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The Life and Rebuild of Dad’s Iceland Green 1955 Beetle
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kintail
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PostPosted: Mon Feb 17, 2025 6:12 am    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Thanks again for all the photos in addressing the issues on the inner section to valence to make it work to perfection.

Taking my muffler off last week and seeing the damage. I want to move forward with the removal of rear fenders to find any further repairs needed for the bumper bracket mounts. Weather warming up for a thaw by end of week.

Hope to get to the my same repair to match the quality of yours!!
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PostPosted: Sun Feb 16, 2025 10:43 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

I made some great progress this weekend buttoning up the back end of this project. I made all the shape modifications i think I needed, then I proceeded with the final prep of the apron for install. Started by spot welding the engine seal channel. I bought the preformed set from Virtanen.

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I decided not to use weld through primer under the seal but rather spray and flood the gap after welding. I did not want this thin metal blowing out from contaminants.
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Test fitting and yes as he advertises, it is the proper length. It fit perfectly to my old channels. It sticks out past the apron.
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I did use weld through primer on the laps of the apron to the valence and to the side panels. The location I used was to center the cutout around the fender bolt hole, and snug against the tails of the inner fender.
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Test fitted the valence to the apron. I had to tap down the flap inside that joins the valence to get a good tight lap. Then I clamped and sheet metal screwed it together. Started spot welding it together in place. There was no way to fit this in elegantly if these two were welded off the car.
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A view of the tight lap. I spent a good amount of time forming this joint.
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The final J-channel joint proximity, spot welded down.
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Then I went for the sides of the valence, and finally the sides of the apron. I put a small bead inside the lap of the engine seal channell to keep it aligned.
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I must say it is a solid structure when fully welded with new thick metal. I can pick up the whole end of the car from just the apron. I am pleased how it turned out. Nice and tidy in the engine compartment area now. Smile
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Then I moved on to removing the old upper rear seal channels. I was amazed how much crud and rust was lurking under the old ones. I will be replacing all of these J channels on this car for this reason.
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I need a dry day to sandblast and chemically treat this rust in prep for the new J channels.
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PostPosted: Tue Feb 11, 2025 9:56 am    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

kintail wrote:
Thanks for all the photos.....The detailed tutorial here is much appreciated!!

My unknown at the moment is the condition of the bumper bracket to body attachment points. However I can see the very rear of my original apron is beaten upwards. We'll have to take some measurements to see if everything still lines up.

Maybe an option to cut the new valence and fit to the original sheet metal. But all depends on how far the "bashing" damage extends. Otherwise this approach may be the way to go.

Have sent the link to Cam, for his consideration in repairing my '54. He also is a perfectionist in his craft.

Anyway no messing around in the garage this morning at -29C!


It is -6C at my house this morning.

I think you are right to focus on the bumper bracket being close. If you have another good car to compare positions to, or the other side of the car, it might be a good idea. Or replace the whole bracket area. I have not found good reference measurements except the one for the last bolt from the package tray step distance.

Put some pictures out there of the condition and the forum can advise you further. My fender bolt template was key at getting the panel placement where I was confident.

Good luck!
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PostPosted: Tue Feb 11, 2025 8:33 am    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Thanks for all the photos.....The detailed tutorial here is much appreciated!!

My unknown at the moment is the condition of the bumper bracket to body attachment points. However I can see the very rear of my original apron is beaten upwards. We'll have to take some measurements to see if everything still lines up.

Maybe an option to cut the new valence and fit to the original sheet metal. But all depends on how far the "bashing" damage extends. Otherwise this approach may be the way to go.

Have sent the link to Cam, for his consideration in repairing my '54. He also is a perfectionist in his craft.

Anyway no messing around in the garage this morning at -29C!
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PostPosted: Mon Feb 10, 2025 11:31 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Looking very good! Brings back memories!
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PostPosted: Mon Feb 10, 2025 10:24 am    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

This weekends progress on getting the inner valence to fit properly.

First I sheet metal screwed the apron and valence together to see how mismatched it would be. I used the "natural" fit of the two together where they would ultimately be spot welded together. Glad I did not just go ahead and weld them.
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Squeezing it in produced this fit. No way I would install this with the shift in the seal channels.
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My engine compartment side cover plates are original except I replaced the seal channels. The rear tips of those begin the radius of the seal path, and the lap to the rear valence. At this lap, I had to trim about 20mm of seal channel from each side of the valence. Now it will tuck under the side plates.
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Trimmed back channels is done. I had to widen the panel using the shrinker to change the bend radius a bit. I had to reshape this step to make the tuck fit. Clamped in the vise and used a flat punch make the offset in a new place.
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The upper corners were too tall so I began trimming those down.
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Used a level to determine the position at the seal channel center was even with the whole compartment.
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Then the big modification. I wanted the pressing to fit the apron lap. In order to that, I needed to take a wedge shape out of the valence, and trim the center by about 1/8".
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The progress of the fit.
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After cutting, welding and cleanup.
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I did not have time to reassemble everything for a final fit but I am pretty confident.
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PostPosted: Mon Feb 03, 2025 9:31 am    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Jimbo, That long reach spot welder is nice when you need it! I have a shorter Harbor Freight model too that just could not get that far back on that last spot.

Kintail, I will do my best to document the approach and results of getting the apron assembly in proper position. It is the next thing I am going to work on. It may be next weekend though so stay tuned.
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PostPosted: Mon Feb 03, 2025 1:44 am    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Following with interest in the rear apron alignment with the bumper brackets. Not sure what I have as I need to cut off the bracket bolts yet and have to wait for winter to move on with non-heated garage. Keep moving forward!!
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PostPosted: Mon Feb 03, 2025 12:07 am    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Nice work! That spot welder barely fits in there!
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PostPosted: Sun Feb 02, 2025 9:46 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Weekend progress to share. I focused on the open engine compartment as it is nice to be in here before the apron is installed. I got the old hacked up firewall tin removed and got my reworked donor part installed. I used a die grinder to break the spot welds from the upper firewall. This way there was no punch through to the inside.

Here is the old hack, done to make clearance for the later model heater boxes during engine install. If I had only realized to put the heater boxes on after the block was bolted in place, I would not have done the hacking. Dumb high school thinking, it was... Sad

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Getting it fitted in, and spot welded what I could. I used sheet metal screws on the upper edge for rough-in.
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I used a pry bar tied to the pan for leverage to push the upper lip tight to the base metal. No pic but I wanted the seam close. The finished results.
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Then I moved on to replacing the seal channels on the side plates. I got about half spot welded on and the remaining area had to be plug welded. I don't have a tight fit spot welding jaw. I replaced all the broken firewall liner tabs in the engine compartment too.
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I am happy to get this tidied up and fixed for a good seal around the engine. Next phase is the inner valence fitting and the apron.
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PostPosted: Sun Jan 26, 2025 9:41 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Finished up the other tail today. The usual fitting to a tight gap, and welding it in.

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Shakin' those new Tail Feathers!
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Apron test fit.
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Prepped the inner valence by adding the wire holding tabs. This part will need quite a bit of fitting to line up with the seal channel and rear apron. I bet some folks miss that these were in there when the part gets replaced. Thankfully, I noticed it from someone who had a picture on the forum. The one in the middle is not a factory original, I believe, but I added it anyway.
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PostPosted: Mon Jan 20, 2025 12:46 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Switched sides and now repairing the right bumper mount area. It had been hit harder and the mount had a big tear but seemed rebuildable. I decided to keep it and just replace the sheet metal where the apron mounts.

I bought a panel from DKB metal and had these findings. The first was the gauge of metal was not 1mm. It seemed flimsy at .8 or .85mm. This being a structural part, it makes sense to match the original thickness. The shape seemed to be a good match but because the thickness, I opted to not use the full panel. I will keep original good thick metal, the original mount, and just trim what I need from the new piece and sell the rest. The new bumper mount portion looks OK and measures up to be the right thickness.

Started by mirroring bending the fender bolt template I used on the left. The hole spacing turned out to match well.
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Then I replaced the flat weld nuts with squares.
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The area of replacement.
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Red line is approximate cut line.
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To repair the bumper bracket, I cut a flap out of the back so I could access the inside cavity of the bracket to work it back into shape, and do a better weld on the tear.
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The repaired bracket.
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Then I Ospho'd the interior cavity with a rag and wire pokey thing to get far up as possible. I will paint up in there after it cures.
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That's it for this weekend's progress.
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PostPosted: Mon Jan 13, 2025 5:35 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Jimbo, no, I did not put the grommet in. The fender beading is not there either and that affects slot position left and right. But I may do it when I rework the other side. Put both sides on and maybe the bumper to check level.

Last resort would be to get creative on the slots in the bumper bracket. But that is truly my LAST resort. Smile
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PostPosted: Mon Jan 13, 2025 9:30 am    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

esde wrote:
Excellent!!
if you don't pay attention to all the little details, there are a number of ways that repair can bite you later, but I think you nailed it!


I will second that statement! Looks great!

Did you try a bumper bracket grommet out on the fender hole? I had a set from a few cars back and installed it after I had sparingly tacked everything into position. Thankfully I had set everything into place (or close enough) that a few hammer blows coerced everything into alignment!

Yours looks like it will fit into its spot perfectly, but better to check it out now!
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PostPosted: Mon Jan 13, 2025 5:51 am    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Excellent!!
if you don't pay attention to all the little details, there are a number of ways that repair can bite you later, but I think you nailed it!
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PostPosted: Sun Jan 12, 2025 10:51 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

I was happy with the modifications and measurements to the repair panel. I finished it up today by exchanging the weld nuts on the fender mount, and a small tweak to the lower edge U-channel where it will match up with the original metal.


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I was not sure that I could effectively spot weld the new nuts in place. I think the factory did the 4 spots simultaneously but I had to do one at a time. It worked but I also used the MIG to add a reinforcement bead. I don't want them to break off.

The final fit. The paint runs are from spraying primer down into the cavity of the bumper bracket. There is no real good way after installing this to protect in there, that I know of. It was the zinc weld through primer and it soaked between the spot welds.
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Tacked in and checking the fender and bumper bracket. I could not see anything out of place.
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The finished step for the day. No pic but I spot welded the engine bay piece. It had a nice fit to the new metal. The weld surface was not the best as I would do on an external surface. I plan on testing out some lead free solder on joints like this to learn that technique, and hide the joint better. It is not bad as-is, and would pass especially if I under coat in here. But, I plan on just leaving the wheel wells painted.

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Enjoy!
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PostPosted: Sun Jan 05, 2025 1:04 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

I committed to making the panel mods to get a good fit. My fender template bar was key at keeping the rear position matching original.

I cut a line and wedged it out to the shape I needed. It ended up being close to 6-7mm at the widest.
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I plan on welding on the matching square nuts to this panel as that is what this car uses for weldnuts.

Still good fit on the front.
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Here is the bar in place. The upper line is good, and the bumper hole distance of 44.5" is good (no pic).
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Welding progress. I cut a thin strip to fill most of the gap. The narrower section I was able to weld with a copper backer.
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The next step is to tack it in and assemble the fender and apron for test fitting. I think my fender is in good enough shape to judge the fit.

This has been a LOT of work! This panel could have easily been closer to the proper shape. Maybe it is based on a different year of car, other than the bracket itself.
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PostPosted: Fri Jan 03, 2025 1:23 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

When I did mine I did not pay attention to angles or measurements or anything of that sort. I clamped the repair panel in place, bolted the fenders on and the decklid and then bolted the bumpers in place. I adjusted the repair panels so the bumper brackets came through the center of the slots in the fenders and the decklid opened without interference and fixed that position.

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Don
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PostPosted: Tue Dec 31, 2024 10:47 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

OK I have the bumper bracket slope data to share. I use bolts threaded into the bracket to rest the flat bar with the level. The body was level to 0.1 degree for the baseline.

The right side, which I consider to be close enough to an undamaged condition for this measurement. 4.3 degrees.
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The damaged left side, with the hammered bracket that I removed, but clamped in as close as I could get it. 7.4 degees
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Left side with the new panel attached through the fender holes. This is essentially with the upper surface aligned with original. 8 degrees.
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Left side with the new bracket rotated so the lower edge aligns with the original panel. Pivoting at the rear fender bolt. 6.7 degrees.
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The lower edge.
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The new panel, rotated to the lower edge aligned, then I loosely attached a (restored) bumper bracket. I am determining how much slop I have to work with from the slotted holes. 5.6 to 6.9 deg slope.
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I am being extra picky here because I want to avoid any metal rework later on, and to certainly avoid the worst case of finding an alignment problem with installing the bumper on a freshly painted car. I plan on installing the fenders and bumper brackets on both sides before welding anything home. I just want to share the progress steps along the way.

My initial conclusion is to align the lower edge of the new panel, and splice a wedge shape in to lift the upper edge to fit. It will be about a 4mm wide pie piece. The sharpie pen line is approximately where I would do the cut. The wiring hole will also line up when cut this way.
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One more day off left to make more progress...
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PostPosted: Tue Dec 31, 2024 7:36 pm    Post subject: Re: The Life and Rebuild of Dad’s Iceland Green 1955 Beetle Reply with quote

Dan22 wrote:
Thanks for the pointer to your thread. Looks like your panels overlaid better than mine to the orginal.

I am in the process of searching where you put your bumper mounts back on. Im up to page 26 on your thread but still looking!


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