'71 Super Beetle Autocross Build

For road racing, autocrossing, or just taking that curve in style. Oh yea, and stopping!
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petew
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Re: '71 Super Beetle Autocross Build

Post by petew » Sat Jun 10, 2017 6:28 pm

Great work. That's a hard repair for sure. :(

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GS guy
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Re: '71 Super Beetle Autocross Build

Post by GS guy » Sun Jun 11, 2017 6:53 am

Yea, welding thin metal is a different beast! 0.025" wire, sharp cut wire after each weld and lots of short welds to keep the metal "cool" enough to not hole-through works best for me. Followed by Lots of grinding of course! Some sanding drums/cartridge rolls (like in a port and polish kit) with a die grinder can help to get into and smooth the tight contours. I agree on using the edge of a cut-off wheel as you mentioned - works great for kissing down weld lumps. Angle grinders are my best (post-welding) friends!
Jeff

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ChadH
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Re: '71 Super Beetle Autocross Build

Post by ChadH » Sun Jun 11, 2017 12:17 pm

Done - finally. It's not perfect, there's a few issues, but I think it will look OK for a racecar. It's time to move on to other things.

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..and a repeat of what I started with.

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ChadH
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Re: '71 Super Beetle Autocross Build

Post by ChadH » Thu Jun 15, 2017 10:08 am

So..I drilled out the window vent baffle, since it's nearly impossible to prep in this space. I didn't want to blast, simply because it would make a huge mess. I would just leave the baffle out, but am worried a "helpful person" might give me a push (it's bound to happen) and bend the vent sheet metal . I'm not sure if it would improve cooling airflow, but I'll either open up the baffle vents (a lot) and re-install it, or provide just a few supports to strengthen the area. When the car is done, I'll make a "DO NOT PUSH" sticker here ;)

FWIW, the car will be stored in the garage, and it's unlikely I'll ever drive it in a hurricane. :wink:

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FJCamper
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Re: '71 Super Beetle Autocross Build

Post by FJCamper » Thu Jun 15, 2017 10:32 am

Don't try this at home boys and girls. Chad is a professional on a closed course.

I once read in Heretics Anonymous the removal of this very panel can cause a sudden ground loop at idle in a soft breeze.

FJC

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ChadH
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Re: '71 Super Beetle Autocross Build

Post by ChadH » Thu Jun 15, 2017 11:25 am

Wait a minute, I'm not a professional, and I am trying this at home. I'm screwed.

I plan on a floating the entire chassis ground at 20kV, so I should be good even if being struck by lightning. I have rubber pants and gloves for safety.

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Piledriver
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Re: '71 Super Beetle Autocross Build

Post by Piledriver » Thu Jun 15, 2017 11:41 am

That's OK as long as you never hit a puddle...
...or get out of the car.
I, for one, regularly embrace our new robot overlords, as I am the guy fixing the robots...

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GS guy
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Re: '71 Super Beetle Autocross Build

Post by GS guy » Thu Jun 15, 2017 7:17 pm

Chop out the louvers, replace with expanded mesh (with front to rear ribs intact), plug weld back in, avoid all the Voodoo Flux Capacitor issues....

:-D

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ChadH
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Re: '71 Super Beetle Autocross Build

Post by ChadH » Sun Jun 18, 2017 7:38 pm

Lots of work for probably marginal benefits, but here's the revised rain baffle:

Removed louvers, and opened up the holes. That 1/2" strip was welded behind/below the window vents to add some more strength for course worker assisted car relocation.
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My oldest kid actually did some productive work..I think this was my father's day present here.
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After some filling and primer
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From the bottom. I think I'll be able to get paint in here much easier.
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Piledriver
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Re: '71 Super Beetle Autocross Build

Post by Piledriver » Mon Jun 19, 2017 1:01 am

I always found leaves to be more of a menace than water, the leaves want to live in the fan or on top of the cooling fins.
I, for one, regularly embrace our new robot overlords, as I am the guy fixing the robots...

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