Emilie Meyer
Shortening a Beetle floor pan is no easy task and requires a lot of preparation. First, the frame must be cleaned and prepared, which includes removing the engine, the rear brake drums, and the emergency brake cables. It is also important to brace the doors before beginning the shortening process to prevent the body from warping. Once the frame has been cleaned and prepared, the next step is to mark the pan section that needs to be removed. This can be done by using a template made of construction paper to draw two parallel lines on each side of the pan. After the pan has been marked, it can be cut using a reciprocating saw, being careful not to cut through the tubes located inside the tunnel. With the pan section removed, the corners can be heated with a torch and bent into place, and the welding process can begin.
Characteristics and Values Table for Shortening a Beetle Floor Pan
| Characteristics | Values |
|---|---|
| Template for marking the pan section to be removed | Cut construction paper 14-1/4 inches wide and 30 inches long |
| Tracing the template on the floor pan | Use a silver drawing pencil to draw two parallel lines from the side of the pan to the bottom edge of the tunnel |
| Cutting the pan | Use a reciprocating "sawsall" or an air-powered cutting tool, being careful not to cut through tubes inside the tunnel |
| Welding preparation | Heat corners with a torch and bend them into place, using pipe clamps to hold halves together |
| Welding process | Tack weld the top center and straight sections of the tunnel, alternating between welding and heating with a torch |
| Strengthening the weld | Cut a 1-1/2 inch wide strip from the removed tunnel piece and weld it over the tunnel weld |
| Engine removal | Remove the engine and turn the pan over to weld the bottom |
| Cleaning and preparation | Remove sound deadening material, rust, and paint; detach shift rod, rear brake drums, and emergency brake cables |
| Bracing | Create a brace frame for the doors and striker plate to prevent warping |
| Replacement parts | Order floor pans and channels from suppliers like Klassicfab or Jbugs, and replace brake and fuel lines |
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What You'll Learn
Prepare the frame by removing the engine and cleaning the pan
To prepare the frame, you must first remove the engine. This process is made easier if you are trying to diagnose an engine problem. Begin by positioning a jack under the engine sump plate, lifting the engine slightly and pulling it back from the transmission. Continue the process of pulling, dropping, and pulling back until the engine is clear of the apron and the lower engine studs are free from the transmission. With precision, the engine can then be dropped into a rolling engine dolly. Next, reposition the jack under the middle of the chassis of the car and jack up the back of the car until the engine can be rolled out. With the engine removed, the jack stands can be removed and the car can be lowered.
With the engine removed, the pan must be cleaned. To do this, first open the access hole at the front of the frame between the front torsion bar tubes and remove the shift rod after detaching it from the front of the transmission. Leave the front suspension on the pan to provide necessary points for measuring and aligning the chassis. Clean the thick tar-based sound-deadening material from the entire pan. This tar can be removed with a chisel and hammer, but an air chisel is a quicker method. Alternatively, you can heat the metal near the tar to cause it to melt away, but this will create a strong smell. Once the tar is removed, the metal can be cleaned of rust and painted.
Before welding the bottom, you must also remove the rear brake drums and take out the emergency brake cables. The process of welding the thin sheet metal floor can then begin. First, cut a dart out of the rear corner before the outside edges of the pan will come together. Draw a line from the rear outside corners of the rear pan sections down along the inside radius of the corner to the bottom of the floor pan. Extend the line straight and parallel to the outside edge forward to the cut between the halves. Use a saw to cut along this line so that the rear corner is loose but not cut all the way off. Fold the loose corner in until the outside edges of the pan match. Use a silver pencil to draw a line on the overlapped portion of the rear section. Pull out the loose corner and cut off the excess material with tin shears. Fold the corner back in place, clamp it, and weld it.
To strengthen the tunnel weld, cut a 1-1/2 inch wide strip from the removed tunnel piece and weld it over the top of the weld. Once the halves are tightly together and aligned, the welding process can continue. Tack weld the top center of the tunnel and then the straight sections of the tunnel sides where they are evenly matched. Now use an oxygen-acetylene torch to heat the mismatched sections and beat them into place with a hammer. Alternate between welding and heating with the torch until the tunnel is completely welded on the top side.
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Make a template to mark the section to be removed
To make a template to mark the section of the VW Beetle floor pan that needs to be removed, you will need a piece of construction paper, a pencil, and a pair of scissors.
First, cut the construction paper to the dimensions of 14-3/4 inches wide and 30 inches long. Next, lay the paper on the floor pan, ensuring that one of the long edges touches the rear of the seat support rails. Using your pencil, draw two parallel lines from the side of the pan to the bottom edge of the tunnel. Repeat this process on the opposite side of the pan.
Now, move the paper template over the tunnel, positioning it about two inches behind the emergency brake bracket. Align the edges of the paper with the lines you previously drew. Trace the edge of the paper over the tunnel at the front and rear with your pencil.
Before cutting, double-check that you are not going to cut through any tubes inside the tunnel. Once you are certain of the tube locations, you can use a reciprocating saw or an air-powered cutting tool to cut along the traced lines.
At this stage, the rear corner of the pan should be loose but still attached. Fold this corner inwards until the outside edges of the pan match up. Draw a line along the overlapped portion of the rear section with your pencil. Unfold the corner and use tin snips to cut off the excess material along the marked line. Finally, fold the corner back into place, clamp it down, and weld it into position.
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Cut the pan using a reciprocating saw
When using a reciprocating saw to cut the floor pan of a Beetle, there are several important steps to follow to ensure a successful cut. Firstly, it is crucial to wear the appropriate safety gear, including eye and ear protection to shield yourself from any flying debris, and sturdy gloves to protect your hands from potential cuts.
Before beginning the cutting process, ensure that you have selected the correct blade for the thickness of the metal you will be cutting. For thin metal, a blade with 20-24 teeth per inch is recommended, while medium-thickness metal calls for 10-18 teeth per inch, and for very thick metal, a blade with around 8 teeth per inch is ideal. Adjust the shoe on the saw to control the depth of the cut and extend the blade life.
Now, you can start cutting the pan. Place the reciprocating saw blade on the marked cutting line, using the shoe as a pivot or fulcrum to guide the blade until it gains purchase in the metal. Slowly squeeze the trigger and maintain a firm grip on the tool housing. You can adjust the cutting angle by lowering or raising the trigger hand in relation to the workpiece, which can speed up the cutting process.
It is important to work slowly and carefully to achieve a precise cut. Cutting metal with a reciprocating saw is most effective when the saw is set to a slower speed than when cutting wood. This slower speed not only prolongs the life of the blade but also grants the user more control and precision. Additionally, ensure that the oscillating setting is switched off when cutting metal, as this setting is more suitable for cutting wood.
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Weld the corners and bend them into place
Welding the corners and bending them into place is a crucial step in shortening a Beetle floor pan. This process requires careful measurement, precise cutting, and the application of heat and pressure. Here is a detailed guide on how to execute this procedure effectively:
First, ensure you have marked the sections to be removed using a template. This template should be made from construction paper, measuring exactly 14 1/4 inches wide and about 30 inches long. Lay this template on the floor pan, with one long edge touching the rear of the seat support rails. Use a silver drawing pencil to mark the sections to be cut.
Now, use a reciprocating "sawsall" or an air-powered cutting tool to cut along the marked lines. Extreme care must be taken to avoid cutting through any tubes located inside the tunnel. Once the cutting is complete, heat the corners of the pan with a torch. This will make the metal more pliable and easier to bend.
Using clamps to hold the halves together, apply tension to ensure proper alignment. You can use pipe clamps between the hand brake hole and the access hole on the tunnel's top. For the bottom, attach a "come-along" under the pan, connecting the front suspension to a chain at the rear forks. This will help bring the halves tightly together.
With the halves securely clamped and aligned, begin the welding process. Start by tack welding the top center of the tunnel, followed by the straight sections of the tunnel sides where they match evenly. Use an oxygen-acetylene torch to heat any mismatched sections, and then beat them into place with a hammer. Continue alternating between welding and heating until the tunnel is completely welded on the top side.
It is important to note that there may be a gap of up to 1/2 inch where the two floor halves meet at the bottom edge of the tunnel. This can be addressed by cutting and welding a strip from the removed tunnel piece over the weld to strengthen it. Additionally, ensure that you follow appropriate safety measures during the welding process, including wearing protective gear and working in a well-ventilated area.
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Strengthen the tunnel weld by adding a strip of metal
To strengthen the tunnel weld by adding a strip of metal, you will need to follow a few important steps. Firstly, ensure you have the right tools and materials, including a welder, a saw, and a strip of metal that is 1-1/2 inches wide. This strip of metal can be cut from the removed tunnel piece, ensuring a perfect fit.
Begin by cleaning and preparing the work area and the tunnel itself. Remove any rust or debris from the tunnel, and apply a protective coating, such as Eastwood Matte Black Rust Encapsulator, to the inside of the tunnel. This will help prevent future rust and protect the metal. It is also important to mask off any areas where panels will fit together and spray them with a weld-through primer. Choose a primer that is suitable for welding, such as U-POL Weld #2 Copper Weld Through Primer.
Once the tunnel is prepared, you can begin the welding process. Start by welding the straight section of the tunnel bottom plate to any additional bottom plate sections. This will create a stronger joint, as you can weld on both sides. It is important to ensure that your welds are hot enough to penetrate the metal and create a strong bond.
After welding the bottom plate, add a connecting plate to the wide end. This will provide additional support and another layer to weld, further strengthening the joint. At this point, you can weld the strip of metal over the tunnel weld to add even more strength. Ensure the weld fully penetrates the strip of metal and the tunnel for the strongest bond.
Finally, finish the process by grinding down the welds on the outside and spraying the inside areas with a rust encapsulator. Allow the encapsulator to cure, and then place the bottom plate back on the tunnel. Check the fit of the frame head bottom plate to ensure everything is aligned correctly. With these steps, you can effectively strengthen the tunnel weld by adding a strip of metal, creating a sturdy and secure joint.
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Frequently asked questions
Before beginning to shorten the floor pan, you must first remove the engine, turn the pan over, and clean the frame thoroughly. This includes removing the thick tar-based sound-deadening material, as well as any rust, from the pan.
It is important to note that you should not cut through the tubes located inside the tunnel. Special care must be taken to locate and avoid them. Additionally, make sure to brace the door gaps before cutting the channels to prevent the body from warping.
First, make a template to mark the section to be removed. Cut construction paper to the appropriate size and lay it on the floor pan, using a silver drawing pencil to mark the cut lines. Once the lines are drawn, use a reciprocating "sawsall" to cut along the marked lines. After cutting, fold the loose corner in, clamp it, and weld it into place.
It is recommended to replace the brake and fuel lines with new ones. Additionally, consider purchasing high-quality floor pans from reputable suppliers, such as Klassicfab or Jbugs.
