Frame head replacement on 1962 VW Beetle - Rusty '62 Restoration - Part 5

Cleaned the frame with chemical paint remover, wire brushes and sand blasted a few stubborn rust spots. Rust converter was applied to the whole frame(inside too). The old frame head was attached to get measurements and then the new part was welded in, after many hours of fitment and measuring.

[@johnfreeman1189]

Excellent fabrication skills. Your videos are interesting to watch. I will be starting work on a 63 beetle soon.

[@AircooledProject]

Good luck with your project!

[@vwcoco]

Nice work !!

[@TheSixgutstring]

Nice work

[@AircooledProject]

Thank you!

[@chrispbacon3042]

You have taken it past just stripping off it’s sock underwear you have taken the bones out of it. Very impressed!

[@AircooledProject]

:)) yes, the frame head was completely broken off. The napoleon hat was keeping it in place.

[@VwRosstorations]

Nice one, along for the ride..👍🏴󠁧󠁢󠁥󠁮󠁧󠁿

[@AircooledProject]

Thank you!

[@Flozman1982]

Excellent work, gives me some courage.

[@AircooledProject]

Thank you, Florian.

[@ricardolemos8225]

Great Job, congratulations.

[@AircooledProject]

Thank you, Ricardo.

[@dozzerg]

Super tare!

[@robertsupriano1969]

Great work and skills. Since there is no talking in the video can you tell me why you cut out and replaced the front piece of the frame head? Thanks!

[@AircooledProject]

Thank you. I did that just to keep the original look. Although it gets covered up with a cap and you can't see it, I want it to have all the original details. Also, was easy and quick enough to do.

[@myovalsplit]

💪🏻🤙🏻👍🏻💎

[@fernandopalominocastaneda8373]

Buenos días que buenos los vídeos esa parte que cambio la necesito y los pisos como los consigo para Colombia gracias traducción español

[@AircooledProject]

Gracias. Compré las piezas metálicas en mecatechnic.com. Buena suerte con tu proyecto!

[@maciejkranik2686]

Hi, Looks like a very good job. Currently, i'm on same level of vw rebuild where i'm trying to replace FWD floor head. However, I have difficulties to achieve dimension in reality vs generally presented dimension on sketches available in web. Do you remember or do you have some trick what could help in setup process. Which dimensions I should follow as major to receive correct geometry of the chassis?

[@AircooledProject]

Hello. I also couldn't find any dimensions that were precise. If you have the old part in place, you should make a jig before cutting it off. For the framehead, there are some designs online that use the shifter and the front axle mounts to position the head. Mine was already broken off, so I took a lot of measurements from a second car that I have for parts. Also, the head should be tilted upwards a little. 5 degrees, if I remember correctly.

[@maciejkranik2686]

@@AircooledProject I couldn't use old frame because it was damaged badly and incorrectly repaired. therefore, i've decided to cut off totally. Now when I'm trying to fit a new one everything is almost on place but is not... if you know what i mean. Do you have any link to jig what you're referring to ? I will appreciate for help because I'm stuck. Trying to find solution over a month or so.

[@AircooledProject]

Yes: www.thesamba.com/vw/forum/viewtopic.php?t=463815&postorder=desc You would have to build it on a good bug chassis, though

[@joeMopar412]

Nice! What rods and settings were you running your stick welder at?

[@AircooledProject]

Thanks Joe. I used 1.6mm 6013 rods at about 40-60 amps. A mig welder with gas and 0.8mm wire would have been better.

[@joeMopar412]

@@AircooledProject I'll be patching a hole in my friend's tunnel on his VW dune buggy. I only have an arc machine. One day I'll get a mig.. 😊

[@AircooledProject]

Get the thinnest electrodes you find and do small welds at a time, so you don't put holes in it.

[@joeMopar412]

@@AircooledProject I have a lot of weld time with 6013 welding as thin as1.5mm stock. I'll be happy with a solid weld just to close the hole properly. Thanks for the info on the settings you ran!

[@David-ty1xz]

Where did you find the drawing with the dimensions? Great work.

[@AircooledProject]

Hi, David. I just googled "vw beetle chassis dimentions", but the numbers were not very precise. I measured a lot with the old frame head in place and put the new one in the exact same position.

[@David-ty1xz]

@@AircooledProject Nice skills. You like stick welding more than MIG?

[@AircooledProject]

@@David-ty1xz At that time I only had stick and tig, but don't have any experience with the tig. Now I also have a mig welder that is much better then the stick for sheet metal work.

[@David-ty1xz]

@@AircooledProject Ok. Is your MIG 120v or 240V? Thanks for these videos. I thought I had it bad having to replace part of the Napoleon hat on my 56, great work.

[@AircooledProject]

@@David-ty1xz I am in Europe(Romania), we do not have 120v here. Te welders are 240v with max welding current of 250A. Make sure to check the tunnel for cracks in the napoleon hat area. Mine was completely broken off, the napoleon hat was the only thing keeping the frame head in place.

[@chrismorfitt7642]

Great videos it’s weird to watch I’ve just the the same things to my 67 beetle full frame head and floor pans replacements check my channel out 👍🏻

[@AircooledProject]

Thanks, Chris. Will check out your channel.