Frame rust

[lawrence1911]

i have a 71 Super Beetle where someone had done a very bad job welding the frame horns supporting the trans axle. the engine is about 1" too low because of this poor repair. Is this hopeless or can I weld new frame horns in place? If I can how do I get correct alignment so I don't end up back where i started

[ProctorSilex]

I doubt it is hopeless, but maybe not worth your time, effort, or money depending on how you go about it.
There are some pictures of a VW alignment tool here.
Some people discussed bad frame horns here and here.
I would collect measurements from at least one good car either myself so I know I was reproducing the measurements exactly or from someone willing to post photos of how they took the measurements. Then try to reproduce on the bad horns.
Without measurements, you could just eyeball it into place with a floor jack then weld it.
Maybe a kaefer bar would help. However you get the horns aligned, the bar should help keep them that way if not help with the alignment.

Why do you mention rust? Was the repair done to rusty frame horns or rust where the horns meet the torsion spring housing? Is all the rust definitely gone? I have never seen rusty frame horns. If the chassis is that bad, it might be shot. You might be better off cutting off the rear and replacing or replacing the entire pan.

[Piledriver]

Welcome to the STF!

Berrien Buggy sells chromemoly tube based frame horns (typically used on buggies) for a reasonable price last I checked.

If the rest of the chassis isn't suffering from severe rustworm that would likely be the ideal way to go.

On an IRS car the frame horns have ~nothing to do with suspension alignment, so it's simply a matter of getting it centered and level, with the engine surround tin hitting the seal right.

[lawrence1911]

Thanks for all the suggestions. The frame horns look like someone used Bondo or fiberglass on them. I haven't taken a grinder to them to see where the metal is and what shape it is in. If I decide to do that I'll pull the engine first to take weight off the horns.

[ProctorSilex]

Talk of replacing rusty frame horns with some pictures of the Berrien and custom
Berrien horns for sale
Unless the Berrien is stronger, I would probably just cut some horns off an otherwise crap pan. Good to know that's available though.

[Ol'fogasaurus]

http://www.jimscustomvw.com/bebutufrho.html

[Piledriver]

Finding and cutting off a set of perfect stock framehorns on an otherwise scrap chassis for less money, and cut so they can be welded on properly again for less time & $$$: Bloody Unlikely.