Rust holes near rear window - Best way to fix?

[djmatio]

Hello,

1972 super, rust holes on either side of the rear window near the window, down near the bottom half. These were painted over when I purchased the car, but my finger poked through one day to my surprise. The total size of the rust spot must be 3" in diameter (mostly still covered with paint and super rusty), and are on either side. Trouble is that they are too far up on the pillar that I cannot access them from under the hood. There is a metal panel blocking access.

These are the only rust spots I have. Can someone suggest a way to fix them? Welding? Bond-o? etc. The location of these holes makes it difficult because you cannot get at the back of the panel. If you would like a picture I can take one.

thanks,

Matt

[Lazarus]

hey matt post a pic. if its where i think it is i may have a solution for you.

[djmatio]

Rear View. You can see rust at bottom corners of window:


Driver Side Rust:


Passenger Side Rust:



Driver side is rustiest. Can poke screwdriver through metal. Not huge, but growing. What do you have in mind?

Thanks

[wrenchnride247]

I would cut out the rust area, and graft in some sheet metal from a donor bug. I belive any '64 and later will work for donor. There's still some bugs out there that are not rusting in this area. This is not the easiest way to fix, but the way i've done it, due to my sheet metal skills from my day job . I'm interested in what Laz has done too. There's more than one way to skin a bug...uh i mean cat .

[Mikey]

That's my suggestion too. Find you a good donor and weld in a patch. A little skim coat of filler later and you'd be set. Yetibone did the same thing in his bug. Might wanna check the thread, or even get his experiance on the problem.

http://www.germanlook.com/Forums/sho...6&page=5&pp=15

I believe it's on that page. Pictures too.

[Kafer_Mike]

Be prepared for that 3" patch to grow when you get under the paint. I agree on grafting in new metal, however much that takes. You'll want to cut back to solid metal...

[djmatio]

I've discovered the extent of the damage. I have since cut out the corners of the rear window from a donor car, but those pieces have metal work that is quite cmplicated, with many different peices of metal converging to form that piece of the rear structure.

The rust is on both sides of the car in the bottom corners of the rear window. Apparently 1972+ have foam that absorbs moisture and creates rust.

Anyone have any suggestions on how to deal with this? Short of getting a new car of course.

[Gdub]

I am getting ready to do this same repair on my 74. I cut some patches from a solid donor and will weld em in as soon as it warms up!

[wrenchnride247]

Originally Posted by djmatio

I've discovered the extent of the damage. I have since cut out the corners of the rear window from a donor car, but those pieces have metal work that is quite cmplicated, with many different peices of metal converging to form that piece of the rear structure.

The rust is on both sides of the car in the bottom corners of the rear window. Apparently 1972+ have foam that absorbs moisture and creates rust.

Anyone have any suggestions on how to deal with this? Short of getting a new car of course.

You should look at rust repair products by this company www.eastwood.com They have quite a few products that can help. For the outside you still cant go wrong with factory metal grafted in. On the inside the head liner material will cover it, but you should treat the rust with the eastwood products. They have very good service and support (they also have a forum for people using their products.

[Steve C]

Hi

I would like the person responsible for spraying that foam everywhere to own up, so that every owner with a late model bug can throw rotten fruit at him.

Steve

[yetibone]

I had to do repairs like that on my Bug's body. 5 total, and I used a '69 model for a donor.

Remove all the foam. It'll catch fire when welding, and the smoke will contaminate the weld.

When doing the repair to the window corner, It's a good idea to remove the spot-welded part at the rear window opening so the new metal doesn't overlap the old layer. If it did, the window would be hard to reinstall, and would not seal up watertight.

I'd suggest cutting out the remaining piece above the rear deck-lid, to the left of the vertical grille, and below the already removed section, and graft in a larger piece of metal. Only reason being that there'll be one less butt-weld to do in a tough to re-shape area when you stitch the new piece in.

[Oval]

Originally Posted by wrenchnride247

I would cut out the rust area, and graft in some sheet metal from a donor bug. .

use an engine lid/hood/bonnet as a 'donor bug' Easy to find and NEVER rusty!