How to Fix a Rusty Beetle

Information you need to keep your Beetle alive

Rust and your Beetle

One of the most important issues facing the owner of an older car is rust. Unless you have a car that has been recently restored from the ground up, any car around 30 years old is likely to have some rust. While replacing mechanical parts is relatively straightforward and inexpensive, major body repairs on a rusty car can be difficult and expensive.

The good news is that if your car is in generally good order, repairing minor rust and preventing its spread can be achieved without too much expense. So where should you look for it?

Where to look for rust

Like all older cars, Beetles will rust in any area where water is prevented from draining away and allowed to collect. Leaking window seals can result in water collecting in the floor pan and blocked drainage holes in the bottom of doors can lead to rusting. Lift up the carpets and inspect the floor pan and make sure the drainage holes in the bottom of the doors are kept clear.

Rust at the bottom of a door.
Serious rust around the rear window.
Rust around the rear window.
Rust first appears as small bubbles underneath paintwork.
Lower doors and rear window: tell tale rust spots on Beetles

Rust in the floor pan, heater channels, rear pillar, upper shock area and lower door posts should be treated seriously. Since the Beetle is a monocoque construction, if rust in these areas is very bad it can compromise the structural integrity of the car.

On the outside of the body rust first appears as small bubbles underneath the paintwork in areas where water has been prevented from draining away, as in the photos.

What are your options?

Although serious rust problems will require professional treatment, minor problems can be treated by the owner. There are basically three ways of dealing with rust:

There are certain measures you can take to prevent the onset of rust. It’s important that your window and door seals are in good condition so that the car doesn’t leak. Remember, we stock replacement seals and Beetle window rubber kits are only $104. As above, make sure drainage points in doors and elsewhere are kept clear.

One preventative treatment that is easy to do at home and will help a lot is oiling your car. It can be sprayed or brushed on areas underneath the body and inside hard to get at places like the doors and guards. The oil needs to be fairly thin if you’re spraying it, like auto transmission fluid. Fish oil is also good. You might like to try Wattyl Killrust Fishoilene, which is a treated fishoil containing rust inhibitor, formulated to provide a protective coating for metal. Of course, while rolling around under your car painting oil on your Beetle might not be that much fun, it is an inexpensive treatment.

An example of bad rust in lower door area.
Don’t despair: this finished up as a fine restoration

Rust conversion involves halting or at least slowing the rusting process by chemically acting on the rusted areas of metal, changing it into a more stable compound. The primary ingredient in cold phosphate converters is phosphoric acid, which converts rust into iron phosphate. One advantage of this method is that the rust does not have to be completely removed for the converter to work. This makes it ideal for large areas like the floor pans if they aren’t rusted too badly or hard to get at areas like the inside of panels.

To prepare areas for a converter you simply need to remove the loose rust with a wire brush or scraper and make sure the area is free from grease or oil. The converter can then be brushed on and once dry, painted with a primer and then with a top coat. Some products are now advertised as two or even one-step, with the treatment and coating in an all-in-one epoxy based enamel. Bear in mind that such treatments are intended for new areas of metal or minor rust spots.

For serious problems, replacement is the only solution. This can involve cutting out the rust and welding in new metal or replacing panels. Many Beetle panels are still available new and there are good second hand options.

Some rust treatment products

There are a number of good products available to prevent and fight rust. Newer technology makes the treatment of minor areas of rust relatively easy. The trick is choosing the right product – here are a few good ones.

Remember that serious rust that presents a structural problem should be referred to a professional. If you’d like information on our services, send me an email.