Installing the front left vw beetle quarter panel part 1.

One of the most challenging of operations is the removal and installation of the front left quarter panel. My bug had been crashed so many times by previous owners that it had no more shape to it. I tried to correct it with bondo, then gave up. 

The first task is to drill out the old spot welds around the front apron, sides, and front cross beam (fire wall) and heater channel. Then you have to unfold the metal around the door. I found that if I cut cross wise above the quarter panel fold, I could chisel the fold down the length of folded metal. That worked.

This is the folded metal. Cut a slit across the fold just above the quarter panel. Then pry the fold open.

This is what the pried open fold looks like. The old metal will slide right out.

I ordered a new panel and began removing the old pane. I drilled out old spot welds and ground out large pieces of metal until all was gone. I pried the rest out and once finished, began prepping the new piece to fit.

 Trying to fit the quarter panel to the front apron and the door post metal fold is difficult. I decided to tackle spot welding to the front apron first. I called my dad to help and thankfully he was available. As I welded he pushed in the quarter panel flush with the front apron. We used pot holders to disperse the heat from the mig welder.

New quarter panel spot welded to the front apron

Spot welds inside the front apron

The fold is straightened and the new sheet metal should fit in.

FItting in the VW Beetle Heater Channel Part 1

 Removing the old rusted out heater channel took a while. I bought a new heater channel with all components as a unit. It fit very well. After drilling out the spot welds, prying and grinding, I pulled out the old stuff piece by piece. I decided to put the body back on the chassis so that there would be less of a chance for the body to warp or fold. That worked out pretty well until I tried to put in the new channel. It just wouldn't fit with the gas,brake, and clutch pedals in the way. I finally lifted the back end off the chassis and put it on a saw horse. I finally had enough room to bolt the new channel to the chassis. Once securely bolted in, I lowered the chassis. I'll weld it in later after I replace the cross beams. They are pretty rusted out as well.

Try as I might, I couldn't get the new channel in.

I lifted the rear of the body off the chassis. Finally enough room.

I bolted the new heater channel to the chassis and lowered the body to the heater channel.

Heat channel fits, just have to finish welding in the new front left quarter panel

New channel fits like a dream.

Look at that

Removing the VW Beetle Heater Channel and Related Sheet Metal

Cut out an old section above the heater channel. I've got  the replacement sheet metal and will fix it later.

Working on the VW Beetle is going waaaay slower than the impression I get from those great car shops on the Velocity channel. Those guys can do way more in 30 minutes than I can do. Anyway, sorry so long without posting, but life got in the way. I did not abandon the work, it just took a while to do anything that anyone would notice. 

So far, I've cut out a little bit of rusted metal, welded in some fender receiver bolts and strategized how I would replace new metal. I've had a welder breakdown as well and spent a few weeks waiting for a replacement. I also ordered new parts and prepared them for welding. 

The new parts arrive with a protective coating. I always remove this coating by painting on aircraft removal chemicals. This is an easier method than grinding with a wire wheel. Once the protective coating is removed, you can apply some primer to protect the metal until you are ready to weld it. I also used POR-15  to protect the inside (parts unseen when welded back to the car).

This piece has POR-15 on the inside to fight future rust. It will go in the cut out area of the picture above.

This is the outside piece that will be primered and painted.

This week I had a great opportunity to get back to work and make some recognizable headway. I drilled out old spot welds and chisled out the remaining metal. This is hard work that takes a lot of time. I removed the left front quarter panel and the left heater channel. I  prepped the replacement pieces and braced the VW with pig iron from Tractor Supply. If you don't brace the doorway, the car could fold when the heater channel is cut out.

 

Will have to replace the crossbeam and end of heater channel

drilling out old spot welds. 

This is the new heater channel end piece.

 

Still more heater channel spot welds to drill out.

Drilled out heater channel spot welds. Notice the weld around
the heater pipe, cut that out with a grinder.

Pig iron welded in as support brackets. Heater channel is gone.

Support vertically and horizontally

Once the spot welds are drilled out, the metal separates easily;
Hopefully.

 

This is an amazing tool for cutting out spot welds:

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Once you cut out the spot welds, use this tool to separate the metal sections: