[Patrick3000]

Originally Posted by Lupin..the..3rd

no kidding, he could charge admission and still fill the garage with people. very nice work.

X2 nice work, thanks for sharing!

[rothaus]

Here is what I did last weekend.

Line up of all the holes between the support rail, the heater channel and the floor pan. This took more time as I have expected.



Some of the holes need some grinding





Finally they all fit.



Starting on the inside to weld in small pieces where I had to cut of the rusted part.





Here after it's welded in, the seam at the bottom get's welded together with the support rail.



A view from the outside, more holes to close.



Fabricating and welding in the new pieces.



Here it is welded in.



More small pieces welded in. Next is the outside.



The last hole between inside and outside is now closed.



I found that the piece which goes under the section, is available, so I ordered that. Saves some cutting, bending and hammering.

More next weekend.

Cheers
Engelbert

[rothaus]

I made some progress the last weekend.

Fitting in the bottom section of quarter panel, and the bottom piece.





A little cutting bending and grinding and it will fit.



Looks a bit ugly, but once it's cleaned up, it will be OK.



More welding and grinding.





This part of the heater channel just did not line up.



I decided to cut of the section.

At least the holes from the support rail line up OK.



Quite a few pieces to fabricate here for this section, a little more than on the right side.



I thought it's a good idea to insert the heating tube now.



I found that the new aluminum tubes are larger then the original once. I used a good piece of the old one and they fit nice inside of the new one and it made a nice fit. I will save the rest of the old one, you never know.



The heater channel and support rail is now complete welded in.





Also the rear section is complete, at least from this angle.



I found some sections at the inside which I need to cut out and make some new pieces and weld in.

More for next weekend.

Cheers
Engelbert

[rothaus]

Time for an update. Not so much done, since I hade to get the green machine ready for the first AX next Sunday.

I gave the drive shaft hardware a treatment.

Here is what it looked like after getting all the dirt and grease off.



I was not happy with the socket heads, somebody must have used a vicegrip or something like that.



So I cleaned them up a little.





Next Bead blasting and send out for yellowzinc plating



Here is what they look like when they came back.



Next weekend will not much happen at the VW, sine I take the green car out and see how the new wheels and tires work.

Cheers
Engelbert

[Dr K]

It's nice that you made those look so pretty, but I've read on this board that you should always use NEW axle bolts. Cheap from McMaster-Carr, come as 25 in a box. I'm not certain but I think they stretch when torqued.

[Dave O]

No big deal at all on a low powered VW. I used, and re-used, the same CV bolts for over 300,000 miles on my '71....

[rothaus]

After a brake, because another unplanned car cam to me,

Saved another one this time a 87 Carrera



I'm now finally back on the Beetle again. I made some progress last weekend, and found more rust. Inside left and right rear section. I just cut out until I hit good material.



Clean it all up, and ready for some new sheet metal.





And one more section done.



More to cut out inside the engine compartment





My plan is to get the welding done by New Year, cross your fingers.

More to come.

Cheers
Engelbert

[rothaus]

I made some progress over the holidays.

Finished the rear inside corners.



So now it's time to move to the right rear corner behind the rear wheel section.



As more I poke around as more I find.



keep cutting until I hit good material.



Welding in more pieces.



I reused a piece which I cut out, since I had to get under there. It was easier to cut it out and weld back in, instead to fabricate the whole thing.



The bottom section I had to make new.



With the rear section done, it's time to move to the left front section, where I had to cut out quit some rust.



Making more pieces and welding in.



One down, a lot more to go.



It's coming slowly together



Now the outside.



And finally the outer skin.



The black piece was purchased.



Almost done



And finally with the rip piece welded in.



Now I moved the the dash section. There was also more rust than I wanted, plus the holes from an after marked AC, which looked like cut out by a chainsaw.





Here a picture of the bad sections cut out.



Here are the pieces which need to be replaced.



The bottom section welded in.



Re-creating the replacement pieces with holes, etc.



And ready to be welded in.



Done with this on.



Now all the bad stuff is cut out. This is not an easy section, all is 3 dimensional.



Here a new piece.



And the last little piece ready to weld.



Here it is, all welded and cleaned up.



That was the last section of the body. I still have to do the doors. They got some rust at the bottom section. That will be next.

Cheers
Engelbert

[N0tt0N]

That is wonderful work. Thanks for sharing.

[Jazzbass]

God I love this thread. Great work Englebert. I had a 73 Super Beetle that lived most of its life in Virginia Beach and wasn't remotely as well cared for as your car. After seeing how much rust is on yours, I can't fathom how my car was even on one piece.