Not every spot on the Beetle can be easily repaired. Unless you completely disassemble your Bug you may not be able to replace metal that is less than favorable. In some cases it's simply not in the budget or time table.
This was the case with Project #Super71 and the metal that is under the gas tank and sandwiched between the front firewall and the back of the spare tire well. In my case the metal was not completely lost, but could use some help. Since I already had the front firewall on the Super Beetle out of the way I decided to get creative and fix things up the best I could.
My plan was to clean up the metal the best I could and remove as much rust or thin mental as possible. I then fabricated a pair of patch panels that would used to laminate over of the old metal. Is it a bit of a hack? Sure it is, but it's my car and after weighing my options this was the best solution. These panels were put in place with some construction adhesive and tightly clamped in place until fully cured. Afterwards the entire section was painted and undercoated for protection from the elements.I was extremely happy with the final result. With that repair completed I could put the front firewall in place.
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