Wednesday, 24 November 2010
Tuesday, 23 November 2010
Front inner wing/ apron - New panels fitted
In order to make sure the new panels fit correctly, the bonnet and wings where fitted.
Beginning to look like a car finally!
Beginning to look like a car finally!
Front inner wing/ apron - Removal
Cleaning up a hinge
Taking the doors off was a bit of a challenge. I had to drive the pin out of one hinge.
After cleaning I put it back together with a new pin.
After cleaning I put it back together with a new pin.
Saturday, 13 November 2010
New panels
So the first problem I had was the new front wing that has been fitted, has no fuel access flap. The panel was available but is about £70-80 more expensive. The access in the old panel is without defect so I thought I would just spend some time cutting it out and fitting it to the new panel. Today, when picking up some new bits, I asked about the old petrol tanks. Pre 68. They have the filler cap under the bonnet. Would they fit my bug?
I was told that it will, I just need to get a new petrol cap to fit the new tank. This worked out really well as I was thinking that I should use some fuel tank sealer as it is almost 40 years old. Who knows what the inside is lined with now!
Also got the rubbers for all windows, the engine bay and the floor to body gasket. The accelerator and clutch cable was also included in my purchases.
The front valance.
The bottom of the spare wheel bay.
Passenger side front wing panel.
I was told that it will, I just need to get a new petrol cap to fit the new tank. This worked out really well as I was thinking that I should use some fuel tank sealer as it is almost 40 years old. Who knows what the inside is lined with now!
Also got the rubbers for all windows, the engine bay and the floor to body gasket. The accelerator and clutch cable was also included in my purchases.
The front valance.
The bottom of the spare wheel bay.
Passenger side front wing panel.
Wednesday, 10 November 2010
Body work - drivers side wing replacement
Previously we have tried to set the size of the door opening correctly but up until now thing have only been tacked in place. With the drivers wing becoming fixed today, it would mean the door post can be fixed in place for good.
As can be seen here (sorry about the contrast, it was a sunny day) the bottom of the wing and the top gutter has been destroyed by rust.
A previous repair (not by me!) was the bottom of the spare wheel bay was replaced and riveted in place. It did not take long to remove.
With the old panel cut off, the remaining parts of it were grinded out.
Cutting the door post for realignment.
Welding the door post in place.
The new panel in place. It was not simple to fit but after much fiddling it was ok.
All the welding needs tidying up but the panel is in place and I have another shopping list of parts to replace!
As can be seen here (sorry about the contrast, it was a sunny day) the bottom of the wing and the top gutter has been destroyed by rust.
A previous repair (not by me!) was the bottom of the spare wheel bay was replaced and riveted in place. It did not take long to remove.
With the old panel cut off, the remaining parts of it were grinded out.
Cutting the door post for realignment.
Welding the door post in place.
The new panel in place. It was not simple to fit but after much fiddling it was ok.
All the welding needs tidying up but the panel is in place and I have another shopping list of parts to replace!
Tuesday, 9 November 2010
Body work - cross panel replacement
Today we raised the car a couple of feet off the ground to give better access.
The first thing we did was to correct the drivers door space.
Malcolm has the ram that operates much like a normal jack. It helped maintain the distance for welding in place.
Unfortunately, this side of the car, the door had always rubbed a little when closing. After it was tacked into place, we found it needed more height. Malcolm raised the door space, placed a filler bit of metal into the door frame and then welded the hell out of it.
Once the door was ok, we moved on to behind the passenger side front section.
Both sides of the front where removed to fit the cross panel in.
I had purchased the complete panel with the intention of cutting it down. This is what was taken off.
Cutting the rusty cross member out.
It took most of the morning to get the new cross member in. It did not line up very well. It makes you wonder who designs these new panels, are they aware that they're for a beetle?
Finally, the cross member gets slotted into place!
I spoke too soon. Just need to take a little more off.
Now it fits, time to weld.
The top edge that meets the old panel did not match up at all. But after much persuasion it did!
Now we could fit the new outer panel.
It fitted really well.
Some minor adjustments...
And it was welded into place.
The cross member was poorly welded in the factory. After banging with a hammer, the second skin began to peel away! More welding required.
We expected to get more done in the day but the cross member held us up loads.
The first thing we did was to correct the drivers door space.
Malcolm has the ram that operates much like a normal jack. It helped maintain the distance for welding in place.
Unfortunately, this side of the car, the door had always rubbed a little when closing. After it was tacked into place, we found it needed more height. Malcolm raised the door space, placed a filler bit of metal into the door frame and then welded the hell out of it.
Once the door was ok, we moved on to behind the passenger side front section.
Both sides of the front where removed to fit the cross panel in.
I had purchased the complete panel with the intention of cutting it down. This is what was taken off.
Cutting the rusty cross member out.
It took most of the morning to get the new cross member in. It did not line up very well. It makes you wonder who designs these new panels, are they aware that they're for a beetle?
Finally, the cross member gets slotted into place!
I spoke too soon. Just need to take a little more off.
Now it fits, time to weld.
The top edge that meets the old panel did not match up at all. But after much persuasion it did!
Now we could fit the new outer panel.
It fitted really well.
Some minor adjustments...
And it was welded into place.
The cross member was poorly welded in the factory. After banging with a hammer, the second skin began to peel away! More welding required.
We expected to get more done in the day but the cross member held us up loads.
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