I could grate cheese with this!

Ok, the windows are all removed, and I've started grinding down to bare metal in some suspect spots.


On advice of a Samba forum post, I took a closer look beneath the headlights. The driver's side is fine, but the passenger side had a tiny discoloration (sorry, no 'before' photo) about the size on a pinhead. Here's what the 2x3 inch area looked like after hitting it with the wire wheel...





Here's an area behind the wheel on the passenger's side. It also started out as a small blister before the wire wheel... now its an opening about the size of a golf ball.
I got some 40-mil aircraft-grade '4130' sheet metal from McMaster-Carr for about $38. The cost also includes angle iron I will use to make a Type III pulley wrench (from the Muir Book) and shipping.

Peeling the Onion

I purchased new window rubber for all side and rear windows from JBugs/California Pacific. Also got a new gas cap, since the old one was a locking type from WalMart and looked a bit ghetto ($228 total for the replacement rubber and gas cap). They were out of windshield rubber, so I will have to go back next week and get some.

Upon closer inspection...

After removing the window rubber, it looks like the rust beneath this rear quarter is a bit more extensive. This may require welding a 'donor piece', which is certainly more than I bargained for when I bought the car.

There is a hump in the driver's side floor pan. Don't know if this is from a wreck or if someone used the wrong jacking location at some point. May require floor pan replacement.

Battery pan rusted through. This is a common trouble spot, and at least new replacement battery pans are available. Guess I'll have to learn welding.

'Before' Shots

I just bought a 1970 VW Squareback off eBay motors for $2550. I'm using this venue to journal the the time, techniques, and resources necessary to complete the job.

Initial purchase: I took the train up to my sister's place in LA. The previous owner ('PO' in VW message forum speak) Did not know too much about the car other than he was the 3rd owner, it ran well, and that the brakes did NOT work well. I drove it home from LA the rainy weekend of the Superbowl (Feb 2nd) and verified the car had anti-lock (and anti-stop!) brakes.

Took the car in to VW Paradise in San Marcos, CA to have the Master Cylinder and brake lines replaced the week of Feb 5th ($500). Drove it home and washed it to get a better look at the body.Pretty straight frame and fenders.
Hopefully this is all the rust that is under the side window.
The engine and tin are stock. Needs a new engine hatch gasket for sure.
Interior is ok but still damp from the rainy drive home. Inside is still the factory color (Savannah Beige?).

A bit of rust beneath the windshield. Hopefully this is no more rust beneath the windshield rubber.