Episode 30 (November 14 - 18)
 
 

This was a really great week for the beetle. Most of the welding is complete and the painting has begun. In a way this is the most exciting part of the process as the day to day progress is often dramatic. The weather has been extremely mild this past week which has made it possible to work with the shop doors open. It's always nice to be working in fresh air!

Old Electrical System

Most of the old wiring is incomplete and really unusable. I tried to be careful when removing it, but after a while it was clear that I would have to replace it all. There is a complete wiring harness available which will replace all the old wires.
 

 

Stripped Down

All the wiring and instrument panels have been removed from the dashboard. The car is pretty much just metal and paint now. No wires, no rust, no cables and no seals.

Curious Rust Spot

In only one spot under the hood there was a rusted area that I couldn't figure out. The hood completely seals the compartment and the wheel well was intact enough that water could not have entered. I had to do some detective work to figure it out.
 

 

The Problem

At the top of the compartment there is a gutter that drains water that gets past the hood seal. On the drivers side, there was a significant dent in the gutter that allowed the water to drain into the car and caused the rusted area. The blue line follows the path of the water.

Fixed up

I carefully hammered the dent out of the gutter which should now allow the water to drain out of the car as it was designed to. I am suspicious that this dent may have been an original flaw in the car as there was no evidence of impact to cause the dent.
 

 

Primed and Ready

The front compartment was hand sanded and epoxy primed to protect it for the rest of time. I have to paint this area before the body is put back onto the chassis in order to protect it properly.

Painted

Two coats of hardened enamel were applied over the primer and everything looks great. I'm going to use the enamel in the places where the final paint job really isn't too visible. Enamel is half the cost of base coat / clear coat paint and is durable enough to do the job in these areas.
 

 

Underneath too.

As we've seen from the original condition of the car, the bottom portion of the body needs to be protected the most. All the new metal has been primed and painted almost to excess to prevent the damage that I've been fixing over the last year. 

Engine Compartment Firewall

For the same reason as the front compartment, I had to paint the rear firewall in the engine compartment. Once things start to go back together I simply cannot get the access to these areas that I enjoy now.
 

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