They repaired it but had to remove the death foam on the right side. Since the car has a dual carbs, there is a nice Kadron sitting right below that area which now makes wonderful race car sounds right through that open area and into my ear.

So the question is - is there anything I can do about it? I don't think sealing the area off with sealer is the answer as it may get water to accumulate there if there is no escape. So what's the usual method and can I do it after they welded everything back up already?
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'72 Super Beetle sunroof sedan

[Pez]

Pre-death foam they stuffed seat material in a triangular bag made out of head liner material scraps. Didn't sound deaden as well as the foam but worked and didn't cause rot. Just check any of the death foam threads for pictures. Also have the other side cleaned of foam while your at it, good preventive maintenance
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Always chasing Squirrel's.

[Hatracks]

i ended up stuffing zip lock bags with insulation material and stuffing them in there, not sure it really helped with noise i was more worried about fumes being sucked through there.
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73 Super Build

[Synchromesh]

Can I still stuff things in there after it's all been zipped up by body work? I mean there is basically no access through the engine compartment so maybe the half-moon vent?
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'72 Super Beetle sunroof sedan

[Tom K.]

Enter from the inside behind the rear seats.. Cut a hole for access.

By the way, here is pic of the rubber seal that failed on your car. Thus seal lies between the vent hole backing metal and the body.

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'91 Vanagon Westfalia
'70 Beetle Convertible
'71 Super Beetle Semi-Automatic: https://www.thesamba.com/vw/forum/viewtopic.php?t=714131&highlight=
'65 Ghia: https://www.thesamba.com/vw/forum/viewtopic.php?t=762478&highlight=

[Buggeee]

[Tom K.]

Right, if all you need to do is stuff material in, then no need to cut interior holes. You can access from the engine compartment as Buggeee says or from the front by first removing the rear "door" cardboard panels.
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'91 Vanagon Westfalia
'70 Beetle Convertible
'71 Super Beetle Semi-Automatic: https://www.thesamba.com/vw/forum/viewtopic.php?t=714131&highlight=
'65 Ghia: https://www.thesamba.com/vw/forum/viewtopic.php?t=762478&highlight=

[Airstream65]

I have often wandered if it would be advisable to spray foam from engine bay on an earlier Beetle along with original pillows?

[Synchromesh]

[Tom K.]

Try this. First spray liberal amounts of Fluid Film or similar into the channel. Then take an ordinary plastic bag and stuff it in deep with the bag opening facing back. Then take a can of expandable foam in a can and spray it into your plastic bag.

The Fluid film protects the metal. The bag allows you to get the new foam out in the future should you need to.

Just one idea.
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'91 Vanagon Westfalia
'70 Beetle Convertible
'71 Super Beetle Semi-Automatic: https://www.thesamba.com/vw/forum/viewtopic.php?t=714131&highlight=
'65 Ghia: https://www.thesamba.com/vw/forum/viewtopic.php?t=762478&highlight=

[Murmsk]

So I have a 72 that shows no sign of rust. Would it be wise to dig that stuff out ?

Steve
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1970 Convertible
1972 super
1946 Willys Jeep

[Tom K.]

[Synchromesh]

[Tom K.]

[74 standard]

I cut holes on the inside to access it like the previous poster did. Then to make sure I removed as much as possible I put a metal coat hanger in the chuck of my drill and went at it from the engine compartment. I then welded the panels I cut out back in and this caused the remaining foam to catch fire pretty much effectively removing the balance.That stuff is highly flammable. DON’T DO THIS WITH THE WIRING HARNESS IN as it will be toasted by the fire as will the paint.

[Synchromesh]

Is there a way to stuff this place without opening it up? I think the holes in the engine compartment are quite tiny so they won't be easy to work with, however, I'd rather try that way than butcher the interior metal.
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'72 Super Beetle sunroof sedan

[vamram]

You can do it from the engine compartment but it's not easy and you'll be doing much of it blind. I've done it like this on two Supers. Come at it from the rear card areas as well using some of the makeshift tools described above.
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Eventually, "we are what we pretend to be.’”
Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
Click to view image
Save the Supers!!

[Synchromesh]

[vamram]

In one of them I used this: https://www.amazon.com/Foam-Packaging-Bags-Tempera...amp;sr=8-5

in the other I used this. https://www.westmarine.com/buy/evercoat--sealant-foam-spray-12-oz--276659

in both cases I cleaned, rust treated the surface, painted it and added rubber undercoating before the foam.
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Eventually, "we are what we pretend to be.’”
Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
Click to view image
Save the Supers!!

[Synchromesh]

Thank you. Since I won't have full access I think the bags are out but I maybe able to spray enough foam in there from the car from second link. Rubber coating is also unlikely but I'll look into it.

Biggest question though - in both cases, did it take care of the sound like the original foam does?
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'72 Super Beetle sunroof sedan