The Vw Beetle Floor Pan Removal: A Step-By-Step Guide

Removing the floor pans of a VW Beetle is a complex task that requires a good understanding of the vehicle's construction. The flat floorpan of the air-cooled VW Beetle is one of its most distinctive features, but it is also a common source of headaches when it comes to rust and corrosion. While some people choose to patch up the floorpan, others opt for a complete replacement. This involves removing the body from the chassis, which can be done in an afternoon, and addressing the rust-prone areas around the edges of the floorpan. There are several bolts that need to be removed, and various components, such as the seats, steering column, brake pipe, and speedometer cable, that need to be disconnected. The engine can be left in situ, but if removed, all wiring must be disconnected.

Removing seats and rear wings

To remove the seats and rear wings of a VW Beetle, you'll first need to disconnect the battery. Loosen the nuts with a 10mm socket and wrap the lead with a towel, placing it away from the battery.

Next, remove the rear seat bench by pulling it up and folding it towards the front of the car. It is held in place by two hooks, which can be released by prying or smacking with a rubber mallet or flathead screwdriver. Once one side is out, the other should follow easily.

Now, remove the backrest of the rear seats by folding the seat flat and removing the headrests. There is a zipper towards the centre/driver's side; open it and you will see a metal bracket with two 8mm Allen bolts. Undo these bolts. Take a look at the corner of the seats—the seat pivots on a metal clip. Take a large flathead and push the clip back towards the rear of the car, then pull the seat up. Repeat on the other side. Pull the passenger side of the rear seat up and out towards the front of the car, then guide the rest of the seat out, keeping the metal bracket inside the car.

For the front seats, first, push the seat to the farthest rear setting. There are two 13mm nuts or bolts; remove these. Slide the seat to the very forward position and pull the side latch as if letting people into the back. Using a small flathead screwdriver, remove the two plastic circular covers at the base where the seats slide on their bracket. Remove the Philips head screws and the plastic pieces. Lock the seat back down and slide it all the way back—it should fall out of the bracket. Tip the seat back and look underneath—there are three connectors/clips: two for the airbag and one white plastic clip that holds the harness. Unclip the airbag connections by pressing a small tab, and unclip the plastic harness holder clip by lifting a small tab. Remove the seat by tipping it sideways.

The passenger side is the same, except there are only two connectors: one airbag and one plastic harness retainer.

Finally, to remove the rear wings, you will need to duck under them to undo the 17mm bolt on each side in the bracket where the shock absorbers bolt to the body.

Disconnecting steering column

Disconnecting the steering column is a crucial step in removing the floor pans of a VW Beetle. Here is a detailed guide on how to do it:

Firstly, remove the steering wheel and signal switch. This will give you access to the steering column and the necessary bolts. Then, remove the tubular column from the interior of the car. This will involve unbolting the steering coupler, which has four bolts that need to be removed. With the coupler disconnected, the steering column should now be loose.

Next, you will need to remove the two bolts at the top of the steering column collar and another rubber washer through the firewall. This will fully disconnect the steering column. As mentioned in the previous step, ensure you have already disconnected the steering coupler before attempting to remove the steering column.

Additionally, it is advisable to remove the gas tank. This will make the job much simpler and provide easier access to the steering column and other components.

Finally, remember that you can leave the engine in situ if needed. If you do decide to remove it, ensure that you disconnect all the wiring. The specific procedure for engine removal may vary slightly depending on the model of your VW Beetle.

Removing petrol tank

To remove the petrol tank of a VW Beetle, you will first need to remove the seats to gain access to the tank. Next, you will need to duck under the rear wings and undo the 17mm bolt on each side in the bracket where the shock absorbers bolt to the body.

With the bolts removed, you can now access the petrol tank. Before removing the tank, you will need to drain the fuel. This can be done by pulling off the rubber hose at the outlet under the tank. Be sure to have a container that can hold 10.6 gallons of gas. Alternatively, you can use a siphon kit to remove the fuel. Insert the suction tube about three feet down into the bottom of the gas tank and pump the handle to start the flow of fuel.

Once the fuel is drained, you can now remove the petrol tank. Be aware that a full or half-full tank will be quite heavy, as one gallon of gas weighs about six pounds. If you are planning to refurbish the tank, you will need to remove it completely. However, if you are not refurbishing the tank, it is preferable to drain the tank and leave it in place.

Removing bolts

Removing the bolts from your VW Beetle's floor pans is a crucial step in the repair or replacement process. Here's a detailed guide to help you through the process:

Begin by removing all the seats in the car to provide access to the floor pans. Next, you'll need to crawl under the rear wings and locate the 17mm bolts on each side, situated in the bracket where the shock absorbers bolt to the body. Using the appropriate tools, carefully undo these bolts.

The next step is to remove the petrol tank. This will grant you access to two additional 17mm bolts located at the front of the floor pan. Undo these bolts as well. At this point, you will also need to disconnect the steering column, either at the box or the rubber coupling.

Additionally, there are other components that need to be detached, including the brake pipe from the fluid reservoir and the speedo cable, which should be disconnected from the hub. By following these steps, you will effectively remove the bolts securing the floor pans, allowing you to proceed with further repairs or replacement of the VW Beetle's floor pans.

It is important to note that there may be variations in the bolt locations and sizes depending on the year and model of your VW Beetle. Always refer to manufacturer guidelines or seek professional advice if you are unsure about any steps in the process.

Sealing the floor

Step 1: Remove Interior Components

Start by removing all interior components that may obstruct access to the floor pan, including seats and carpets. This will give you a clear and unobstructed work area.

Step 2: Scrape Off Old Seam Sealer

Use a suitable tool to scrape off as much of the old seam sealer as possible. This step ensures that the new sealer will adhere properly and creates a smoother surface for the next steps.

Step 3: Prepare the Surface

Use a metal prep solution, such as POR-15 Metal Prep, on all surfaces that will be sealed. This step helps to clean and prepare the metal for the new sealer. Follow the manufacturer's instructions for proper application and safety precautions.

Step 4: Remove Surface Rust

Use a wire wheel or grinder with a wire wheel attachment to grind off any remaining surface rust. Ensure you remove all traces of rust to prevent further corrosion and create a smooth surface for sealing. Wear appropriate safety gear during this step to protect yourself from rust particles and wire wheel debris.

Step 5: Clean and Degrease

Spray and wipe down the floor pans with a suitable cleaner degreaser. This step ensures that the surface is free of any remaining dirt, grease, or residue. Follow the manufacturer's instructions for proper application and safety precautions.

Step 6: Apply the Sealer

Using a foam brush or another recommended applicator, apply a thin coat of a high-quality rust-preventative sealer like POR-15 Rust Preventative Sealer. Follow the manufacturer's instructions for proper application techniques and safety precautions. Allow the recommended curing time between coats, typically around four to five hours.

Step 7: Second Coat and Curing

Apply a second thin coat of the sealer, following the same application process as the first coat. Allow the sealer to cure completely according to the manufacturer's instructions. This typically takes around four to five hours, but it may vary depending on the product and environmental conditions.

Step 8: Final Inspection

Once the sealer has cured, inspect the floor pan for any signs of missed spots or imperfections. If necessary, apply additional coats of sealer to ensure complete coverage and protection.

Additional Tips:

• Always work in a well-ventilated area when using chemicals and wear appropriate safety gear, including gloves, eye protection, and a respirator.
• Before applying the sealer, ensure the surface is completely dry and free from any moisture or condensation.
• If you're using a brushable seam sealer, use a paintbrush for a smooth and even application over large surface areas.
• For small cracks or touch-ups, use a sealant that comes in a nozzle for precise application.
• Consider using a build-out agent, such as POR-Paint, and then coating the floor with Rustoleum for added protection.

By following these steps and taking your time, you can effectively seal the floor of your VW Beetle, protecting it from rust and corrosion for years to come.

Frequently asked questions