Anyone who has repaired and or restored Vintage VW Beetles and Karmin Ghias, knows that they disassemble easily. The "peoples car" was designed for easy repair and restoration. The car can be disassembled down to it's chassis fairly easily. If the goal is to restore the car to original or better condition, your restorer will have to deal with some rust. The most typical problem areas are the galleys that channel heat from the heat exchangers into the cab and onto the windshield to defrost and defog during bad weather.
The galleys are problematic because they are the only source of heat, and windshield protection. If the galleys are perforated from rust and corrosion, the holes will bleed off the warm air being blown into the car from the engine. They are also difficult to access, unless you remove the floor panels. Attributable to the thoughtful design of vintage VW parts, the floor boards are separate removable parts. If the galleys of your car are rusted through, it is likely the floor boards are perforated as well, and should be replaced. Once they are removed, access to the interior side of the heat galleys, is more convenient. The repair is truly dependent upon your goals for the car. If you are restoring to show quality, you will need to repair metal with metal by cutting out the corroded sections, and welding into place new metal. If you are looking for a quick less involved repair, fiber glass can be a good solution for repairing holes in the galleys, since they will not be particularly visible.
If you decide to replace corroded metal with clean metal, be aware that the welding process will expose metal to accelerated rusting, if rust protection is not applied. There are several methods for applying rust protection, and it is important to remember that the galleys will be passively transporting heat into the car so it is important to rust proof with compounds that will not contribute chemicals, and odors into the air stream.
Spray application using a wand will effectively manage rust protection. There are products now available that are non toxic but very effective at stopping and preventing rust. Coating the complete interior surface of the galleys is a good idea because the continual hot, cold environment of the galley interior is a rust haven.
Short driving trips can pump warm air into very cool galleys causing condensation. Unless the galleys reach full operating temperature they will condense moisture on the inside, especially in winter. The nature of the heating system, deriving the heat energy from exhaust heat exchangers having air forced over the cooling fins to first cool the exhaust manifolds, and secondarily heat the interior, and defrost the windshield, makes condensation inside the galleys impossible to prevent during cold weather and short trips. Therefore it is critical that rust prevention inside the repaired galleys be effective.
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