68 SqBack - Baby Huey

[RIX70Bay]

I decided it is time for me to open my own post with a few pictures to start. I have removed the body from the pan. I have already purchased a set of Gerson pans. After separating the body from the pan, looking at it I think I only need to do the passenger side pan. I think I only need to do about a half of that pan.

_________________
Rick

1970 7 Passenger Bus (Rose)
1968 Square back (Baby Huey)
1970 Standard Bug
1951 Crosley Super
1968 Camaro (Gifted to my son)

[Bobnotch]

Since you already have the body off, you might as well replace both sides full length. The hard work is already done. The dirty job is just beginning though. Once you do both sides and paint them, you'll thank yourself for going the extra distance, as you'll have a nice foundation to build upon. Just my take on it. And I've done several over the years, including a couple of bugs and a Thing. That's not even mentioning doing a T-34 or either of the 2 Notchbacks, or my wife's 70 Fastback.
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Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120

[RIX70Bay]

Thanks for your input. I will keep all that in mind. That was my thought going into this. I don't have any welding skills except for school many years ago. All that I have read here is cut to good metal. This car has surprised me, everything I take apart is in my opinion, do not need to replace. The grinding process continues.
_________________
Rick

1970 7 Passenger Bus (Rose)
1968 Square back (Baby Huey)
1970 Standard Bug
1951 Crosley Super
1968 Camaro (Gifted to my son)

[RIX70Bay]

How do you guys repair the pan divider panel when replacing the floor pans? I have purchased a repair panel, but it is just a half panel not a full replacement piece. Just wondering if there is another option.

_________________
Rick

1970 7 Passenger Bus (Rose)
1968 Square back (Baby Huey)
1970 Standard Bug
1951 Crosley Super
1968 Camaro (Gifted to my son)

[Mike Fisher]

Don't cut it off of the tunnel making more work!
Weld on the 1/2 section repair panel as that is the only thing reproduced.
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https://imgur.com/user/FisherSquareback/posts
69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
two 57 oval ragtops sold
'68 Karmann Ghia sold

Society is like stew. If you don't keep it stirred up you end up with a lot of scum on the top! - Russ_Wolfe/Edward Abbey

[Bobnotch]

[RIX70Bay]

I have started to grind away at the bad metal.

_________________
Rick

1970 7 Passenger Bus (Rose)
1968 Square back (Baby Huey)
1970 Standard Bug
1951 Crosley Super
1968 Camaro (Gifted to my son)

[RIX70Bay]

Thanks for your replies, Mike Fisher and BobNotch. Here is a photo of the pan divider replacement piece. It looks like it will do the job there.

_________________
Rick

1970 7 Passenger Bus (Rose)
1968 Square back (Baby Huey)
1970 Standard Bug
1951 Crosley Super
1968 Camaro (Gifted to my son)

[RIX70Bay]

The next phase of grinding is the forward section of the pan. The front pan divider may need to get replaced also, if the whole pan gets replaced. Do you guys know where to get some kind of repair panel for that?

_________________
Rick

1970 7 Passenger Bus (Rose)
1968 Square back (Baby Huey)
1970 Standard Bug
1951 Crosley Super
1968 Camaro (Gifted to my son)

[Mike Fisher]

You need a Good welder with gas shielding to proceed or you are stopped 'dead in the water!'
www.masterseriesct.com satin silver and/or gloss black brushed on looks good on chassis/suspension & inner fenders.
_________________
https://imgur.com/user/FisherSquareback/posts
69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
two 57 oval ragtops sold
'68 Karmann Ghia sold

Society is like stew. If you don't keep it stirred up you end up with a lot of scum on the top! - Russ_Wolfe/Edward Abbey

[RIX70Bay]

I like the idea of using masterseries, I will have to get an order going soon. As for a welder, I have a Lincoln Handy Mig welder. I am not sure if it is big enough to do this job. I need to get it set up and start practicing.

I am going to get out in the shop and continue cutting and grinding today. I would like to see a photo of how far you all cut when you all cut the pan off.

Again, Thanks for the replies. Everything helps at this point. 👍
_________________
Rick

1970 7 Passenger Bus (Rose)
1968 Square back (Baby Huey)
1970 Standard Bug
1951 Crosley Super
1968 Camaro (Gifted to my son)

[Bobnotch]

Here's some of mine from when I did my 71 Notch.

this was in prep for replacing the front frame head.

Note that the body is off, and the pans are good used (more metal than rust) as the Gerson pans weren't available at the time (2007). They got sand blasted and epoxy primed before being painted (last pic).
I hope these help.
_________________
Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120

[RIX70Bay]

This really does help; I am fighting my fear of getting in way over my head (skill wise). Your first pic shows what you did with the front pan divider. I ground all of the rust off of mine today and they look good. I had a feeling that when the pans are completely replaced that they get cut off. My other fear is cutting off all of the good metal from the rear napoleon hat. I also see how you did the rear pan divider so the new pan can be fitted in. I'm also afraid that cutting the outside bolt pattern off that the body will not fit well.

Thanks, Bobnotch, it really does help.

I'm going to continue cutting, grinding and fitting. I will get more and more confidence as I go.
_________________
Rick

1970 7 Passenger Bus (Rose)
1968 Square back (Baby Huey)
1970 Standard Bug
1951 Crosley Super
1968 Camaro (Gifted to my son)

[Bobnotch]

Most of those pics I posted above were from the tear down phase of my 71 Notch (link in my signature). If look in the background, you can see the new frame head I replaced the rusty one with, along with an entire front clip I used as well.I also had to fabricate some inside corners to tie in the rear clip to the heater channels. A lot of the body repair work can be found in my build thread, although you can also see pics in my Gallery, which is where I dug up from (above pics). I had started a tear down thread, where a lot of pics of the pan work were hiding, as that's where all the rust was shown. This was probably the rustiest car I ever did, and I had a lot of after work hours and weekends into it (6 solid months worth). As some of the comments were that I was fueled by beer and smokes while doing it, as I had a lot of late nights into it. I know every bolt except the trans got removed on that car.
_________________
Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120

[RIX70Bay]

I cut a lot out of the passenger side pan and then had my wife come out and have a look. She says there is still some rust. So, I decided, it is a full pan at least on that side.

I think I have the front pretty much figured out where to do the cuts. The rear is a little harder to know exactly where to cut. I am going to try to find your teardown photos (BobNotch) thanks, and maybe get a better idea.

The welder I have is a Lincoln Handy Mig, do you all think that it will be good enough to do the job?
_________________
Rick

1970 7 Passenger Bus (Rose)
1968 Square back (Baby Huey)
1970 Standard Bug
1951 Crosley Super
1968 Camaro (Gifted to my son)

[TheGrafs]

Hey there,

Just stumbled upon this and wanted to say I made a video a few years back about floor pan replacement on Type 3’s using 3M panel bond adhesive. I get mixed feedback on it, but regardless if you weld or glue the pans on, it may be a useful resource. As far as your Lincoln welder, dialed in right it should do the job no problem. Be mindful of the duty cycle (amount of time in use) and also do “skip welding”. Skip around rather than weld from one end to the other. For small panels it prevents warpage but for a large panel like floor pans, itll help it from “moving around” as metal tends to do when it gets hot!

Best of luck,

Alex
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1957 Oval Semaphore Beetle
1964 Notchback S
1966 Fastback
1970 Squareback

Youtube: GrafsGarage3
Instagram: GrafsGarage

[Tram]

Alex:

Agree that the panel bonder is damn good stuff, but this is way better:
https://www.autobodytoolmart.com/product/3m-impact...gKoUPD_BwE

Yes, it's spendy but it really helps eliminate corrosion from a weld, plus it goes a long way. Install it with rivets to really hold it down. Once cured, drill out the rivets and tack the holes.
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Немає виправдання для війни! Я з Україною.

[TheGrafs]

Hey Tram,

I agree that is a great method as well. I used 8115 and rivets on my fastback. I have trust in the repair and this will be a forever car so I wont be selling it to anyone who may worry about that repair procedure.

Alex
_________________
1957 Oval Semaphore Beetle
1964 Notchback S
1966 Fastback
1970 Squareback

Youtube: GrafsGarage3
Instagram: GrafsGarage

[Bobnotch]

[RIX70Bay]

I am meticulously slow at cutting the passenger side pan off. At first, I wanted to keep the outside rail that the body bolts onto so that the body will just bolt right back on. Now I am realizing that it will be better to use the entire funky green pan.

I looked at your gallery, Alex and my "where to cut questions" are answered. My new question is: are there any measurements that you took prior to cutting the old pan off to know where to trim the new pan?
I like idea that Alex and Tram have with the adhesive and rivets. Then come back and drill out the rivets to spotweld.

Thanks again for all of the replies. I am a fairly good mechanic, but it is kind of fun trying to learn this body shop stuff.
_________________
Rick

1970 7 Passenger Bus (Rose)
1968 Square back (Baby Huey)
1970 Standard Bug
1951 Crosley Super
1968 Camaro (Gifted to my son)