As we mentioned in our previous post, we had a lot of rust to chase out of the body of this Super Beetle. The front firewall was a mess and after we removed it we had several trouble spots that would need to be repaired before we could move forward with installing the replacement firewall.

This post outlines the strengthening if the sheetmetal above the front firewall and under the gas tank. For the most part the metal was all there and in place but it was thin and had some holes. We decided to fabricate our own patch panel that would be welded in place from the top. It was made out of 3 separate pieces of sheet metal and trimmed by hand to fit just right. Once it was snug as a bug we welded it into place.

This is a pretty low-tech repair, but it's solid. Once we cover it with seam sealer, paint it, and install the gas tank you will never see it again.

Thanks for following the build. Please leave your feedback, questions and comments below.

THEBUGNUT