New Here... Boy, Do I have my work cut out for me...

[Dubble_D70]

Hey everyone. I just picked up a complete, running, driving '69 Bug that I have some plans for.

The first thing I felt I needed to address was the cancer on this thing. The DS front panel had evidently been hit at some point. The previous bodywork must have been slapped on thick and in a hurry from what I've been reading, as it's all cracking and was separating from the panel. So I started grinding and sanding to find this.

I've been wanting to buy a welder and learn how to weld... No time like the present! Shouldn't be too difficult from what I've read and watched and from speaking with my brother, who welds for a living (Too bad he's in TN and I'm in AZ). It's flat metal there, no?

The were two other bubbly spots, so I hit them with the grinder and found this. How the hell am I going to attack this mess? I haven't tried to look at it from inside the bug. Is it reachable from in the cab?

The DS spot looks like I may be able to get it with the grinder and build it back up with filler.

But this goes all the way through. What if I chop it out and lay fiberglass in there? Then finish with filler?

Or, will I need to source some junkyard chunks and graft both sides?

Either way... Let the fun begin!!!

Any tips would be greatly appreciated.

[bomberbob]

Welcome to the house of pain. When I started examining/evaluating my 68, the drivers side front panel was damaged similar to yours. Previous owner(s) had drilled holes and injected what must have been pounds of bondo filler into that area. I cut mine out and welded in a whole new panel, along with a new forward bulkhead, and a bunch of other parts. I would say the hardest part and the part that I don't like the results was the vertical pinch weld on the rear edge. The rest of it came out fairly well. Problem is you can't easily get in there with a hammer and dolly, maybe you could try one of those devices that welds the stud to the panel, you use a slide hammer to pull out the dent, then grind off the stud.
I think the other rust spots on the rear of the drip rails you can cut out the rust and weld in new metal. I would not use fiberglass, but others may chime in on that. Cut it back to a point where you meet good solid steel. If you try to weld to rusty weakened thin metal, it will just blow holes. This spot is very close to the common rust spots on the newer bugs that have some kind of foam in there that holds moisture and causes rust. If you search for "death foam" you will find posts concerning rust damage very close to what you have.
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1968 Beetle torn apart again
1990 Jetta GLI megasquirted, burning E85 (currently in storage)
2004 Jetta turbo GLI
Marion, Iowa

[Dubble_D70]

This is what it looks like now... Mangled Swiss Cheese.

[bomberbob]

There is a pretty good YouTube video that you can watch that shows replacing that front quarter panel. Search for Niko Brothers, and "Wrecked Vintage 1968 VW Beetle Chill While We Rebuild Montage". I don't know if I can paste the URL, so I will just tell you what to look for.
I do not think that removing that panel from a donor and then transplanting it to your car is a viable task. If you watch the video you will see all the points where it's welded. I welded in a new aftermarket panel.
Where I screwed up was I saw someplace that they just took a grinder and ground off the top edge of the pinch weld. It was easy and fast, but when I went to attach the new panel I only had half of my pinch weld left. Don't do what I did, watch what Niko bros do, peel it back and save it.

_________________
1968 Beetle torn apart again
1990 Jetta GLI megasquirted, burning E85 (currently in storage)
2004 Jetta turbo GLI
Marion, Iowa