This Rust Looked Small… Until I Started Cutting
Episode 14 of the 1964 Karmann Ghia restoration series.
Rust always looks worse… once you start cutting.
And once you cut, there’s no going back.
What begins as a small repair quickly turns into fabricating patch panels, shaping steel, and working out how to make everything fit back together properly.
In this episode, I work through repairing rusted sections by cutting out the damage, making custom patch panels, and welding them back in. Along the way, I experiment with different tools and techniques, and learn what works, and what doesn’t.
This is one of those jobs where progress comes slowly — but each step brings the car closer to being whole again.
🔧 Key steps covered:
0:00 — Assessing rust damage
0:20 — Fabricating patch panel
1:08 — Cutting out rust
2:25 — Welding
4:14 — Dent pulling
5:27 — Patch panel corner
6:44 — Shrinker / stretcher shaping
7:42 — Cutting second section
8:22 — Welding
9:00 — Body filler & result
🎬 Watch the full 1964 Karmann Ghia restoration series:
• 1964 Karmann Ghia Restoration | One Bite a...
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