C-Pillar Rust Repairs on Late Model Bug

cam070 Custom Title Time!

1,332 posts · joined Jul 2009 · 3 Jan 2010, 10:48 pm

#755490

Am about to embark on the rust repairs to a 76 bug which has the expected rust in the C-pillar around the black plastic air vents on both sides.

Obviously the offending sponge material will all be removed and new metal will replace rusted sections.

Once this has been repaired, what do people do to prevent future rust?

Weld cover plates over vent holes
Put in new vents with seled back side to prevent water entry
POR15 the interior sections
Other

Also, what do people do to re-fill the C-pillar section to prevent reduce noise into the cabin?

68AutoBug Beetle Restorer - Experience over 138\% - YIKES --

11,654 posts · joined Aug 2002 · 3 Jan 2010, 11:27 pm

#755494

cam070 wrote:Am about to embark on the rust repairs to a 76 bug which has the expected rust in the C-pillar around the black plastic air vents on both sides.

Obviously the offending sponge material will all be removed and new metal will replace rusted sections.

Once this has been repaired, what do people do to prevent future rust?
Weld cover plates over vent holes

Put in new vents with sealed back side to prevent water entry

POR15 the interior sections

Other

Also, what do people do to re-fill the C-pillar section to prevent reduce noise into the cabin?

Hi
You can refill the C-pillar with expanding foam...
which will not absorb moisture etc...
Audis and BMWs etc are full of it...

also, If You see a New Mexican beetle... the last models..
and there are a few in Australia..

You will notice the indent is there for the vent...
but no hole etc...

many people smooth over the vent so there is no indication it was there...

You can use POR15 or fish oil etc...

once the old moisture absorbing material is gone ..

then fill with expanding foam...

cheers

LEE

- Helping keep Air Cooled VWs on the road - location: SCONE in the Upper Hunter Valley - Northern NSW 320 kms NNW of SYDNEY---

cam070 Custom Title Time!

1,332 posts · joined Jul 2009 · 3 Jan 2010, 11:51 pm

#755498

68AutoBug wrote:
cam070 wrote:Am about to embark on the rust repairs to a 76 bug which has the expected rust in the C-pillar around the black plastic air vents on both sides.

Obviously the offending sponge material will all be removed and new metal will replace rusted sections.

Once this has been repaired, what do people do to prevent future rust?
Weld cover plates over vent holes

Put in new vents with sealed back side to prevent water entry

POR15 the interior sections

Other

Also, what do people do to re-fill the C-pillar section to prevent reduce noise into the cabin?

Hi
You can refill the C-pillar with expanding foam...
which will not absorb moisture etc...
Audis and BMWs etc are full of it...

also, If You see a New Mexican beetle... the last models..
and there are a few in Australia..

You will notice the indent is there for the vent...
but no hole etc...

many people smooth over the vent so there is no indication it was there...

You can use POR15 or fish oil etc...

once the old moisture absorbing material is gone ..

then fill with expanding foam...

cheers

LEE

So its OK to replace the vent and you can add a waterproof expanding foam to replace the water friendly VW stuff? Any suggestions of what brand to use from those who have been down this path before?

vw54 Administrator Always Waiting 4 Friday

16,723 posts · joined Aug 2002 · 4 Jan 2010, 6:38 am

#755509

do NOT replace the foam

once you cut it open to do the rust repair scrap and dig out all the foam towards the engine compartment as well

you can disolve the residue with some CRC carby cleaner but it will run down inside the car

use Wurth Wax to protect against futher rust

Put up with the noise its not that bad

I read it on FACEBOOK so it must be true

http://forums.aussieveedubbers.com/viewtopic.php?tid=91278&page=1#pid848630

http://forums.aussieveedubbers.com/viewtopic.php?tid=63561&page=1#pid624099

http://forums.aussieveedubbers.com/viewtopic.php?tid=4832&page=1#pid452603

http://forums.aussieveedubbers.com/viewtopic.php?tid=60650&page=1#pid574409

Yogie Moderator Custom Title Time!

1,608 posts · joined Jun 2003 · 4 Jan 2010, 8:59 am

#755543

Our cabrio has little triangle shaped pillows that stuff up in to the cavity to reduce the noise. It seems to work well. They are made from offcuts of the headliner material with some padding inside it. Each side of the triangle is about 150mm long if that helps.

Yogie

matberry Moderator Go hard or go home

8,114 posts · joined Mar 2006 · 4 Jan 2010, 9:09 am

#755544

Yep, dont put in more foam, and the pillows is what vw did in the earlier cars, before the moisure trapping foam. The problem isn't the actual foam but the condensation that forms inside the roof and runs down the gutterline can't get out. The vent doesn't cause the rust either, so only remove it if you want the smooth look, when prepped, painted and rust proofed properly, you wont have any drama.

Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE

cam070 Custom Title Time!

1,332 posts · joined Jul 2009 · 5 Jan 2010, 12:43 am

#755712

Thanks for all the feedback guys. It all helps!

Joel Now containing 100\% E-Wang

9,368 posts · joined Feb 2006 · 5 Jan 2010, 9:13 pm

#755879

you can shoot foam back in there if you like but just make sure its the new closed cell stuff not open cell

open cell is the old stuff that holds water

it actually does make a fair difference to noise/dust/fumes in the cabin, i dug it out of one of my old bugs years back

German Bug Commited Dubber

73 posts · joined May 2009 · 13 Feb 2010, 12:21 am

#762417

I opend my C pillars up from the inside to get rid of the foam. After getting it out and seeing the damage, I would not put more foam back in - open or closed cell. Either would hold condensation against the metal and the nasty rust would come back again from the inside.

I am cleaning as much of this off as I can with a flap disk, welding in new metal and then giving the inside a good treatment and coat with POR15

Without the foam may be noisier, but at least my bug will be pristine!

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68AutoBug Beetle Restorer - Experience over 138\% - YIKES --

11,654 posts · joined Aug 2002 · 13 Feb 2010, 12:36 am

#762420

cam070 wrote:
68AutoBug wrote:
cam070 wrote:Am about to embark on the rust repairs to a 76 bug which has the expected rust in the C-pillar around the black plastic air vents on both sides.

Obviously the offending sponge material will all be removed and new metal will replace rusted sections.

Once this has been repaired, what do people do to prevent future rust?
Weld cover plates over vent holes

Put in new vents with sealed back side to prevent water entry

POR15 the interior sections

Other

Also, what do people do to re-fill the C-pillar section to prevent reduce noise into the cabin?

Hi
You can refill the C-pillar with expanding foam...
which will not absorb moisture etc...
Audis and BMWs etc are full of it...

also, If You see a New Mexican beetle... the last models..
and there are a few in Australia..

You will notice the indent is there for the vent...
but no hole etc...

many people smooth over the vent so there is no indication it was there...

You can use POR15 or fish oil etc...

once the old moisture absorbing material is gone ..

then fill with expanding foam...

cheers

LEE

So its OK to replace the vent and you can add a waterproof expanding foam to replace the water friendly VW stuff? Any suggestions of what brand to use from those who have been down this path before?

Hi
I used heaps of good quality FISH OIL in the inside roof gutters etc.... everywhere... let it dry.. do it again... again..
then finished off with the expanding foam...
the expanding foam is water proof....

just remember how long it took the bad foam to cause rust in beetles....
so , good rust proofing, and expanding foam...
and NO noise and no rust etc....

LEE

IMHO... of course..

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- Helping keep Air Cooled VWs on the road - location: SCONE in the Upper Hunter Valley - Northern NSW 320 kms NNW of SYDNEY---

cam070 Custom Title Time!

1,332 posts · joined Jul 2009 · 13 Feb 2010, 1:11 am

#762423

German Bug wrote:I opend my C pillars up from the inside to get rid of the foam. After getting it out and seeing the damage, I would not put more foam back in - open or closed cell. Either would hold condensation against the metal and the nasty rust would come back again from the inside.

I am cleaning as much of this off as I can with a flap disk, welding in new metal and then giving the inside a good treatment and coat with POR15

Without the foam may be noisier, but at least my bug will be pristine!

That there is ugly....and one of my next jobs on the list.....I hate rust!

DylanTheDubber Custom Title Time!

1,252 posts · joined Jun 2009 · 13 Feb 2010, 6:56 am

#762429

I Know someone who has no rust in his pillars but to rust prevent it to , He drill a small hole on each side under the gutter where the top of the door sits and sprayed fish oil in it untill it was coming out of the back vents but he is also now going to weld up the holes he drilled and weld up the vents. The vents dont do much anyway and i reccon it looks better without them and also no rust that way. From Dylan

1303Steve Scirocco Rare

8,650 posts · joined Aug 2002 · 13 Feb 2010, 8:33 am

#762440

Hi

Jak Rizzo filled his vents but kept the indent, I think this looks better than completely removing it.

On the A pillar cut the very bottom 1 or 2 mm of it, that lets crap fall straight though and stops rust forming.

Steve

68AutoBug Beetle Restorer - Experience over 138\% - YIKES --

11,654 posts · joined Aug 2002 · 13 Feb 2010, 2:36 pm

#762467

DylanTheDubber wrote:I Know someone who has no rust in his pillars but to rust prevent it to , He drill a small hole on each side under the gutter where the top of the door sits and sprayed fish oil in it untill it was coming out of the back vents but he is also now going to weld up the holes he drilled and weld up the vents. The vents dont do much anyway and i reccon it looks better without them and also no rust that way. From Dylan

I also know of a 1965 custom beetle with small holes drilled in front of top door hinges for fish oil...

I actually poured/sprayed many coats of fish oil into that crevice from inside the boot... then filled it with expanding foam...

LEE

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- Helping keep Air Cooled VWs on the road - location: SCONE in the Upper Hunter Valley - Northern NSW 320 kms NNW of SYDNEY---

DylanTheDubber Custom Title Time!

1,252 posts · joined Jun 2009 · 13 Feb 2010, 4:10 pm

#762491

Lee , Is it realy nessesary that you put a picture of your bug in every post. it would be clogging up the forum a bit and wasting bandwidth. Why dont you just put a picture in your signature.

From dylan

cam070 Custom Title Time!

1,332 posts · joined Jul 2009 · 5 Apr 2010, 8:16 pm

#771839

Guys, does the vent actually serve any purpose on late model bugs or is it purely aesthetic?

Craig Torrens 6 times Australian, 7 times State Hillclimb Class Champion

8,040 posts · joined Jan 2003 · 5 Apr 2010, 8:24 pm

#771840

its there for 'flow through' ventilation.

cam070 Custom Title Time!

1,332 posts · joined Jul 2009 · 25 Apr 2010, 5:50 pm

#775051

Craig Torrens wrote:its there for 'flow through' ventilation.

Could this be solved using pop outs?

cam070 Custom Title Time!

1,332 posts · joined Jul 2009 · 25 Apr 2010, 5:53 pm

#775055

OK started work on C-pillar rust today and dug out this materilas that is carcinogenic to bugs.

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cam070 Custom Title Time!

1,332 posts · joined Jul 2009 · 25 Apr 2010, 6:00 pm

#775060

OK now my question, I managed to dig out the spongey crap that I could access via the engine bay, but I noticed a slot where it seems to go down behind the wheel well. How do I access that area to get the rest of the spongey crap out? See image for more details.

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BajaChris Commited Dubber

62 posts · joined Jul 2004 · 26 Apr 2010, 11:59 am

#775174

You might be able to get at it from behind the trim panel inside.
When I did mine I cut a access hatch on the inside of the c-pillar where there is a ~15mm hole. You would have to remove the hood lining to see it.

Volksclub Bendigo