Front chassis cracks

[Indikaper]

Hi folks,

I am having vw bug since few years..few years ago I gave it to a body shop to do some tinkering..that stupid bugger did it bad and fogot to fix bolts on front mounts as well..I didn't see it unfortunately.due to that my front chassis got cracks as below...I have to tinker again..but I can't do it now due to financial issues..I have to run few months with this issue..so I need your support..what will be the cheapest way of fixing these cracks..is it repairable??

thanks,
indi

[67rustavenger]

Indi,
Where are these cracks located. The pics look somewhat like they are located on the inner fender wells.
Perhaps you can post a couple more. With the camera a little further away from the cracked area.

If the cracks are on the tunnel, near the frame head. This could be a real issue that needs addressing right away.

If it's in the fender wells. You can monitor the cracks until funds come available for a proper repair. But be aware that the body strength can be compromised.
_________________
I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!

[mukluk]

I really do hope that's not where I think it is. Those pictures appear to be the inside of the tunnel behind the emergency brake -- the two nutplates located on the pinched-in area are for the front seatbelts. That would mean not only is there a very sizeable hole in the tunnel's bottom plate, but also that the tunnel is practically cracked in half in the middle of the car.
_________________
1960 Ragtop w/Semaphores "Inga"

[VW_Jimbo]

WOW! Never seen a crack like that on the tunnel! I hope I am seeing this wrong.

Can you take 2 giant steps back and give some perspective of the area?
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[Indikaper]

Thanks guys.. for all the replies...


@67rustavenger

Your second guess is right. Those cracks are on the tunnel near frame head. Bottom plate is not available due to rust. That’s why i can get a picture..i took it underneath. How can i repair it? is it repairable?

@mukluk
This is not the area of hand brake brother. This is right below the firewall..

@VW_Jimbo

There is nothing WOW feeling for me.. ...looks huge trouble brother..i wonder nobody post such thing earlier in this forum..i have driven the car around 40mph without two front mount bolts. Likely i am alive i can't still believe how i survived with such crack. Miracle.. isn’t it?

Thanks,
indi

[VW_Jimbo]

Spelled it wrong. My brain is great numerically, but linguistically is a challenge. I meant WHOA!!!!

So, with that....

WHOA!!!!!

The Frame head, comes as a complete assembly. As long as you jig it correctly, you can cut the old one off and weld a new one in.

It’s not an easy job, but it is doable, if you have the brain and the tools!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[scrivyscriv]

There was a thread here a few months back with similar cracks but I can't recall the details. Stop drill the ends, grind the cracks out the thickness of a cutoff wheel, and weld it in several passes with cooling time in between.

The structure there is big and complex enough that you shouldn't see too much metal movement but welding will induce stress and will move the metal around some - it is just sheet metal after all. A stress relieving technique is to weld some, then tap the area with a body hammer to slightly relax the metal back down, and blow it off with air to cool it.
_________________
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.

[Indikaper]

[Indikaper]

[Busstom]

[Indikaper]

[ashman40]

Any chance that is some type of undercoating that has flaked/cracked? Can you actually see light coming thru the other side?
_________________
AshMan40
---------------------------
'67 Beetle #1 {project car that never made it to the road }
'75 Beetle 1200LS (RHD Japan model) {junked due to frame rot}
'67 Beetle #2 {2019 project car - Wish me luck!}

[Indikaper]

here is what welder did as temporarily solution..any idea? is this workable? since it is 17$ work..