Off with your head!

After taking many measurements and setting the chassis up on the stands so the two axle tubes were perfectly plumb, I took the leap and made my initial cut! I had to cut very carefully so as to only cut through the frame tunnel and not through the reinforcement underneath. I "snuck up" on the cut, making my initial cut about an inch away from where it ended up. I then positioned the new frame head exactly an inch away from the final position, got it perfectly plumb & straight, and used blue masking tape to mark the final cut. After very carefully making the final cut & filing it perfectly straight I was very happy with how tight the seam ended up. And the measurements are perfect! I drilled the hole for the fuel line in the side of the new head. I have not yet welded the frame head on because I still need to treat the inside of the tunnel with POR15 to stop the rust. I will also weld up all of the openings on the new head and tunnel so as to completely seal out the water. No moisture, no more rust! I went to the local junk yard today to check out the half dozen or so beetles they have. I was disappointed to find they were pretty rusted into the ground and had been picked over pretty thoroughly. However, I did score 5 beautiful, original wheels!! The wheels that came with my bug are horrible, unusable. Very pitted (see below). I was able to get the nice, original wheels (see below) for $20 a piece! That means the 5 original wheels cost the same as ONE new reproduction wheel!!! I also picked up a battery hold down bracket for $2, mine was missing when I got the car. Al in all, it has been a great day for my beetle project, very productive!