Hood Fresh 1962 Euro Rag

[thekera]

jzjames, I have been keeping an eye out for my next project. I would love to do an old type 2 or a single cab. I also would not mind a Ghia, just with a Ghia it might be hard finding good replacement panels? Also would like to do another Beetle just something a little older. What can I say, I like them all lol.

[wcfvw69]

I just happened across this thread. You're doing a great job there. It's reminded me of replacing the lower 12" of my convertible 16 years ago. I will say, I don't miss the smell of grinding disc's nor do my eyes miss the sparks (even with eye wear). lol

Did this bug spend time where it was exposed to snow and salt? My bug had spent several years in the Kansas City area were it suffered from the salt..

Keep up the good work!
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Decades of VW and VW parts restoration experience.
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**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
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[thekera]

wcfvw69, Thank you for the compliments. I know what you are talking about when it comes to the sparks and smell of grinding metal. I will probably try and show a post of some safety items, I have found to be very helpful in minimizing some of the very real safety concerns when doing panel replacement.

As far as the 1962, I would be the third owner. The OG owner from my understanding was in the military stationed in Germany and brought the car back with him to Tacoma WA. The second owner was a father and son who are VW collectors up here in the NW outside of Tacoma. Now it is in my hands. As far as the 1962's exposer, up here in the NW it rains I would say 280 days out of the year. From what I have heard, The OG owner Had it under a carport and many people tried buying it from him for many years but he would not sell.

I just hope to do this VW justice in resurrecting it to the best of my ability.

[thekera]

It's been awhile. Been busy, but also I have been working on the rear passenger section. In particular, the passenger side luggage section. This section gave me a run for my money. I can't say for sure but I believe the metal in the luggage panel is slightly thinner gauge metal than most panels on the Beetle. It looks to be about the same gauge as the front upper kick panel.

I started this section by making a replacement panel, using a combination of the shrinker stretcher, english wheel, and brake.

After making the panel, I welded in the panel starting at the bottom and working my way back. This panel, like I said seemed to be thinner gauge than most the other panels I have welded in so I made sure to back it up with copper.

Now you cannot see in the photos, but I was not happy with how this section turned out. It was not horrible, just not up to my OCD standards lol. I also was having a hell of a time with pinholes in one little area. So, I decided to cut out the area I was not happy with and made a little panel to replace the area giving me trouble.

Now, this section still has more. Welding the flange to the wheel well and installing and welding it to the rear cross member. This section was a pain, but I was happy with the outcome once I finished welding in the small patch.

Keep posted, more to come of the rear passenger section. Thanks for following the thread and keep checking in.

[thekera]

Before I weld the flange of the package tray to the rear wheel well, I started cleaning up and preparing the rear cross member and other odds and ends in the rear corner.

After cleaning up the rear cross member, I located the cross member using the jig I made. From here, I started the install of the cross member and tacking in the flange of the luggage tray. This was a little tricky plug welding all of the factory spot weld locations as it was hard to get to some areas.

There is still some final metal finishing left to do, but most of that I will try and get to after all the panels are in. This back corner takes a lot of time. I will be happy to finish up the passenger side heater channel soon. I hope lol.

Keep checking in, and thanks

[thekera]

It has been awhile since I have done a tool update. When doing panel replacement and fab work I cannot stress enough the importance of safety. Flying hot metal, air particulates, and many hazards associated with welding. I can speak from personal experience and have been overly safe. Ive had to have metal dremeled out of my eye, on two different occasions at the optometrist and was wearing two-forms of eye protection when this happened. Point being, be safe. You only are born with one body, take care of it.

- Two forms of eye protection. glasses and a shield
-good auto darkening welding helmet
-leather gloves
-dust mask, especially when grinding
-hearing protection
-knee pads, for those awkward positions

On a lighter note, these pliers are awesome for metal work! Not cheap but worth the money and there made in Germany.

[thekera]

Been cleaning up some odds and ends in preparation for the install of the heater channel. The inner B pillar on this side was in much better shape than the drivers side. I did go ahead and replaced the headliner retainer strip and the corresponding triangle that its spot welded too. The retaining strip is from Mika, and is spot on. Also the Flap that wraps onto the heater channel needed replacing.

Thanks for checking in and keep coming back
GOT RUST?

[thekera]

In getting ready to install the passenger side heater channel, I did some prep work. I first removed green primer in the soon to be welded areas and applied weld thru primer. I used Zero Rust and an internal frame wand to coat the inside of the channel with rust preventive paint.

[charliesnyder]

Just skimmed through the entire thread. I must say amazing work!

One question... When can I drop my '65 off?!?

[67rustavenger]

[thekera]

charliesnyder, Thank you for the compliment. Another WA guy! About the 65........Im actually in the process of having another garage/shop built that will be based around metal work on these old crusty VW's. I would like to someday be able to offer metal work to others, so keep in contact and keep checking in.

GOT RUST?

[inzel]

Looking really good. Im very impressed with what you have done here. Look forward to seeing this when its complete. Im expecting an entry in to Hot VWs or something
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--inzel--

66 Bug
69 Fasty
Old school Sandrail

[thekera]

67rustavenger and inzel, Thank you for the kind words. Keeps me going. Don't worry, I got you in the Q 67rustavenger.

So back at the top of page 5, I mentioned I would be installing the Klassic Fab inner firewall section when I installed the heater channel. This actually worked out quiet well. Better than the way I did it on the drivers side.

I prepped the backside of this panel with Zero Rust. This section I used both Mig and the spot welder to install.

OLD PANEL:

NEW PANEL:

Keep posted, keep checking in and thank you for following the thread.
GOT RUST?

[wcfvw69]

Nice job sectioning in that firewall patch. I wish I did that on my 69 convertible. I removed the entire firewall and it was a TON of work.

I like the attention to detail of this repair. Good attention to detail to use a stud puller to get the panel flat after grinding the welds.
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc

Decades of VW and VW parts restoration experience.
The Samba member since 2004.

**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours**

[charliesnyder]

[thekera]

wcfvw69, thanks for noticing the amount of detail it takes to do panel replacement/metal work. slow and steady.

[thekera]

charliesnyder, i live in north Seattle.

[67rustavenger]

thekera, I'm wondering if you can post a couple of pics showing what you are grinding your welds with. Maybe the proper position of the grinder. I know that you have said that you use the edge of a cutting wheel for the high spots. I was carefully grinding a couple of welds that I made on a rear fender yesterday and it seems that the metal near the welds gets thin. I knocked down the high spots and then get a flat file out to finish the job. This method worked but was time consuming.
The work you do is inspirational. Thanks for sharing your well documented progress. It helps those of us out here working on similar projects.
Have a great Memorial Day weekend.
_________________
I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!

[thekera]

67rustavenger, Thanks for the question. Grinding your welds flat is probably the hardest part of this kind of work. To make it appear as though the panel was never replaced takes a lot of practice. It is by far the most time consuming part of the process of replacing a panel. Sometimes I will spend up to 5 or more hours metal finishing a panel, that being said I may be sick with OCD lol.

Some tools I use are a flap wheel on a 4 inch grinder, 3inch cut off wheel, angle grinder with assortment of 3M grit wheels, belt sander, body file, and sand paper.

One thing to remember is any welding will cause distortion of the panel, especially at where you will be grinding the weld. It is important to get the area as flat or back into its OG shape before grinding. A good way to practice knocking your welds down is to lay strips of blue tape on either side of the weld, now grind down the weld without cutting into the tape. Just remember it is a process and takes time and PATIENCE. Only at the very end of finishing the weld will I blend a very small amount with the surrounding metal.

Just like anything that's worth getting good at, its hard and takes time and practice. I like to think of it as an art and want to take pride into my work and keep perfecting it.

Keep practicing you will get it down. Don't be afraid to make a mistake either it can all be fixed.

Thanks and keep checking in.

[thekera]

Like the drivers side, many of the panels being replaced in this thread are building up to the replacement of the heater channels. It sure feels good getting to the point of welding in the channels as it takes months of hard work to get there.

Before actually welding in the channels it takes quiet a bit of double checking measurements and checking fitment. The welding in of the channels requires many different techniques of welding: spot welds, lap welds, and bead welds.

It's starting to come together. Still some work left in the rear quarter and up in the front end. Keep posted and thanks for checking in.