DIY door bottom repair with replacement panels

[Bruce]

In that long weld, I would clamp a copper bar on the other side of the panel while you weld. That way the bar pulls the heat out faster than you can drop the torch and grab a wet rag. Also, you can increase your heat and weld longer distances with the copper. Copper is magical! Experiment and see.
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[eurodub]

i use a TIG welder with good results on beetle metal. the secret is patience as everyone said before, welding in small areas far apart so each cools as much as possible.
my split has overlapped door skin repairs made in the past, i got the doors from Belgium that way. i tried everything to seal the area but the paint and filler keep on bubbling. the only repair for me now is to weld it all the way once i get Mika's repair panels.

as for the door hinge rivets, VW suggested using bolts when replacing them.
you can see it in the below link

http://fridaysplit.blogspot.de/2012/05/mera-dorrar.html
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1960 1200 model 117 deluxe ragtop
1974 T2 Westfalia Campmobile
1976 MK1 Golf

[Hebster52]

Great thread!
Is there some drawings or diagrams of these doors where you can find measurements for helping to get the panels right? I'm also in the process of starting this same repair.

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~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD

[sinclair]

[Hebster52]

The past weekend I tackled the rust issue on the first door. Getting ready for welding!

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~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD

[type4split]

Hebster. did you make the vertical support brace?
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'67 deluxe bus w/the little windows
'52 beetle
'55 convertible
'50-something convertible (*need ribbed 'vert quarter panel )
'63 "milo" beetle
Part, parts and more parts

[Hebster52]

[Hebster52]

Had to make a tool for aligning the hinges too.

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~Kris~
The Hebster52
The 912ST
The KidVRod project
The 356 Pre-A replica,SOLD
The 1966 Kommanderwagen, SOLD
The Doppel -67, SOLD
The Singlecab -72, SOLD

[esde]

I harvested an interior part from another door, which was fine, and used the lower repair panel from Mika. I tried my best to use the flange for the repair, but ended up with a bit of warping that was disappointing. IN the end, a donor skin was found and the weld seam was higher up where it is easier to keep straight and hidden.
During the repair attempt, I made a plywood form, so I could reference when things were in line or starting to warp. While it didn't help me that time, I do still make forms to use as a reference..

Problem with the flanged repair, is that you cannot correct anything with a shrinking disc. So, the full skin was removed for a donor skin. You can use almost any skin up to 64 if you correct the door handle hole

lotta wasted time and money getting to the finish line here, at least it's in the rear view now..
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that.