Classic VW Beetle Bugs How to restore repair Floor Pan Battery Tray

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In this short video I show you how to replace your battery tray area on your beetle floor pan. THIS IS FOR THE HOME RESTORER, yeah the guy in his backyard.
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Chris

[@222billp]

your offering your free time to help people and the critics come out of the woodwork. Peoples attitudes never cease to amaze me. Keep up the good work it is appreciated !

[@zoegibson1557]

Making use of the kzbin.infoUgkxcJ22tnHH9l1vjdIdEIG27iOG55P7LXI8 reconditioning plan, I just saved 2 auto batteries from being completely junked. The guides were very simple to follow. I wish I would have found this years ago! You may use the guide to recondition any battery type

[@gforcepdx]

I bought my first MIG last month and used it to the point I'm ready to tackle the rotted battery pan. I could have figured this out (eventually) through trial and error but watching you do it once means my final job will look and perform much better for the fifteen minutes taken to learn from your patient example. Thank you so much for taking the time to walk a nubie through the process. You rock... j

[@steveirving1]

Chris, I never did pans before, watched this video, and over the weekend easily replaced both quarter pans for about 80 bucks pans and sealer. Thanks for all the vw advise and support.

[@TheParanorm]

Great video Chris!!! Your KZbin channel is one that I refer to weekly when doing projects.Thank you for taking the time to put together such good info with good quality video!

[@joelpalmer]

Thank you! These videos have given me a start on a 66 that was in dead storage for 25 years; wish me luck!

[@joseprado1972]

Chris, I don't have a bug but I always love them. Thanks to you I will be buying a bug soon...love your videos and I don't care if my wife beats me again.I will be happy driving my bug with a black eye but I am a proud man with a lot of dignity.

[@classicvwbugs]

+Jose Prado Jose that is very cool my man. Let me know when you get the bug.

[@markcolegrove2896]

Thanks for sharing.I just tackled my tray and ur tips helped me stay calm.Bug Love 4-ever.

[@IgnusC]

Hi Chris, Thanks for the videos, i did a LOT of repairs on my 64 using your tips. What helps me a lot is a full restoration can be quite costly, and here in South Africa we are limited with suppliers, so these videos got mine bug on the road. One thing that i can suggest the guys do while removing the old pieces of metal is to wear a dust mask, the dust is not good for the lungs. I learned that on the hard way.

[@dwightgeorgecarlson]

One thing which is common and good practice to do when doing this type of 'overlap' welding, is to apply weld thru primer to the two surfaces which are in contact with each other and then use seam sealer to prevent water getting between the two layers of steel to prevent corrosion.

[@shehatakamel8997]

Thanks so much Chris Vallone for sharing your videos , it's so helpful

[@craigclement5520]

Thanks Chris for a good informative video. Love your channel and I really appreciate you doing these videos for us.

[@backyardsounds]

Great tip, Chris. One thing I've seen a lot is where the bottoms of the heater channel is rusted out. They have replacements of course... the repair you're doing here is quite similar to patching up under neat that channel too.

[@Alternabear]

Double thank you for the reference of your welding machine. I didn't know such a device existed, solves my problem of learning how to weld. I'll just pick up my own electric machine and practice.

[@Alternabear]

Excellent as usual Chris. I just recently did something similar, though I caught the rust early enough to not have to put in aftermarket pans. Working with EXTREMELY limited funds, I sanded the toughest rust, sprayed on a rust to primer converter and filled a couple pea sized holes with steel epoxy. Once all that was good and dry I painted on a cheap Duplicolor bedliner material. Lookes awesome, next is the duct insulation you use, then carpet pad and new carpet. Very excited!!

[@melisidro6639]

Hey Chris, I just started watching your videos and cruising your site. I enjoy it very much - lots of great valuable information. Can't wait to start a bug project. For those wanting to do it differently check out Restoration Design's channel. Mostly for Porsches but great restoration welding information. The repair looks solid for the backyard guy which for some reason most seem to be missing the point about. Please keep the videos coming as I just subscribed to your channel.

[@gassergregmac2153]

Awesome Chris. My brother gave me a 72 Bug that I am going to fix up. The battery tray area is rusted through about like the video car. Your video was the best instruction I found. I have similar home tools and I am now cutting and shaping. Soon to be welding. Thanks Bro!!!

[@polymendoza1]

Chris Thank you for your video, your video giving me the courage to attempt to change my floor pan on my VW bug. I need to get me a wire welder; I look forward to see more videos to fix my VW bug. I don’t want my bug to be a museum piece, just to be able to drive it.

[@vwmetal66]

Makes me feel a little more confident to try this on my 65 bug. On mine most of the pass side rear quarter was "fixed" but with 2 pieces of regular sheet metal. not an actual vw section. its holding up ok still but it was probably done like 15 years ago and it wasnt sealed or painted. Really want to use that POR-15 to coat the pans!!! Looks solid and great!!! Again another great vid!!

[@zzzdogutube]

Thanks, I remember fixing my VW back in the 70s with a streets sign that said 55 MPH. It was when they changed the speed limit to 65mph and signs were around. LOL old days

[@kurtrobinson458]

Excellent work and thanks for the video. I'm getting ready to do this exact area and with the body on. Ignore the people who think you need to TIG weld everything and make your beads look like a stack of nickels....back in the day they welded with wire coat hangers!! If it holds up then that is all that matters!

[@mitchabshier568]

Great job! I'm about to do my '71

[@1uptospeed]

thanks for the tip showing how its done father& son team cant be beat!

[@borna430]

Chris, we love you. Please use the guard on your grinder

[@mk6matt]

Thanks for the video! Very helpful, i may be getting a 68 Beetle soon and this is the only place that has rust. I will be sure to watch this video when replacing the battery tray!

[@Alex-oz9eh]

How did it go?

[@jonathan461965]

Nice work Chris and thanks for posting bud. :-)

[@ohcaptaindj]

Fantastic video and good editing.

[@Hoodhistorian562]

you're the man Chris !

[@IAMBRIANJOHANSON]

Man I can't wait to find my bug it's Gunna be so fun

[@SladesVWBeetle]

You did a great job.

[@tedmartin5688]

Great video, thanks for making it. What voltage and wire speed do you use? I have a rather rusty pan and want to avoid burning holes in the existing pan.

[@PUBNave]

That was cool. I love my '68

[@josealfredodeleonalvarez8120]

Excelent vídeo brother.

[@balconio1172]

nice vid- i'm not a great welder (using a harbor freight flux core for pete's sake) but the 3 revelations I had in welding were: - auto darkening helmet, worth every penny - turn wire speed way down on sheetmetal/exhaust tubing - keep the nozzle real close (almost touching the work, maybe 1/4 inch away). If your wire is sticking out an inch or so it ain't going to work well. i've found if you do these and you'll get that nice 'sizzling bacon' sound even on sheetmetal.

[@jonathan461965]

Great vid thanks. One questoion. When you weld underneith doesn't the sealer you put in on the top melt with the heat from the spot weld?

[@Philip.Magnusson]

your videos are very helpful even though i dont have a bug. ;) but hopefully soon i do!

[@giantj6ft7]

You're definetly not a welding artist haha, but was glad to see someone doing the underside of a panel instead of a bondo-paint combo.

[@classicvwbugs]

It truly is amazing what the internet has spawned up, people have no problem getting behind a computer screen to leave negative comments, but yet no one in these comments below out of the 4 years it has been up has shown me a video of what YOU CAN DO. I never meant this to be a show quality job, the weldings on my bugs go out to a pro body shop. This is what I did with a walmart welder for a noob, not a pro. If you guys have any idea of the real work we do, get yourself over to my website and see the concourse stuff. This is just ONE example www.classicvwbugs.com/52Zwitter PEACE.

[@BrownPP46]

+Chris Vallone I was a welder for 12 years, I have one of those cheap flux core welders and with the low wattage power coming into my garage, my welds come out looking just like yours. I just make sure I have extra weld on there so I can grind it down a little bit after if I want it to look good. If its covered by something, I don't worry about it. I am currently looking into buying a 68 autostick which will be my first bug. It needs floorpans badly and nothing but a big hole where the battery should go. You do good work and I enjoy watching your vids.

[@nuttyrabbit7030]

Chris Vallone you are claped

[@cacapodridacochinada]

Thanks for the info!

[@dominicdavis117]

Thank you used this vid to fix my battery pan ! Thanks !

[@classicvwbugs]

Again, this is for a home restorer, not a demo for a body shop. These are the same techniques the Higgins family do in their bugmevideo series. If you have a video showing how you do it better, we are all eyes and ears.

[@TRcustomengineering]

Good cause thats how much I bought. Thanks again.

[@mariloubuenviaje]

hi chris, what do say about using carbon fibers for floor restoration instead of steel sheets?

[@tepp4083]

how do the original style battery straps hook together?

[@WhiskeyTango68]

Chris your going to want to go with a solid wire spool with gas instead of the flux core wire. A lot less spatter and debris after welding, it'll save a lot of time and you'll have a better looking weld.

[@kamnili6159]

Great Video. a glowing metal still emit harmful radiation after the welding is stopped .So please leave the goggle, helmet on for a few sec more until the metal is not glowing anymore.

[@michaeld.3779]

Chris, I think you did a great job. I wonder if rafal could pop that patch out of there with his hoity-toity attitude. I think not. Besides, most people doing this job are not professional welders, and asking them to produce a perfect bead is really asking too much. I have one question, however: I noticed surface rust on the rest of the pans. You did not mention wire brushing these before adding the POR15. Did you remove the surface rust before applying the POR15--or was it unnecessary?

[@herbie2001tdi]

Thanks, Chris,, Published on my birthday, no less :) How long did this take, approximately? I have a small hole in the passenger well, but not under the battery in my '69 I want to repair.

[@Bugfreak88]

Is it useful to paint the axles (front and back) with POR 15 too ?

[@cacapodridacochinada]

I have a question about restoring another area of a super beetle. I have a 1971 sp and it has rust on the shelf behind the back seats above the motor. Could you do a video on how to restore that part? What would you recommend doing? It is very rusty on that one spot that you can see holes through it. I can't seem to find a replacement part for that section to weld it in :(

[@tospicy4ya]

Do u not have to wire brush all the surface rust before using por15? Would this be the same standard on a show car? What about sandblasting the pan?

[@alexp.7855]

Beautiful welding job man. I'm going to be restoring my beetle when I have the money for it.

[@tsavman]

Thanks dude, this video was just so great, that I might replace my battery pan just for fun!

[@TimsVideoArchief]

and, what do i have to do when it is just a small hole. because i used a jack in the jack stand, and the jack stand started to come loose, is it a good idea to remove the rust weld a little plate in it, and maybe a bolt trough the jack stand so it will hold when i jack the car up??

[@redskinfaithful]

Just bought a 66 type 1. I noticed the floor pan had ALOT of fresh battery acid. I tried cleaning the mess up with baking soda and water. Then tried removing rust with a wire wheel. Do you know of any better methods? Great vids by the way!

[@TheCarNextDoor]

Hi Chris, Good video. Huge help. I have a 1978 Super Beetle. I’m about to replace the floor pans and I’m hoping you can answer a question for me. I have good seats from a 1969 beetle that I would like to use. Are the seat rails the same for 1969 and 1978? If not? Will the floor pans for a 1969 beetle fit in the 1978? Thanks, Darin.

[@classicvwbugs]

The rails are not the same. Not sure about the pans, I think they will fit, maybe with some mods.

[@SmittysPlace]

cool video

[@Toerme]

Did you use a shielding gas or flux core?

[@TRcustomengineering]

About how much POR-15 does it take to do the pans? Thanks

[@triariicat8448]

can I coat my whole chassis with por 15?

[@bunorah]

Chris, I have looked up this welder online and found different ones with different apms... do you mind giving me some details on the welder you used? i need to buy one of those!

[@drumrooster]

nice video but get u a small hand held air saw,,uses small blades and cuts through pans like butter u can follow a line with it and not have all the jumping around like the saws all..trimming is a breeze..great video..

[@jensgrini7578]

Hey Cris, did you use fluxcore-wire?

[@akokarski]

What happened to the guard on the die grinder?

[@menetoo]

Hello, rather than fixing or restoring the floor pan battery in the long term as it get rusted by time, is there any practical preventive method which is used to prevent/lower the battery leakage and hence damaging the pan over the time ?

[@robertcastanon3786]

Hi there Mr. Chris,my name is Robert, n I have a 1970 buggy that I'd like to work on on my own but don't know much bout them...I do wish to learn though,could u assists me with it?? I will appreciate you Sir. Thank you.

[@GMTecano]

How can I search this kind of pieces ? Any webpage for buying this kind of metal plate

[@MrStevenbakeris]

did you use a flux welder or a mig with gas? I couldn't tell when I saw the welder. My son and I are looking at replacing the drivers side pan on his 74 super with the body on.

[@classicvwbugs]

A gasless mig welder

[@kavenmendes]

Looks good! Shame it's that nasty/messy flux core wire

[@tarciomalcher7273]

The weld quality is not the best out there but you got the job done. Congrats

[@willfrankfurt2698]

I have to ask, why didn't you just weld all the way around? that would saved having to use the sealer. like you videos. i have a 69 bug myself

[@crankbait09]

I notice when the pan was replaced, you used the por 15 at the end on the whole floor pan. Did you do any sanding of the original floor board, or did you apply the por 15 right over the surface rust?

[@classicvwbugs]

You do have to get the surface scuffed before applying. So with a wire brush or something you need to scratch off the heavy rust, get it as smooth as you can then you can paint over it.

[@crankbait09]

thank you very much

[@lennyauditt]

can you put roll on bedliner over the POR 15 ?

[@lennyauditt]

never mind they actually sell POR 15 bed liner ! $130 for a gallon

[@classicvwbugs]

We actually did that afterwards.

[@vintagegirl1961]

HI Chris. I am in N/ Phoenix. Can I hire you to do this to my 1965 beetle? If you're in the area

[@classicvwbugs]

We use the gas all the time in our shop, again, this is for the HOME USER. Many home restorers are not going to have access to gas.

[@jeanniefrost]

Is there a reason why you didn't paint the middle part with POR 15 and only the pans?

[@cccvwbug4646]

+Jeannie Frost I just did my floor pans on my 1970 beetle and used the POR 15 all over except the chassis (middle part) due to not seeing any rust and having the tar paper on it. You can actually still see the tar paper in the video of this car too. If you feel you need to use POR 15 on the chassis I recommend you clean it off really good before applying it.

[@chrischapman276]

CHAPMAN ELECTRIC CHAPMAN ELECTRIC 1 second ago Chris Thanks for the video's you do. I'm new to the resto adventure part of repairs. Having many classics in the past, I've gofew projects going at this time with different situations needed done o n each. You do a great job helping my ignorance become knowledge.....I owe you a beer next time you're in Cali..... from my first to today started in 85... 71 SB first rebuild stocky 58 beetle 1600 rebuild. painted...poorly. cleaned it up just enough for a typical teenager..... (a couple water cools..) 70 bus rebuild a couple 70 beetles 58 pan with 36 horse Dick Dean Shalako body Projects now... 70 Ghia sedan sleeper 2332 67 Beetle one owner all original...Yes, ORIGINAL. patina since 85. Saving her......number match. 70 Rat. 1775 12in. extension. 7 in. chop. vert. 33's rear, low pro front. Raked big! Select a drop. 64 Ghia baja. pro-comp suspension. 1775.

[@nancyhahn9077]

Chris, I have a '72 Super Beetle , great near newly rebuilt engine, new tires, window seals, brake job, suspension work and new carpet and seat upholstery. When I started working on the back seat upholstery I quickly realized the flooring was badly rusted with holes. Additionally, the heater channel on the driver side was rusted out at the bottom. This had all been covered with thick asphalt boarding and carpet so I didn't initially see this even after looking ( not very in depth ) under the car. My question.....will it be worth it to most people to buy this car ? It's in great shape except the floor. I replaced the floor pans in my last beetle ( before a tree fell on it ) and it didn't seem too difficult a job to tackle but the heater tube is the real issue. It was also 10 years ago that I did that work and I don't think I can do it again. What do you think? I would also appreciate your fans giving me their opinion about this. Thanks again for all your advice...you're the best. I also love how you say "putty" knife. so cool.

[@classicvwbugs]

+Nancy Hahn Hey Nancy, its worth it to someone, everyone has their favorite year. You can list it on multiple sites and see what bites you get.

[@kelleygrosso28]

Pretty decent. I think im going to do a video but without overlapping the pan where it looks like it was never cut out and replaced. Just need to buy a couple tools and get a decent camera.

[@JintySteam1]

my dad says that wouldn’t do in england it would have to be a continuous weld

[@Bugfreak88]

@brighteyefilms just a way to reduce the bodywork costs

[@classicvwbugs]

Ok, then show us what you can do. Painted over clean surface rust with POR-15, stops it in its tracks. Still holding up today.

[@Porfisdavid]

If you get the tip closer less splatter and not gum like the gas does its magic but maybe your using 110v which sucks btw

[@Nyc_Nick_]

great video man don't listen to the haters there all over the word no matter what videos i think it gets some of them off haha thank you for the video

[@classicvwbugs]

thank you my friend

[@gr2262]

So why do these companies who make the pan sections paint it black if it needs to be removed to weld it

[@mohammedalbalooshi7023]

Where is the saftey guard of the grinder..please saftey first always

[@jeffferguson7256]

you really should be drilling holes in the new section and plug welding the new pan to the old pan. also you are holding the tip of the welding gun too far away from the metal when you weld. You will stabilize the arc much faster and better if you move the tip closer to the parent metal when welding. not criticizing just giving some tips from a pro welder. I enjoy your vids btw

[@jeffferguson7256]

My apologies if you took my comment the wrong way. just trying to help, cheers, Fergie

[@classicvwbugs]

about a quart

[@c43939]

you should of used the grinder to grind down the spot welds

[@Hilfe88]

thats what we call "kattskit" in sweden

[@cacapodridacochinada]

Ohh nevermind. I found a website where they sell the entire luggage shelf. Thanks anyways!

[@curtismichael14]

or you can spray the pans with oil and throw sand on it... this works like a cement so it will never rust again

[@lockfordian]

if you did a video on fully replacing a floor pan, heater channel out of a bug i will pay 29.99 plus S&H as long as it goes in depth like this video. maybe also rust protection :)

[@classicvwbugs]

vwtrendsweb had an article on the exact issue you have. It is an old site, but if you go thru their tips section, under project super 71, it should still be there.

[@larrywoodruff7530]

These cars no longer get driven in salt, your floor repair will last forever, nice job, simple, straightforward, no anal crap.

[@willfrankfurt2698]

plasma cutter

[@ownTer]

@ShaurntheSheep Your dad does not know how to weld this type of material.

[@prostreetnotch]

Better sandblast the Chassis and don't do an overlap welding. In this area it is not original.