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    11/15/08*

Answer:--->  This is a short question but requires a long answer. I will try to point out a few places to look for rust on all bugs and hope some of the  Forum members will help, as I know my listing will not be complete.     Vic.

Starting at the front you will notice a large percentage of  B.J. front ends will have rusted out shock towers. And the K.P. shock tower will only have surface rust. This was due to a vent hole in the bottom of the B.J. tower. This vent also let's moisture in and then often got plugged up with mud & crud. This might have been a good Idea if the vent hole was cleaned every year or so, but this never happened. We like to drill a small hole above the upper beam so oil can be squirted on the inside surface before plugging the hole. This can also be done on the K.P. front end but generally not needed. The B.J. shock tower can have an external patch applied #113 401 021RK for about $15.00 or replace the B.J beam #113 401 021D for about $120.00 and the new beam comes with all new bearings.

Front and rear Fenders are normally replaced rather then patched. If the nuts welded in the inner fender well are broken loose (quite common) The nuts can be replaced with new "Nut Insert" that are installed some thing like a pop rivet. If the inner fender well is rusted out it's time to look for another car or a donor car that panels can be cut from. Later Super Beetles attaches the McPherson Strut to this area so make sure there in good shape. If just a small area where strut is attached is bad a reinforcement section are available and can be installed, but this seldom  fixes the problem. 

Front and rear Apron's can just be replaced. Many other body panels are available, but inspect heater channels and the rest of the car before starting on rusty car. Until VW's become really hard to find you might be better off starting with a different car. Floorboards or Floor Pan's come in right and left side and have the seat mounting attached to them. Different years will have different seat mounts and floor pans are best replaced with the body off, but many have been installed from under the car. The VW  Bug relies on the pan & body bolted together for it's strength. For this reason the convertible has additional supports under the pan so if replacing your convertibles pan always save the reinforcement rails as they are expensive.  Most VW's will have a small amount of rust under the battery, and replacement battery trays are easily installed.

Next inspect under the door, where the running board attaches. Replacement panels (running board fastening panels) #113 801 047/048 are an "L" shaped and easy to replace. Running Boards are also easy to replace, but panic when they appear quite flexible. The gain the required strength when they are bolted in place. Next check out the Heater Channels found behind the running boards with the inner heat tubes. These heat channels are a major part of the structural support of the car. When these are bad, you quite often find the door sagging and not close properly. These are fairly expensive and harder to replace. We normally recommend looking for another car. If the outer heat channel has several small holes rusted in it, the cold air will come in one hole and out the other taking most of you heat with it. We have found the expandable foam used in home repair to cure this problem. Most users think they have more heat after installing the foam then when the car new. Any time you patch or remove a rust it is wise to coat the area with some rust inhibitor, like "Extend" or "Noverox" and then undercoat to prevent future rust. 

Hood, Doors and Rear Engine covers can often be replaced easer & cheaper then repairing them.

Heat exchangers must be replaced when rusted through. Do Not patch or repair. They are purposely designed to go bad on the outside, long before the interior exhaust gas leaks into the heated air going to the drivers compartment. The T-3 had heater boxes wrapped with an asbestos cover but replacement are not available. When Exhaust gases enter into the drivers compartment it is almost always do to bad engine compartment seals not because of a rusted out exhaust.

Gas Tanks are quite often found full of rust and in poor condition on cars that have set for many years. The gas tank was originally lead lined so any welding or brazing on the tank is a short time fix at best. ( long time for welder if  all the gas fumes or not removed ) Many good gas tank sealers are available and not hard to apply. They seal from the inside and last for many years. Por and Kreem are both good products and used in the aviation field.