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bullibene
Samba Member
Joined: August 20, 2011
Posts: 70
Location: Munich, Germany
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 Posted: Mon Jun 27, 2016 2:47 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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Next step as previously mentioned was the conversion of the front bumper mounts.
I removed the bumper mounts...
and blasted & primed them.
Due to the different pressing of the later front quarters i used, the bumper mount needed to be modified to fit properly.
big gap
I made a template out of paper and transfered it to some 2mm steel
cut off the flange from the mount and bent the built metal piece into the right shape
after welding, grinding and blasting it looked like that:
widened vs stock bumper mount
aligned and welded:
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grandpa pete
Samba Member
Joined: July 06, 2008
Posts: 6426
Location: St. Petersburg, FL
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1960 euro crusty 1
Samba Member
Joined: June 18, 2014
Posts: 29
Location: seacoast
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| Posted: Tue Jun 28, 2016 5:08 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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| that is some nice work!! cant wait to see more pics |
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bullibene
Samba Member
Joined: August 20, 2011
Posts: 70
Location: Munich, Germany
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| Posted: Thu Jun 30, 2016 2:32 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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| grandpa pete wrote: |
| Do you have the measurements for your bumper adaption piece ? If that inner panel is the only one available there will be others looking to make it fit . |
Measurements vary depending on where you cut the flange of the bumpers mount.... also this is not very difficult to measure 
Thanks for all the compliments!  
I blasted the horn mount and primed it with weld thru primer on the inside
Installed and primed
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Instagram: 089garage |
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Joseph DR
Samba Member
Joined: December 20, 2004
Posts: 180
Location: Texas
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| Posted: Thu Jun 30, 2016 8:53 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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Wie gehts! You're bringing this bug back from the dead. Excellent work!
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1964 Beetle |
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bullibene
Samba Member
Joined: August 20, 2011
Posts: 70
Location: Munich, Germany
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| Posted: Tue Jul 12, 2016 2:53 am Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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Front end is finished 
It starts to look like a car again
Front apron aligned and welded on. The hood latch was zinc plated.
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Instagram: 089garage |
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TheDon
Samba Member
Joined: July 14, 2005
Posts: 498
Location: Windermere
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| Posted: Tue Jul 12, 2016 11:01 am Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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Amazing work!
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ratlooker
Samba Member
Joined: February 12, 2009
Posts: 5
Location: Germany
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| Posted: Tue Sep 06, 2016 5:05 am Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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Bene, where's the next update on your ratty fuckin' cool project?
We're waiting |
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bullibene
Samba Member
Joined: August 20, 2011
Posts: 70
Location: Munich, Germany
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| Posted: Tue Sep 06, 2016 6:54 am Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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I've been a bit lazy with updates...
I managed to source a better 62 pan for cheap. So i will not use the original pan...
or whats left of it. I took some pictures together with the panels i cut out of the body.
I only cut out the leftovers of the floorpans.
All the missing metall of the frame head and napoleon hat rusted away!!
However the paint still looks nice on the inside 
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Instagram: 089garage |
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kokanee
Samba Member
Joined: April 15, 2007
Posts: 329
Location: Washougal WA
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| Posted: Tue Sep 06, 2016 1:26 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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| You are a brave man nice work |
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bullibene
Samba Member
Joined: August 20, 2011
Posts: 70
Location: Munich, Germany
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| Posted: Tue Sep 13, 2016 2:12 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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Regarding the pictures of the original pan, most of you will agree it was far beyond for being safed
Thats why i bought another 62 pan from the local classifieds for the price that the repro panels would have cost to fix my old one(also safed me a lot of work).
The condition was described as "No rust repair needed".
That was not 100% the case but still the pan was in great shape.
It needed minor rust repair at both napoleonhat bottom plates, one outter piece of the napoleon hat and one jack stand mount.
"old" vs. "new"
100% original including the 62 only heater outlets
Before blasting i fixed all the rust issues i mentioned above.
First was the area behind the jack stand mount....
...the first napoleon hat bottom plate...
...and the second, including the napoleon hat itself.
i decided to weld up the holes as the metal still was strong
view from the outside - already ground down
Bottom plate:
grinded
Now the pan was 100% solid again and was ready for blasting and zinc coating. (called "Flammspritzverzinken" in german)
Haulin in style
The white coat is zinc. The zinc is melted and shot onto the pan while liquid. Probably the best way to prevent your pan from corrosion (Still needs to be painted)
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Instagram: 089garage
Last edited by bullibene on Thu Mar 22, 2018 5:01 pm; edited 3 times in total |
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bullibene
Samba Member
Joined: August 20, 2011
Posts: 70
Location: Munich, Germany
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| Posted: Wed Sep 14, 2016 2:45 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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After zinc coating the pan was painted.
1. layer: grey
2. layer: matt black
I also applied seam sealer. I taped of the areas around the seam for a clean look
3. layer: gloss black
Looks almost to nice for a rat look project
Now i need to finish welding on the body that i can get it also in covered in paint!
best regards
bene
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62ItalianRagtop
Samba Member
Joined: August 18, 2007
Posts: 1354
Location: Italy
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| Posted: Wed Sep 14, 2016 11:12 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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_________________
LOOKING FOR 62 ENGINE WITH NUMBER FROM 6.904.xxx TO 6.915.xxx
http://tettodistraccio.blogspot.com/ |
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coxbzh
Samba Member
Joined: March 01, 2016
Posts: 22
Location: Brest meme
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| Posted: Thu Sep 15, 2016 6:55 am Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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| very good result ! |
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bobnorman
Samba Newfoundlander
Joined: August 09, 2010
Posts: 1389
Location: Newfoundland
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| Posted: Thu Sep 15, 2016 7:22 am Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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Very, very nice. Did you graft the old chassis number? Or will you register it under the new one?
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Air does not freeze. Air does not boil.
http://www.thesamba.com/vw/forum/viewtopic.php?t=289807 |
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bullibene
Samba Member
Joined: August 20, 2011
Posts: 70
Location: Munich, Germany
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| Posted: Thu Sep 15, 2016 12:04 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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| bobnorman wrote: |
| Very, very nice. Did you graft the old chassis number? Or will you register it under the new one? |
Thank you
No i didn't graft the old number. The new pan came with papers and the car didn't. So this suited actually quite well
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bullibene
Samba Member
Joined: August 20, 2011
Posts: 70
Location: Munich, Germany
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| Posted: Sun Sep 18, 2016 1:36 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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Back to the body:
I used the repair panels of hookeys panel shop from the UK to repair the front windscreen corners.
Really good panels for a good price
The repair panel was a bit to short. So i bent a piece of sheetmetal to extend it.
welded and ground down
I cut out the rotten metal to make room for the repair panel.
As you can see in the pictures, the area of the dash behind the cutout corner was also rotten.
rotten metal cut away and area prepped with rust converter
Windscreen corner in place. I forgot to take pictures of the repair of the part of the dash. But you can see the fresh metal behind the screen corner. The radius still needs to be corrected
First, the area behind the seal strip on the cowl looked solid but after a quick clean up.... it didnt anymore  So i had to weld them up to.
Some time ago, next to my garage a new house with 5 flats was built. And these new neighbours aren't very happy with whats going on in my garage.
Especially the noisy things as grinding...
And as i dont want to overstrain their nervs, i came up with the idea of grinding down the welds somewhere else.
I loaded the body onto a trailer and grabbed my generator to drive into the middle of nowhere
Set up camp 
After grinding down all weld it looked like this:
Same procedure on the drivers side
best regards
bene
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Instagram: 089garage
Last edited by bullibene on Thu Mar 22, 2018 5:02 pm; edited 2 times in total |
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Rome
Samba Member
Joined: June 02, 2004
Posts: 9640
Location: Pearl River, NY
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| Posted: Sun Sep 18, 2016 7:26 pm Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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Did you fabricate the patch metal for the hood edge along the cowl? Or were you able to fill the metal by welding up each of the rust holes, as you mentioned?
On your windshield corner patches, did you notice if your Beetle already had the two small drain holes near the corners? The original metal looked too rotted away to tell. They'd look like on this '66-
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bullibene
Samba Member
Joined: August 20, 2011
Posts: 70
Location: Munich, Germany
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| Posted: Mon Sep 19, 2016 3:20 am Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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| Rome wrote: |
Did you fabricate the patch metal for the hood edge along the cowl?
Or were you able to fill the metal by welding up each of the rust holes, as you mentioned?
On your windshield corner patches, did you notice if your Beetle already had the two small drain holes near the corners?
The original metal looked too rotted away to tell. They'd look like on this '66-
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Hey Rome,
I did a combination out of both. Where the metal around the rust holes was still solid enough i just welded them up.
In the middle i welded in a flat piece of sheetmetal.
The drain holes are already drilled. I forgot to drill them before i took pictures
I guess it had drain holes from factory. Without them, water remains between the window rubber and the windscreen corner and can't drain off.
Missing drain holes result in extensiv corrosion.
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Silvester
Samba Member
Joined: February 03, 2005
Posts: 75
Location: Michigan
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| Posted: Mon Sep 19, 2016 9:27 am Post subject: Re: The "Gartenkäfer" - '62 resurrection |
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Wow...I am amazed by your talent. Keep up the awesome work. I am inspired for sure!
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Jeremy
Vw's currently caretaking
61 Beetle - Pastel blue
79 Scirocco - Kolibri Green
80 Scirocco S - Alpine white - Drake built 1.8 W/ Stage II Callaway. |
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