My Baja Bug Rebuild

Give details and pictures of your ACVW projects here.
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Edmond
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Re: My Baja Bug Rebuild

Post by Edmond »

retrovan wrote: Mon Mar 22, 2021 8:38 pm Nice work so far,

Always good to get yet another thing done.

Soon you will be driving with joy.

Keep posting, love to follow your thread.

Herman
Thanks Herman

Likewise I love following your Mefusco thread as it is really something different and interesting


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Edmond
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Re: My Baja Bug Rebuild

Post by Edmond »

Made some more progress, more rust cutout, templates created, now just need to get some 1.2mm plate for the repair sections

The sound is almost sorted, I picked up a 8 inch pioneer active sub with remote for R300, just need a set of component splits(mids and tweeters with crossovers) but these can wait a bit
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Edmond
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Re: My Baja Bug Rebuild

Post by Edmond »

I haven't posted in a while so thought it's time to update this thread. I have started cutting out some rust by the back windscreen, also welded in a patch panel on the left back fender well. I also removed the previous fiberglass repairs on the roof that were starting to lift, uncovered some nice holes and major rust.
I need some advice on how to fix the roof/roof gutter area and how best to kill the rust so it does not return.
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retrovan
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Re: My Baja Bug Rebuild

Post by retrovan »

Problem with the roof gutter is its two parts welded on top of each other

So once the rust has got in between its hard to stop it without cutting the joint open and re build the roof completely.

But what you can do is expose both sides and wire brush as much as you can even into the joint, then brush in a rust converter, keep wetting the joint with rust converter so it can soak in between the two layers of steel.

Now try to seal the joint once dry with a thick coat of clear coat, this will stop air going in and starting the rust again.

Rust cannot rust unless it gets water or air. it you stop both she will not get worse

Good luck and nice work.

Herman
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Edmond
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Re: My Baja Bug Rebuild

Post by Edmond »

Thanks Herman

That's what I was worried about, the rust has crept between the two layers. Will try your suggestion with wire brush and rust converter.
Do you think fiberglass is the best to use for this repair, it lasted 20 yrs on the previous repair or should I rather use aluminum mesh and fiberglass filler, I don't really want to cut out that part of the roof and weld in a donor piece but if it's the only way so be it.
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retrovan
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Re: My Baja Bug Rebuild

Post by retrovan »

Fiberglass is very old school, as they did not know that fiberglass was hydroscopic.

It will draw water into it and rust the metal contact surface faster then when left open.

Your best bet it to tape up the underside after applying your rust converter

pour in a water proof epoxy resine compound, the same I use for sealing tanks.see below.

And when dry paint on the underside in layers. Maybe apply a clear coat just to seal the edge of the resine, as its in your headliner, I would not sand or polish it for max strength

You can then sand it smooth an cover with your paint and it will last indefinite.

Hope this helps.

Herman

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1952 Split Beetle 1835cc (Azure Blue)
1968 Fastback 2Lt.type4( Red)
1972 Low Light Bay Panel Van 2Lt type 4(White)
1975 Fleetline Panel Van 1914cc (Aqua Blue/White)
2020 MeFusco Beetle Truck 2Lt type 4 (ww2 colours)
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