Episode 26 (October 15 - October 22)
 
 

The weather has been lousy, so the beetle can get more attention. Nice days are reserved for fall portraits and other outdoor pursuits. Fran and I have now fully decided to go ahead with plans for my new studio, so the beetle will have to be done by the summer. My shop will have to return to woodworking when construction begins. Ahhh, finally a real deadline.

Separation Time

With all the major panels in place, it was time to separate the body from the chassis for the last time...hopefully. It's much easier to get at the underside of the body when the two are apart.
 

 

New Welder

I had to return the borrowed MIG welder after having it for nearly a year. I bought this unit and a larger gas cylinder for a decent price. Notice the Vise Grip collection on the welder and floor.

One Piece at a Time

I guess the best way to tackle this job is one piece at a time. I don't really have enough room to paint the car in my shop, so this is my only option at the moment. I focus on finishing the welding in a particular area, wire brush it clean and put a coat of epoxy primer over it as soon as possible.
 

 

  New Approach

The need for a more organized approach quickly became apparent. I decided to start at the very front and work my way back.

 A Good Start

All the welds were finished on the front compartment and firewall, the sharp edges were removed and a quick coat of primer was applied.
 

 

New Paint Gun

This little gravity-fed paint gun has been great for the early coats of primer. It takes any amount of paint or primer in the hopper and uses it all up before quitting. The primer costs $100 a liter so you don't want to waste it.The hopper also is adjustable so you can spray the paint at any angle.

Before....

Here's a good example of what stage I'm at. This is the inside of the front wheel well on the passenger's side. You can see the new metal pieces haven't been completely welded in and the old welds haven't been cleaned up yet.
 

 

... During ...

All the welding for this area has been completed. I now have to grind the welds down and wire brush all the seams and joints.

....and After.

Can you see the difference?

Even with only a single coat of primer on it, the whole area has cleaned up dramatically. Almost everything you see will be covered by the carpets when the car is complete.
 

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