The 1978 VW Beetle Cabrio


Disassembly begins
Restoration of the Chassis
Restoration of Suspension Components
Major Rust Repair of the Body - page 1
Major Rust Repair of the Body - page 2
Major Rust Repair of the Body - page 3
Prepping the Body for Paint before mounting to the Chassis
Prepping for Paint
Assembly after Painting
Interior

Major Rust Repair of the Body - page 2

Now I need a new heater channel, and the plate that goes between. Also some more pieces to fabricate.

The new heater channel came. Here a few picture during cutting out careful the old rusted pieces.

Laying the whole thing at the side like this makes it so much easier to work on it.

Turning it to the position so it's comfortable to work.

A section of the old channel is gone, and so some other rusted bits and pieces.

Finally, the complete heater channel is out.

Now the challenge starts. I sandwiched together the support rail and the heater channel, and the holes do not line up.

The rails are made in Germany, the channel is made in Danmark.

Looks like I have to do some fitting of these holes, between the channel, rail, and the floor pan. Also the front end piece I had to flatten out, because it was too short.

I put in some bolts between the rail, floor pan and channel, and here goes the first test fit.

Some pushing and wiggeling and it actually doesn't fit that bad.

Looks like I need to fabricate some pieces to fill in the holes, LOL.

Checking the inside, and it doesn't look that bad, as well the measurements of the door opening.

On the front side I have to make some pieces. I got the outer skin, but there are some pieces to fabricate. A little more as it was on the right side.

Here it is fitted in. Next I will check it out, mark all the holes which need rework, and if it's all good, tak-weld in the channel.

One last look on the RIGHT side, to see some positive things, and then it was time for a nice beer.

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. 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.

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. 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.

Finished the rear inside corners.

More to cut out and welding inside the engine compartment

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.

Disassembly begins
Restoration of the Chassis
Restoration of Suspension Components
Major Rust Repair of the Body
Major Rust Repair of the Body - page 2
Major Rust Repair of the Body - page 3
Prepping the Body for Paint before mounting to the Chassis
Prepping for Paint
Assembly after Painting
Interior