Tech Note: When replacing a VW Beetle Frame Head we suggest taking several measurements before you cut the original frame head off of the chassis. For example, take a measurement from the bolt holes on the chassis tunnel and the rear chassis support panels to the very front of the existing frame head. Do this on both sides to make sure you get the frame head on square. Make sure you write the measurements down in case this is an on-going project. This will make the replacement much easier!

We also offer frame head bottom plate patch panels so you dont have to remove the entire frame head. Using a replacement bottom plate, you can either peel off the original with an air chisle or leave it on and place directly over for added strength. You will have to cut out the mounting nuts for the sway bars on Super Beetles as well as flatten the original bottom plate and cut into two pieces (one front) (one rear) this of course if you leave the factory lower control arm mount in place. You can remove the factory lower control arm mount but it has heavier welds and you will have to cut it off with a torch or use a grinder to eat through the welds.

It is best to have a chassis turned completely upside down in order to replace the bottom plate neatly and to achieve nice strong welds. A set of sturdy saw horses work very well keeping the chassis about waist high. Remember most of the weight of the chassis is at the back so the back saw horse will need to be almost directly under the front transaxle mount. Otherwise the chassis front can pop up when you slightly bump it.

Most generally when a frame head needs replaced, part of the tunnel bottom will be rusted and or missing. In the picture above you can see where a new cap has been made, formed and welded in for structure and to protect the tunnel. You can not get a tunnel cap anymore unless you go to a salvage yard and can cut out the same section. One can be formed out of a flat piece of sheet metal, .20 gauge or thicker. Our universal piece of sheet metal works great for a chore like this. Just determine what size you need, tack into place and heat up and form in with a hammer as you go. Our hammer set works fine as well.