Volkswagen Beetle Sheet Metal: Hinge Pillars & Door Skins

In this video we begin by showing you what the heater channel looks like and the different kinds available. We then move to our 63 sunroof bug and show where the channel is located in the car and exactly where and how it is attached. We then drill out the spot welds and cut the solid welds showing what tools can be used and where care should be exercised. When completely loose we show how to brace the door opening and lift the body enough to remove the old channel. (removing the body was demonstrated in Vol.6 and is needed info) Once the channel is out we repair a badly rusted door post (A pillar) by butt welding in a replacement panel. This is explained and demonstrated in clear detail.

Now the new channel is put in place; the body is lowered; and the channel is welded back into place. Door alignment is given attention during this final part.

At this point we move on to a '70 beetle convertible. The extra strengthening gussets and panels are pointed out and removed. Now a procedure that allows the channel to be removed without lifting the body is demonstrated. This is done by replacing the lower portion of the rear quarter panel (which was badly rusted on our car) and replacing a strip of metal in the front wheel well. Once these panels are removed the channel can be maneuvered out the side of the body. Another manner of securing the door opening is demonstrated here. With the channel back in place we show how to do a lap weld with a joggle in the panel when replacing the lower quarter panel. We show an inexpensive spot welding tool that can be used with any DC arc welder and how to do a plug weld. All without warping the flat panel.

Just for fun, the last few minutes of the tape is filled with outtakes from the video.