Page 34 - Karmann Komment - V38 Issue 3

Karmann Komment Volume 38 | Issue 3 READER’S RESTORATION
Andrew Morris
As with all things bodywork related, little
jobs become major tasks! It all started when I decided to take the side trims off my Karmann. I prefer the cleaner lines with them off and realised I would be left with numerous small holes to fill, so I decided to buy a Sealey gasless welder (132 pounds off Amazon).
I have never welded in my life! I practised on old bits of metal and finally tried to do the holes. I did not do too bad at all, so I decided to address the other bits of bodywork that had bugged me since I bought the car. There had always been a funny cracking noise that came from the rear passenger side each time we used the car, but we could never find
out where it was coming from. I now know.
I decided to grind out some imperfections
on the lower back panel and when I started grinding a large piece of filler, attached to a piece of poorly welded in metal, about the size of a dinner plate, just fell off! The cracking noise had been this slowly detaching itself. So now I was left with a gaping hole.
I decided to try my hand at making a panel for this area. I know you can buy them, but I just wanted to give it a go. As you can see by
the photos, it did not turn out too badly at all.
I have now made a panel for the inner wheel arch too. I am learning all the time and luckily I am pretty good at body filling, so I will be able to cover any welding imperfections. I utilised metal from an old Ford Ranger body that I had lying around, selecting the bits with the curves that I needed to give me a head start.
I did not try to make the panels in one piece, instead making cardboard templates of each component first (the face, the return and the bottom) and then welding them together on the bench before doing final shaping when it was offered up to the car.
This will be butt welded into place, ground down and finally just smeared with filler. I
am learning a lot and I have been helped
by watching videos on YouTube by Fitzee’s Fabrications, give it a search! Without his help, I don’t think I would have had the confidence to give it a go. I have also taken advice from friends who do this for a living. I would guess that the welder has already paid for itself and
I am enjoying learning something new. As you know from my previous articles, I have already rebuilt the engine after finding a bent conrod and with all this rusty bodywork removed, I should have a really nice car.
Everything I am welding is cosmetic and not involving any structural parts, for that I would seek a professional welder, but I am going
to have a go at painting it, however I cannot decide on the colour just yet. I think I will stick with blue, but possibly a slightly lighter shade. My wife is good at spraying, so between us we will get there in the end.
Andrew Morris
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