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: