It looks horrible, but everything is possible. Just keep the faith!! There is only one good method to tackle this much work, lots of TIME.
After an incredible amount of time, you will get something that looks like this.
When all the sanding is done, be sure to clean all dust and use something like thinner to remove oil and grease (your air-tools usually use a little oil). After that you can apply the zinc spray.
The first thing I did was welding a few small holes (after sandblasting them). Next came a lot of sandblasting, grinding with the angle grinder and using a wire-brush. Here is the work in progress
You can see an old repair at the left of the pictures. I gave it a fair beating and it didn't budge, so I guess it's good enough. Not all the rust in the pits could be removed (within a reasonable amount of time) but I hope the zinc spray will neutralize for the coming years. After cleaning all the dust and using thinner to remove some compressor oil spray it was time for the zinc.
Beetle (VW) 2009 Wall Calendar 12 X 12
ASIN: B0018NT626
This large format calendar features 16 months and 13 full color photographs with plenty of room to write special dates, birthdays and anniversaries on the calendar grid. Size: 12x12
Follow this link to BUY THIS CALENDAR @ Amazon: Beetle (VW) 2009 Wall Calendar 12" X 12"
Nice floorpan and gearbox. But...... I prefer disk brakes, to give me serious stopping power.
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Nah, impossible to fix this. Just cut it out completely and fabricate everything anew.
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Very nice engine with huge turbo compressor. Incredible that you can fit this in a standard engine bay!!
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Beautiful engine detail. Yes, the spark order is cylinder 1-4-3-2.
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The hard work resulted in some nice clean metal. No welding was needed. The same day I sprayed zinc spray to protect it from corroding again.
One last look before the rust removal begins.
The last thing I did with the floor pan is cut out the rusty floor pan halves. You can see the remaining metal of the floor pan halves which have to be removed before I can fit new ones.
To remove the spot welded remaining metal of the floor pan I used an air chisel. Sometimes you need a hammer to make some room for the air chisel, but when it gets started the spot welds are hacked loose before you know it.
Here some pictures about the removal of the spot welds.
Sometimes the below piece of the floor pan can be reused. I decided not to use it.
The clambs are lose, but the tank won't budge, what to do??
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Nice two tone paint. Still much to do.
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Well sometimes you may dispair when you see your floor pan. But even this one is going to be excellent.
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Still a lot of work to be done. But this floor pan is going to be very nice.
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Very nice stripped beetle
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Rating poor. This is not a web shop. They have great products though, very nice W-deck lid, and many more great fiberglass products. The navigation of the website is very unclear. If you want to buy a product you just have to call them or send an email.
Visit their website @ http://www.vwinnovations.com/
Click on more to locate their store.
Rating Poor. Primitive looking website, the navigation is not very friendly. The online ordering system doesn't look very safe (it's a secure connection, but it doesn't feel good).
You can find fiberglass products in the following categories: Exterior Accessories, Fenders, Front Ends, Hoods, Kits, Other Cool Stuff, Rear Ends and Seats.
http://www.markvfiberglass.com/catalog/catalog.html
Click on more to locate their store.
Rating: average. The website is not very professional and the navigation is sometimes confusing. Most items they sell are engine parts, cylinder heads, engine cases, pistons, carburetors etc. They specialize in Empi parts.
No international shipping. Payment through Visa, MasterCard, American Express and Visa/MasterCard Debitcard. One great feature is their help-desk, a lot of great information about their webshop.
Visit their web shop @ http://www.actionimport.com/
Click on more to locate their shop on a googlemap.
Rating: Good. Great looking website, with easy navigation and a very large selection of parts. You can pay with PayPal, MasterCard, Discover Card, Visa and American Express.
Visit their website @ http://store.mofoco.com/
Click on more to locate their store on a googlemap.
Their main categories are: Cylinder Heads, Engines, Engine Parts, Carburetors & Parts, Transmissions, Clutch, Exhaust Components, Brakes, Empi, Front Suspension, Performance Parts, Rear Suspension, Shocks, Cables, Body Parts, Electrical, Interior, Tools, Used Vw Parts, Used Vehicles For Sale, Apparel.
They ship internationally but not to all countries, here is their selection: Aruba, Australia, Austria, Belgium, Brazil, Canada, England, France, Germany, Italy, Japan, Mexico, Norway, Puerto Rico, Spain, United Kingdom, United States.
Rating Poor. This is not a webshop just a being there website. The pictures of one of there customers cars are nice (I presume the car is restored by now). It's probably a good idea to visit their shop in real live and to stay away from the website.
Visit their website @ http://www.herrellbugparts.com/
Click on more to locate their store on a googlemap.
Rating: Good. Webshop in two parts. First you visit the website of Classic Camber. Here you can find much information about current and past projects. You can see which cars are on sale and what kind of products they sell. When you click on "online Catalog" you are redirected to Fixx Tuning & Classic Camber webshop. The sell not only VW parts but also Porsch, BMW and AUDI. Navigation is easy and most creditcards can be used.
Visit their shop @ http://www.classiccamber.com/
Click on more to locate their shop.
These are pictures of it's previous state.
I made the first cut just before the B-post.
The piece between the A and B post is removed.
The it's time to remove the hard parts. First the front end.
No more time to remove the rear piece.
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James Richardson
ISBN: 1861269404
The VW Beetle is one of the best-loved of all classic cars, with many thousands preserved across the world, many in regular use. Over the years countless changes were introduced, together making a mid sixties Beetle, for instance, very different from one built in the mid-50s, or mid-70s, despite the obvious similarities. With the aid of hundreds of full color photographs this book documents all the Beetle's specification changes and model differences during the classic period 1949-67, making it possible to determine the original specification and fittings of any Beetle from this period.
Follow the link to BUY THIS BOOK @ Amazon: VW Beetle: Specification Guide 1949-1967
Volkswagen of America
ISBN: 0837603897
Now available after being out of print for nearly 40 years, a vintage reprint of original Volkswagen repair information for all Type 1 (Beetle and Karmann Ghia) models sold in the USA and Canada. This manual is an historical record of the illustrations and procedures for routine maintenance, troubleshooting, repair and rebuilding.
Follow this link to BUY THIS BOOK @ Amazon: Workshop Manual: Volkswagen Types 11, 14, and 15 : 1952-1957 (Volkswagen)
Rating: Good. Professional looking website with a good selection of parts. You can buy air-cooled or water-cooled VW parts. The navigation is sometimes a little confusing, but you can find most parts. They ship internationally (contact them for a shipping quote). Payment through PayPal and Mastercard, Visa or Discovercard.
You can filter parts on your car model: Beetle up to 1967, Beetle 1968 and up, Bus/Transporter up to 1971, Bus/Transporter 1972 and up, Karmann Ghia up to 1967, Karmann Ghia 1968 and up, Type 3, Type 4 or Vanagon 1980-1983. Their main categories are: Tune Up Parts, Engine & Clutch, Fuel System, Exhaust System, Transaxle Parts, Front End, Rear Suspension, Brake System, Cables & Chassis, Body Parts and Electrical Parts.
Visit their shop @ http://www.evwparts.com.
Click on more to locate their store.
Rating: average. The site doesn't look like much. The number of parts being sold is very limited, most parts are used (so the prices are good). The navigation of the site is very easy and clear. You can browse these categories: Body Metal, Brakes, Cables, Chassis, Clutch, Electrical, Engine, Exhaust, Exterior, Fuel, Hardware, Hoses, Interior, Rubber Seals, Suspension, Tools, Transmission, Wheels and Sale Items. All parts are accompanied by a good clear photograph.
You can visit their webshop @ http://www.theairhouse.com/
Click on more to locate their shop.
Rating: good. Nice looking webshop with a nice amount of parts. The naviagation is easy, but some categories are almost empty. They ship internationally, just contact them to get a shipping quote. Payments are through paypal, visa, mastercard, discovercard and american express.
Visit their webshop @ http://www.mikesbeachbugs.com
You can locate their shop by clicking on more.
The categories on their site are: Accessories, Billet Aluminum Parts, Body Parts, Books And Manuals, Brake System Parts, Bras And Car Covers, Bumpers And Parts, Cables, Exterior Dress Up Parts, Carburetors & Parts, Carpet, Convertible Parts, Electrical, Engine Compartment Misc, Engine Parts, Exhaust Parts, Exterior, Flat Four Parts, Fuel System Tanks And Parts, Grease & Lubricants, Hardware, Ignition And Tune-Up, Ignition Switches Keys And Parts, Interior, Lighting & Lenses, Off Road Baja, Pedal Assy & Parts, Rubber Seals, Scat Procar Interiors And Seats, Steering Wheels, Sunroof, Suspension & Drive Axle, Tools, Transmission, Type 2 Parts, Vdo Gauges, Wheels And Tires, Windows & Wiper Parts.
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Rating: Good. Very good looking website, easy navigation. You can find a picture and additional information about every part. When you click on a picture you get a nice enlargement (great to be sure it's the right part). They are specialized in performance parts. You can't buy body metal (fenders, hoods, etc.) here.
The main categories of their navigation are: apparel, Beard seats, Books, manuals and signs, Brake parts, Chassis components, Clutch and transmission, Dj safety belts, Electrical, Engine accessories, Engine components, Exhaust components, Exterior accessories, Ignition components, Intake and fuel components, Interior parts and accessories, K and n air filters, NOS, Off road, Oil system components, Performance plumbing, Xtreme Racing Products, Piaa lights, Promotional items, Stock vw parts (oem), Suspension and steering, Tools, Vp racing and Wheels and accessories.
You can find additional information on pages about racing news, machine shop, engine building, tech talk, dyno page, idf adjustment.
Visit their webshop @ http://www.vwparadise.com/.
Click on more to locate their store.
Rating Poor. It's not a webshop, just pictures of a lot of parts. They state on the site that it's indeed an older site but they like to play with their turbo's insteed of working on the website. Don't go to their site, just call, e-mail or visit them.
If you want to see for yourself visit their site @ http://www.carcraftinc.com
Click on more to locate their store.
Rating Good. Great webshop with lots and lots of parts. Every item is photographed and accompanied with extra information. Very intuitive navigation. You start at the following main categories: Bug Parts, Bus Parts, Ghia Parts, Type 3 Parts, All New Parts, Hella Products, Used Parts, Safari Windows, Thing Parts.
In the Bug Parts category you find the following items: Accelerator Parts, Body Trims & Parts, Bolts & Chemicals, Brake Systems, Bug New Parts, Clutch & Engine, Conv. & Sunroof Parts, Electrical, Exterior Body Parts, Fuel Systems, Headlight & Tail Light, Interior, Mirrors & Wipers, Muffler & Exhaust, Rubber Seals, Sheet Metal, Suspension Parts, Tires & Rims, Turn Signal & License, Windshield & Glass and Wires & Switches. One negative point, the Forum doesn't work. The payment methods are: Discover, MasterCard, American Express, Visa or Pay Pal.
Visit their webshop @ http://www.eisparts.com
Click on more to locate their shop.
Rating poor. Not a webshop. They are specialized in rebuilt VW Engines and Components. The naviagtion of the website is not very friendly. They have the following main categories: Turnkey Engines, Longblock Engines, Transmissions and Cylinder Heads. You can browse through several engines per category, a few pictures give you an idea about the looks of the engine. For every enine you can find info about crankshaft, pistons, cylinderheads, etc. Some links on the site don't work. You can find prices for most featured engines.
Visit their site @ http://www.jcsvwparts.com
Click on more to locate their store.
This is not a webshop. They are a specialty shop for air-cooled vintage Volkswagens and Porsches. They have over 15 years experience in caring for air-cooled vehicles, and are specialized in full restorations. Their shop is staffed by lifelong enthusiasts who have become excellent mechanics, and are well connected with people, parts and services.
On their site you can find basic information on: Maintenance and Repair Work, Engine overhalls conversion and repair, Restoration and rustoration, Performance Upgrades and a Gallery. It's all rather general, so contact them for detailed information.
Visit their site @ http://www.transporterwerks.com
Click on more to locate their shop.
Not a webshop. They are specialized in suspension and brakes for VW Super Beetles: Brakes, Strutts, Springs, Sway Bars, Steering Boxes, Camber Adjusters, etc. You can find information about the products they sell, one pricelist and detailed tech info. The site is not very attractive (bit amateur like). If you want real info you have to mail or call them. The mail handling lady looks fine.
Visit their site @ http://www.toplineparts.com
Click on more to locate their store.
Rating good. Very professional looking website (don't forget to accept the certificate if you browse to the site). You can buy all top brands known in the VW beetle industry (for example: MSD Ingition, Fox, Elbach Springs, Auto Meter, CNC, Hella, Corw Enterprize, Tatum, ProAm, Howe, King, Kep, Empi and Mikey Thompson. Most parts are shown with a description and a photograph. Minimun orders are 25 dollar. You can pay with Visa, Mastercard, Discover and American Express.
The main categories on their menu are: Over Stock Specials, Specialty Items & Manuals, Engine Accessories, Fuel System & Exhaust Acc., Transmission, Front End Suspension Acc., Rear Suspension Acc., Brake System & Wheel Acc., Chassis Components, Interior & Exterior Accessories, Electrical Components, Manufacturer Product Lines, Rhino ATV Accessories, Chassis Frames, Clearance Center.
Visit their shop @ www.pacificcustoms.com
Click on more to locate their shop.
Rating poor. Not a webshop at all. Just a 4 page site with some basic information about Beetle Barn. They don't even have their address on the site, only a phone number.
You can visit their site @ http://www.beetlebarn.com
Click on more to locate their store.
Rating: Poor. Very limited website with just a few categories of products. Some are empty, others only contain one picture and a table with prices. It's not a webshop, you have to e-mail or call them to get the products.
Visit their site @ http://www.gemvw.com
Click on more to locate their shop
Rating: average. This is a webshop, you can buy parts here online. However it's not easy to navigate through the site. There are not many pictures on the website, all parts must be found through a text search. That's not a big problem, but it would be nice if you could see if it's the correct part.
The categories of their catalog are: Accessories for your ride, Accessories for you, Body Parts, Books and Manuals, Bosch Parts, Brake Parts, Electrical, Engine Parts, Fluids and Such, Frame Related Parts, Front End Parts, Fuel and Exhaust, Nuts and Bolts, Read Drive Parts, Tools and Things, Transmission Parts and VDO Instruments.
They ship internationally. Payments can be made with credit card. I couldn't see what cards are supported but I presume als the regular cards.
Visit ther shop @ http://www.wolfgangint.com
Click on more to see their location on a map
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Enthusiast's Restoration Manual. Tips, techniques & step-by-step procedures for preparation & painting.
Martin Thaddeus
ISBN: 1903706637
The complete guide Written by a paintwork professional Step-by-step, illustrated procedure Preparing your workshop Colour mixing and matching Includes the art of filling with lead Covers all stages from paint removal to applying a new topcoat Packed with professional tips What to do if something goes wrong. This book takes the reader step-by-step through each stage of preparation from minor repairs, through filling and undercoats to a paint finish fit for a classic car. Over 140 color photographs illustrate every stage of the procedures. Paint like a professional!
Follow this link to BUY THIS BOOK @ Amazon: How to Paint Classic Cars (Enthusiast's Restoration Manual)
Table of contents
1 Introduction
2 A word of caution
3 Painting—the big picture
4 The modern paintshop
5 Tools, equipment & workshop
6 Color matching
7 Panel beating techniques
8 Paint removal
9 Filler
10 Masking
11 Primer
12 Flatting and panel preparation
13 Spraying paint
14 Topcoat application
15 Blow-ins, fade-outs, & false edges
16 Alternative panel materials
17 The finishing touches
18 Gun care & troubleshooting
Metal, Fiberglass, and Plastic Bodywork
Staightening, Welding, and Filling
Unibody and Conventional Chassis
Minor to Major Damage Repair
David Jacobs
ISBN: 0879385146
Dings and dents, creases and tears, trim, seams - all areas of repair are covered in this thorough and well illustrated guide. Frame problems, inner and outer panels, hidden damage, bumpers, grilles and lights are included, along with tips on the tools, materials and terms used in the trade. ...considering the wealth of information contained, it turns out to be an absolute bargain. Skinned Knuckles.
Follow this link to BUY THIS BOOK @ Amazon: How to Repair and Restore Bodywork (Motorbooks Workshop)
Table of contents
1 Autobody work defined
2 Talking to an autobody specialist
3 Tools and materials
4 Assessing damage
5 Part replacement versus repair
6 Minor ding and dent repair
7 Moderate damage repair
8 Multiple panel repair
9 Major collision damage considerations
10 Autobody repair extras
11 Preparing for paint
A Guide to Plasma Cutting, Oxyacetylene, ARC, MIG and TIG Welding
Richard Finch
ISBN: 1557885133
A newly-updated, state-of-the-art guide to MIG and TIG arc welding technology. Written by a noted authority in the field, this revised edition of HP's bestselling automotive book-for over 20 years-is a detailed, instructional manual on the theory, technique, equipment, and proper procedures of metal inert gas (MIG) and tungsten inert gas (TIG) welding.
Follow this link to BUY THIS BOOK @ Amazon: Welder's Handbook, RevisedHP1513: A Guide to Plasma Cutting, Oxyacetylene, ARC, MIG and TIG Welding
Table of contents
1. Introduction
2. Metal Basics and Heat Control
3. Welding, Brazing and Cutting
4. Welding Equipment
5. Welding Safety
6. Fitting and Jigging
7. Cleaning Before Welding
8. Gas Welding and Heat Forming
9. Torch Cutting
10. Gas Brazing and Soldering
11. Arc Welding
12. MIG Welding
13. TIG Welding
14. Plasma Cutting and Welding
15. Special Welding Processes
16. Welding Rods, Wires and Fluxes
17. Welding Projects
18. Welding Certification and Training
The Ultimate Guide to Building Your Dream Machine (Motorbooks Workshop)
Gerry Burger & Steve Hendrickson
ISBN: 0760307679
Does the smell of gear lube get your juices flowing? Does the sound of a small-block Chevy with uncorked headers dimple you with goosebumps? Do you think ALL cars should be flamed? Do you mentally lower every car you see? If you answered yes to any of these questions, congratulations, you have the mindset of a hot rodder.
Whether you're a grizzled, gray-bearded rodder of someone with latent hot rodding tendencies, this is the book that will get you off the couch and into the garage. Hot rodder's Bible contains all of the information you need to find, build, and enjoy a hot rod.
Follow this link to BUY THIS BOOK @ Amazon: Hot Rodder's Bible: The Ultimate Guide to Building Your Dream Machine (Motorbooks Workshop)
Written and compiled by guys with more than 40 years of hot rod experience, this book will teach you to:
- Find your perfect hot rod project
- Build a better body by chopping, frenching, welding or glassing
- Slect and improve the hot rod frame
- Set up hot rod syspension from lowering to front end replacement
- Improve your hot rod's brakes
- Build your dream motor and mate it to the right tranny
- Design, install, and modify hot rod interiors.
From big projects such as building a frame, to small ones like hammer-forming a custom air cleaner base or installing modern gauges in a vintage dash, each chapter explains a general ot rodding principal and then follows it with detailed, in-the-shop photo sequences that show you how to do it. There's even a color Roque's Gallery of finished hot rods that will inspire weterans and newbies alike.
So whether you are just thinking about dusting off that old rod or completely building one from scratch, the Hot rodder's Bible is the book that will show you how to modify it, improve it, and most importantly, have fun while you build it!
Table of contents
Chapter 1. A brief history of the hot rod
Chapter 2. Finding your hot rod project
Chapter 3. Building a better body
In the shop
Removing rust
Fixing dents
Hammer-welding a patch
Replacing rotten body wood
Installing Bear Claw door latches
Chopping an F-150 Ford pickup
Top Chop techniques
Chapter 4. The hot rod frame
In the shop
Custom tubular X-members
Custom motor mounts
Installing a subframe front suspension
Chapter 5. Hot rod suspension basics
In the shop
Installing an aftermarket independent front suspension
Swapping power steering
New rear springs for fat Fords
Choosing the right wheels
Chapter 6. Hot rod brakes
In the shop
Installing big brakes on a Mustang II front end
Plumbing a hot rod chassis
Chapter 7. Hot rod engines and drivetrains
In the shop
Designing an automatic shfter linkage
Making a retro-tech air cleaner
Chapter 8. Hot rod interiors
In the shop
Haning a steering column
Anchoring seatbelts
Installing a four-point harness
Installing new gauges in old dashes
Restoring heaters
Chapter 9. 15 Things to do with your hot rod
Chapter 10. The Ten Commandments of Hot Rodding
Start-to-Finish sequences with Master Craftsman
Techniques for Steel and Aluminum
Fabricate Motorcycle and Hot Rod Parts
Tim Remus
ISBN: 978-1929133123
A follow-up to his popular Sheet Metal Fabrication, author Tim Remus taps into the talents of master craftsmen to bring you more techniques for forming aluminum and steel into the one-of-a-kind parts that make your street rod or custom cycle more than a "me too" machine. This book is lavishly illustrated with quality photographs. Remus takes you through a number of start-to-finish sequences with the finest metal workers in the field. If you strive build a truly unique machine, Advanced Sheet Metal Fabrication is the book for you.
Follow this link to BUY THIS BOOK @ Amazon: Advanced Sheet Metal Fabrication
Veloce Enthusiast's Restoration Manual Series
Martin Thaddeus
ISBN: 1-903-7066-29
Gives the do-it-yourself restorer the confidence to tackle bodywork repairs and achieve professional results. The text is easy to read, the photos bright and colorful, and the instructions are clear. This book gives the backyard mechanic confidence to tackle bodywork repairs and achieve professional results. Specially devised techniques which don't rely on professional workshop equipment enable even the most difficult tasks to be undertaken.
Follow this link to BUY THIS BOOK @ Amazon: How to Restore Classic Car Bodywork (Veloce Enthusiast's Restoration Manual Series)
Table of contents
Introduction
Scope of the book
Buying your classic vehicle
Vehicle construction
Mild steel sheet
Surface tension
Spot welds and spot welding
Chapter 1. Rust - know your enemy
Protection
Chapter 2. Tools, equipment & workspace
Basic tools
Hand tools
Hydraulic gear
Power tools
Welding gear
The workspace
Chapter 3. Workshop safety
Specific hazards
Welding
Power tools
Hand tools
Chapter 4. Basic panel removal
A very simple panel
Fron wing
A real life example
Drilling spot welds
Alignment
Welding at last
Welding completed
Problem areas
Chapter 5. Basic panel fitment
Alignment
Welding at last
Welding completed
Problem areas
Chapter 6. Sectional repairs to basic panels
Circular patches
Corner repair section
Sill end
Salvaged panel sections
Typical lower wing sectional repair
Proprietary wing bottom section
Proprietary boot lid section
Supporting structures and alignment
Section upon section
Bowl sections
Pillar joints
Methods of joining and fixing
Gas welding
Soldering
Chenical bonding
Chold rivets
Pop rivets
Chapter 7. Doors
Door construction
Problem areas
Window frames
Hinges and supports
Check-strap
Removal and handling
Door bottoms
Basic door skinning procedure
Tools and equipment
Starting off
Grind off the return edge
De-seam
How's your bottom
Split off the skin
Clean up
Position the new skin
Seal and clamp
Tap up
Fettle
A few good tips
Extra safety
Chapter 8. Sills, floors & outriggers
Triumph Spitfire sills and floor
Assesment
Set up and support
Work order
The Triumph Stag
Tread-plate sills on a separate chassis car
Half sill section and oversills
Half sill
The oversill
Chapter 9. Chassis members - repair & renewal
The basic checks
Lift check
Drop check
The jig
Outriggers
Example 1
A bit more on safety and fuel lines
Example 2
Repairs to chassis main rails
Miscellaneous
Chapter 10. More about floors
Thypical mid-floor repair
Half floor sections
Making floor sections
Chapter 11. Multiple panel assemblies
Triumph GT6
Inner wheelarch rebuild
Rejoining the inner wheelarch to the bonnet
Fitting new wings
Lamp panel repair
D-plate and inner valance
Chapter 12. Wheelarches
The options
Assessment
Replacing a wheelarch
Inner wheelarch repair
Welding in the new wheelarch
Making a new wheelarch
Shape formers
Forming the wheelarch
Half round repair section
Arch lip repair
Templates
Remove old metal
Fix the new metal
Full rear quarter panel/rear wing replacement
Concealed welds, brazed joints, etc.
Pillar joints
Internals
The inner wheelarch and location
Half panel sections
Welding
Chapter 13. Metal forming techniques & panel beating
Basic metal forming techniques
Folding
Curving or rolling
Shrinking and stretching
Edge spreading
Cold shrinking
Planishing, raising and hollowing
Chapter 14. Basic hammer exercises
Planishing
Raising and hollowing
The teardrop bowl
6in bowl form a 7in disc
Annealing
Folding, curving and shrinking
Bonnet (hood) scoop
Fabrication
Dorian's spoiler
Chapter 15. MGB facelift
The design
Constructing the station former
Creating the blank
Hollowing, raising and planishing
Finishing the edges
Folding
Flanging
Swaging
Wiring
Welding panel sections
Chapter 16. Panel repair techniques
Principles
Assessment
Roughing out
Hammer and dolly work
Indirect hammering
Direct hammering
Other panel beating techniques
Spring hammering
Pick hammer
Hot shrinking
Faux shrinking
Metal finishing
The body file
The bumping file
Finishing up
Nice site about the restoration of a 1957 Oval. Not much text about the project itself but pictures about the various stages of the restoration. The car was in very bad shape when it came to John, but it's comming together nicely. However I don't think that painting in the open air is good for a high quality paint job.
Visit his site @ http://www.vintagevwcars.com
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Excellent site about the restoration of a 1978 Last Edition Beetle (number 250 of the last 300 beetles build in the UK). The restoration is still in progress. On the progress-o-meter you can see where they are now with the restoration. Unfortunately june 2006 is the last entry in the calendar.
The rolling chassis looks amazing. Very detailed and very straight (hopes mine will also look that good when finished).
Check out their site @ http://www.lasteditionbeetle.org/
]]>Rating: average. The site looks a little amateur like. You can search for parts in the following main categories: Beetle, Cabriolet, Split Van, Bay Van, Type 25 Van, Karmann Ghia, Type 3, Type 181/182 and Type 34 Ghia. The interface works fine but the look and feel of the site doesn't give you much confidence that your money is well spent here.
Visit their shop @ http://www.status-vw.co.uk/
When you click on one of the categories you get an overview of sub-categories, when you select Beetle you get: Window Seals & Pop-Outs, Door Parts & Seals, Bonnet & Decklid Parts, Wheels & Hub Caps, Chrome Trim, Bumpers & Parts, Exterior Mirrors, Running Boards & Wing Beading, Lights, Windscreen Wipers, Exterior Accessories, Interior Parts, Brake System, Axle, Steering & Suspension, Gearbox Parts, Engine Components, Ignition & Electrical, Cables, Fuel System, Exhaust & Heater Systems, Repair Panels or Stickers. Some categories have a sub-subcategory others display a list of parts.
You can fill your shopping basket by adding items from the list. The interface is quite easy to use. When you proceed to the checkout you have to select you shipping method/region and you payment method (AMEX, Mastercard, Maestro/Switch/Solo, Cheque of Visa/Delta/Electron). It all works fine, except that the simple look doesn't give you much confidence that it's safe to spend you money here.
You can contact them @:
Rating: good. Very nice web shop, easy navigation through their excellent inventory of VW Beetle parts. Very good description of the parts and quality pictures to be sure it's what you need. They turned their shop into a shop+forum+gallery for the real beetle enthusiast. You can find lots of interesting information on their forums. You can find a lot of tech articles about project they did themselves (however not always detailed info). Nice collection of VW Beetle pictures on their gallery. The shop accepts all standard payment methods: credit cards, pay pal, money order and checks. Standard shipment UPS ground.
Visit their shop @ http://www.chirco.com
Their sitemap gives you an excellent way of navigating to the right information:
Click on more to view the map with the location of the store.
Buy Body Hammers and Dollies @ Amazon:
Astro Pneumatic 5510 Body & Fender Hammer and Dolly Set 7 PC
7 Piece Body and Fender Hammer and Dolly Set
7 pc. Fiberglass Hammer & Dolly Set-Cast iron hammer heads & dollies, PVC case
The Nichols/Chilton Editors
ISBN: 0-80199-073-4
Volkswagen Air-cooled 1949-69 repair maunal covers all U.S. and Canadian models of Beetle, Karmann Ghia, Bus Fastback, Notchback and Squareback. Includes wiring and vacuum diagrams.
The Total Car Care series continues to lead all other do-it-yourself automotive repair manuals. This series offers do-it-yourselfers of all levels TOTAL maintenance, service and repair information in an easy-to-use format. Each manual covers all makes format. Each manual covers all makes and models, unless otherwise indicated. :Based on actual teardowns :Simple step-by-step procedures for engine overhaul, chassis electrical drive train, suspension, steering and more :Trouble codes :Electronic engine controls
Follow this link to BUY THIS BOOK @ Amazon: Volkswagen: Air-Cooled 1949-69 (Chilton's Total Car Care Repair Manual)
Volkswagen of America Inc.
ISBN: 0-83760-390-0
Now available after being out-of-print for nearly 40 years, a vintage reprint of original Volkswagen repair information for all Type 1 models sold in the USA and Canada. This manual is a historical record of the illustrations and procedures for routine maintenance, troubleshooting, repair and rebuilding, including:
- Engine and cylinder head service, repair and reconditioning, including bench testing procedures and specifications for 36hp motors.
- Solex 28 PCI carburetor and Solex fuel pump troubleshooting, rebuilding, and adjustment.
- Transmission removal, rebuilding, and adjustment, including ring gear tooth contact for Gleason and Klingelnberg toothing.
- Frame, floor and body panel repair. All measurements and detailed cutting, alignment and welding instructions. Painting preparation and procedures.
- Body repair and replacement procedures, including the sliding fabric sunroof and convertible top.
- Complete wiring diagrams.
- All factory changes and updates are noted in the text by manufacturing date, chassis number and part number
- Full explanations of the operation of all systems, with exploded views, cuataways and diagrams.
- Required workshop equipment, tools, and equipment for local manufacture listings.
- Troubleshooting tables for clutch, carburetor, fuel pump, steering, brakes, generator, starter, and wipers.
- Maintenance and lubrication charts and procedures.
Follow the link to BUY THIS BOOK @ Amazon: Volkswagen 1200 Workshop Manual: 1961-1965, Types 11, 14 & 15 (Volkswagen)
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Wright Publishing Company Inc
ASIN: B-00006-KC-86
Edited for Volkswagen owners, off-road enthusiasts, racers and general automotive enthusiasts. Includes technical articles, how-to-do-it's and competition coverage.
Follow the link to GET A SUBSCRIPTION @ Amazon: Dune Buggies and Hot Vws
Pet Prints
ISBN: 1-84662-363-4
This large format calendar features 16 months and 13 full color photographs with plenty of room to write special dates, birthdays and anniversaries on the calendar grid. Size: 12x12
Follow this link to BUY THIS BOOK @ Amazon: Beetle VW 2008 Wall Calendar
Bob Tomlinson
ASIN: B-000-JLL-072
Great book for VW enthousiasts with Weber powered engines. Diagrams photos and much more for VW and Porsche engines. Much information how to keep those engines running to maximum performance.
Follow this link to BUY THIS BOOK @ Amazon: Weber Tech Manual (VW Aircooled specific)
Rating: good. Nice looking web shop with easy navigation. Most parts are presented with a good quality picture. The main categories are "Featured Items", "Accessories", "Body/Interior", "Rubber Kits", "Electrical" and "Mechanical". You can make a selection of parts which will fit on your year and model car. The prices are fair. The information about shipping is very nice, they can ship international (contact them to get the shipping total). There is a forum where you can discuss about beetles and tech issues. The Tech Articles section give you some minimal info, but it's not a great help. They accept payments with all major credit cards, Paypal, COD, check and money orders.
Visit their shop @ http://www.airheadparts.com/home.asp
Click on more to see the location of their shop on a map.
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Rating Poor: This is not a webshop. You can browse through their parts. It's like a digital catalog without the benefits of today's digital possibilities. They sell carbon decks which look great (if you fancy this kind of look). There are a lot of pictures of parts, but mostly the bigger parts. You can buy the "Herbie" engine for $3000. All sales are through phone or at their store.
Visit their shop @ http://www.qualitygermanautoparts.com
Click on more to view the location of their store on a map
Tom Wilson
ISBN: 0-89586-225-5
Don't just keep your VW engine alive, make it new! Complete details for rebuilding air-cooled engines in all chassis from 61 - 83: Beetle, Ghia, Bus, Squareback, 411/412 and Porsche 914. Includes comprehensive chapters on how to:
- Troubleshoot engine and decide to rebuild.
- Remove, disassemble, inspect and assemble engine.
- Recondition cylinder heads and crankcase internals.
Invaluable parts identification and interchange section tells what parts can be swapped where, and specifies the best parts for durability or performance.
Concise text and 500 photos, drawings and charts lead you through each rebuilding step. Finish with an engine ready for thousands of miles of service!.
Follow the link to BUY THIS BOOK @ Amazon: How to Rebuild Your Volkswagen air-Cooled Engine (All models, 1961 and up)
James Hale
ISBN: 1-90370-699-8
Applies to all air-cooled-type Volkswagen Beetles, but does not cover MacPherson strut-type front suspension found on 1302 and 1303 models.
- The first reference book devoted solely to Beetle chassis, suspension and braking systems.
- Suitable for the home enthusiast as well as the more experienced mechanic.
- Based on the successful "How-To" technical features developed by the author for Volksworld magazine.
- Includes detailed coverage of the process for shortening the Beetle floorpan for kit-cars and dune buggies.
- All the information is based on practical experience of specialist VW mechanics.
Follow the link to BUY THIS BOOK @ Amazon: How To Modify Volkswagen Beetle Chassis, Suspension & Brakes (SpeedPro) (Speed Pro)
Bob Cropsey
ISBN: 0-97652-610-7
Large size hardcover book covering everything about Volkswagen and their vehicles. This is not just a Beetle book and it will interest everyone from the owners of the OLD VWs right up to the NEW Beetles.
You will get 550 Complete History facts, 100 Herbie The Love Bug facts, The famous VW Advertising Campaign with 402 ads, Year to Year breakdown of the Beetle from 1945 and the Bus from 1949, 65 Fun facts of things done with VWs all over the world, VWs used in 40 movies, Great stories about VWs. And Much Much more. The only book of it's kind. If you own, or have ever owned any kind of Volkswagen, this book is a must have! Everyone loves this book and so will you.
Follow this link to BUY THIS BOOK @ Amazon: Volkswagen History to Hobby: All the Facts - All the Fun
Laurence Meredith (Author), Mark Hughes (Editor), Rowan Isaac (Photographer), Dieter Rebmann (Photographer), James Mann (Photographer)
ISBN: 1-87097-984-2
Once production of the Beetle was under way during the dying days of 1945, it became obvious to Major Ivan Hirst of the Royal Electrical and Mechanical Engineers, who was in charge of the factory at Wolfsburg, that some kind of internal transport was necessary for delivering components around the vast, bombed-out building.
Follow this link to BUY THIS BOOK @ Amazon: Original Vw Bus (Original Series)
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WheelsTV.net
ASIN: B000LZ59HS
The history of the people's car is one that spans a world war, the hippie era and today's high-tech automotive world. When the Volkswagen Beetle was first produced in post World War II Germany, its creator, Dr. Ferdinand Porsche, never imagined how enduring this bug shaped car would be.
Today, The Beetle is the most popular car ever built and Volkswagen has evolved into the maker of precision engineered automobiles that are both practical and a pleasure to drive, hallmarks of today's highly successful New Beetle. The story of the lovable Beetle is a salute to the indomitable spirit of human ingenuity. This exciting story is brought to you by the multi-award winning production team that created Wild About Wheels.
Follow this link to BUY THIS DVD @ Amazon: The Lovable Beetle
Buy Slide Hammers @ Amazon:
Cummins Industrial Tools Heavy Duty 9pc 10 lb. Slide Hammer Puller Set
K-D Tools (KD 41700) Slide Hammer Puller Kit
Cummins Industrial Tools 9pc - 5 lb. Dent Puller Set
"The Shark" Dent Puller - DF-595
After using the sand blaster the total damage is visible. Time to buy a repair panel or create one myself.
Last week I had time to finish the luggage shelf. Almost al the rust was removed with the sand blaster and the remaining rust treated with Fertan (chemical rust remover). This is what it looked when I started. And with the Fertan treatment.
This is the first result. Completely sprayed with Zinc spray. Needles to say that I still have to weld in the new parts.
I am probably going to remove the Zinc spray when it's time for the real primer. But this way I am preventing new rust during the stripping and cleaning proces. The surface still has to be treated with a filler to ease out the small holes.
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Rating: poor. This shop is focussed on paper. The website is a digital version of their paper catalog. However they have lots and lots of quality restoration parts. The pictures from their catalog make it very easy to select the right parts.
Visit their shop @ http://www.westcoastmetric.com
Click on more to view their location
A small quote from their website:
"Welcome to West Coast Metric, here you'll find the best parts and accessories to restore your Volkswagen. At WCM we take pride in manufacturing the highest quality and finest fitting parts at the lowest prices. Offering OEM German and quality reproduction parts for VW Bug, Bus, Ghia, Thing, Type 3, Vanagon, Cabriolet and New Beetle. Since 1977, we have been the premier supplier of high quality parts for Volkswagens."
]]>Check the site @ http://rides.webshots.com/album/16795691NnhOJcwDcB
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Check this site @ http://www.vwtrendsweb.com/features/0501vwt_1952_split_window_volkswagen_beetle/
]]>The front of the beetle is what got my attention. The spare wheel well has to be replaced and the bumper mounts are attached to very week metal. First I cut the wheel well out with the reciprocal saw. This resulted in this nice hole.
On close inspection you can see that the underside of the left bumper mount is attached to NOTHING! The underside of the wheel well is a combination of repair panels, glass fibre, dirt and Schutz. It will be a hard job to remove all the remaining pieces of the wheel well. But that’s the challenge.
Buy an Air Impact Wrench @ Amazon:
Porter-Cable PT382 3/8-Inch Pneumatic Impact Wrench
Ingersoll-Rand 231C Super Duty 1/2-Inch Pnuematic Impact Wrench
Chicago Pneumatic (CP 734H) 1/2" Air Impact Wrench
1/2 in Drive Impact Wrench
Buy a pneumatic body saw @ Amazon:
Ingersoll-Rand 4429 Super Duty Pnuematic Reciprocation Saw
Jet JSG-0822 16 Gauge Pnuematic Body Saw
Astro Pneumatic Mini Air Reciprocating Saw
Heavy-Duty Reciprocating Saw
Editors of VW Trends Magazine
ISBN: 1-55788-483-8
Covering all Super Beetle models manufactured in Volkswagen's glory years of 1971-1974, this indispensable resource for Beetle enthusiasts details the ground-up restoration-from the chassis and engine to the drivetrain and interior- of the most popular vehicle Volkswagen ever produced.
Follow this link to BUY THIS BOOK @ Amazon: The Volkswagen Super Beetle Handbook HP1483: A Restoration Guide For 1971-1974 Models
Table of contents:
The rise and fall of the Volkswagen Super Beetle
Initial inspection and evaluation
Interior/exterior disassembly
Front suspension disassembly
Front suspension rebuild
Rebuilding the steering box
Replacing the package tray
Rebuilding the brakes
Replacing the spring bushing plate
Removing undercoating
Basic bodywork
Removing window glass and door locks
Sanding and priming
Removing the body from the pan
Replacing the rusted fenderwells
Final paint
Assembling the long block
Replacing the IRS transmission
Installing the headliner
Installing rubber, doors and windows
Installing wiring harness and electrical components
Soundproofing our Beetle
The fuel and fresh air vent systems
Finishing the interior
Installing exterior body parts and trim
Follow this link to BUY THIS BOOK @ Amazon: The Volkswagen Super Beetle Handbook HP1483: A Restoration Guide For 1971-1974 Models
Rating Poor. Performance turn key engines, long blocks and quality built transmissions.
Amateuristic looking site, where you can by engines, trannys and a few options. No information is specified about the products, so this site is no addition to their ad's in Hot VWs magazine. You can order at their website, but it's not very customer friendly.
One good point about stricly VW is that they ship World Wide.
Visit their shop @ www.strictlyvw.com
Click on more to locate their store.
My compressor has a 220 volt motor which drives 2 cylinders with a 100 liter tank.
Buy a compressor @ Amazon:
Porter-Cable CPF4515 15 Amp 4.5 Horsepower 15-Gallon Oil-Free Wheeled Single Hot Dog Compressor
Porter-Cable CPLC7060V 15 Amp 7 Horsepower 60-Gallon Oiled Vertical Compressor
DEWALT D55168 Heavy Duty 15 Gallon Heavy Duty Wheeled Portable Workshop Compressor
Campbell Hausfeld VT6275 15 Amp 6.5 Horsepower 60 Gallon Oiled Vertical Compressor
Maxus EX8041 15 Amp 3 Horsepower 60 Gallon Oiled Vertical Compressor
Buy respirators @ Amazon:
AO Safety 95190 Woodworkers Respirator
AO Safety 95090 Quicklatch PRO Dual-Cartridge Respirator
AOSafety 95115 Paint Pesticide Respirator
Buy Goggle's @ Amazon:
Uvex S3960C Stealth Chemical Splash and Impact Goggle, Clear Lens with Indirect Vents
SAFETY GLASSES
Protective Safety Goggles Anti-Fog Lens
SAFETY PLASTIC FLEX GOOGLE Safety Flex Goggle
Buy Hearing Protection @ Amazon:
Peltor H10A Professional Earmuff Hearing Protector (Noise Reduction Rating 30dB)
Laser-Lite LL1 Disposable Foam Earplug by Howard Leight NRR30, Sold by the Box of 200 Pair
Bilsom Leightning L3 Earmuff
I have tried different models from cheap to more expensive but my conclusion is they are all sufficient. The metal on the beetle is quite thin so you don't niet much power to cut through.
My best advice on angle grinders is: YOU CAN'T HAVE ENOUGH ANGLE GRINDERS!!!!! It's very time consuming to change disks, so with multiple grinders you can have one with a corse sandig disk, one with a cutting disk, etc.
Here are some pics of my angle grinders:
Buy Angle Grinders @ AMAZON:
Black & Decker 7750 4-1/2" Small Angle Grinder
DEWALT D28110 Heavy Duty 4-1/2" (115mm) Small Angle Grinder
Cheap!! 4 1/2 inch Angle Grinder
BOSCH 1800 4 1/2" Angle Grinder
Of course I didn't use this disc on my beetle :)
This sandblaster has a reservoir for the blasting material. The white bag is used for recovery of the used blasting material.
These two blasters make a bigger mess. The used material just falls on the ground.
Buy sandblasters @ Amazon:
Cummins Industrial Tools Air Sandblaster Kit
Gilmour 70HDG Handi-Sand Blaster
'Spot Shot' Air Sand Blaster Kit - Closed Cycle/Recycling
30in. x 20in. Plastic Blaster Cabinet
A detail:
Some details:
Some details:
Some details:
It's second hand, so not all is perfect.
Keith Seume
ISBN: 0-76030-314-2
Your complete and definitive guide to ground-up Beetle restoration. Contents include: how to renovate chassis and bodywork - including the renewal of major panels and repainting, how to renovate interiors - including the re-covering of seats and renewal of the hood, how to give new life to mechanical and electrical components - including engine overhaul, and how to use your Beetle as the basis for a special or kit car.
Follow the link to BUY THIS BOOK @ Amazon: Aircooled VW Engine Interchange Manual: The User's Guide to Original and Aftermarket Parts... (Motorbooks Workshop)
Table of contents:
1. Introduction (when in doubt ask..)
2. Crankshafts (getting to the heart of the matter)
3. Con-Rods (from stone stock to trick titanium)
4. Cylinder Heads (breating live into the VW engine)
5. Camshafts & Valvetrain (camshafts, lifters, push-rods, rocker arms, springs and retainers)
6. Crankcases (from 1131cc to 3 liters and beyond)
7. Cylinders & Pistons (cylinders, pistons, piston rings, wrist-pins and wrist-pin retainers)
8. Carburators & Fuel Systems (bigger is not always better - but it can be)
9. Exhaust Systems (one of the most effective ways to make horsepower)
10. Ignition Systems (putting the spark back in your Volkswagen)
11. Lubrication and Cooling (it takes more than air to cool a Volkswagen engine)
12. Address File (principal product manufacturers and suppliers)
Follow the link to BUY THIS BOOK @ Amazon: Aircooled VW Engine Interchange Manual: The User's Guide to Original and Aftermarket Parts... (Motorbooks Workshop)
Keith Seume
ISBN 0-76030-469-6
Your Volkswagen Beetle is not only the worlds most popular car, but a favorite for those of you who cant wait to wrench out every ounce of performance and handling from your Bug. This detailed guide shows you how to upgrade your Bug for total performance and reliability.
Follow the link to BUY THIS BOOK @ Amazon: VW Beetle Performance Handbook: A Step-by-Step Guide to Upgrading Engine, Transmission, Suspension and Brakes (Motorbooks Workshop)
Follow the link to BUY THIS BOOK @ Amazon: VW Beetle Performance Handbook: A Step-by-Step Guide to Upgrading Engine, Transmission, Suspension and Brakes (Motorbooks Workshop)
Lindsay Porter
ISBN 1-85960-615-6
Your complete and definitive guide to ground-up Beetle restoration. Contents include: how to renovate chassis and bodywork - including the renewal of major panels and repainting, how to renovate interiors - including the re-covering of seats and renewal of the hood, how to give new life to mechanical and electrical components - including engine overhaul, and how to use your Beetle as the basis for a special or kit car.
Follow the link to BUY THIS BOOK @ Amazon: VW Beetle & Transporter: Restoration Manual
Follow the link to BUY THIS BOOK @ Amazon: VW Beetle & Transporter: Restoration Manual
Bill Fisher
ISBN 0-91265-603-4
Describes procedures for redesigning the body and tuning, modifying, and rebuilding engine systems for increased performance
Follow the link to BUY THIS BOOK @ Amazon: How to Hot Rod Volkswagen Engines
Table of contents:
Chapters: Beetle Power - The People's Car - VW Engines All Alike? Hardly - Bolt-on Horsepower - Adding Performance - How Much HP Can You Afford? - HP Ratings-Real or Imaginary? - Ignition - Carburetion - Exhaust - Cylinder Heads - Pistons & Cylinders - Crankshafts - Lubrication, Cooling & Breathing - Camshaft & Valve Train - Blueprinting - Engine Assembly - Supercharging - Porsche Engine For Your VW? - Installing '66-and-later Engines in Earlier Chassis - Converting Flat Engines to Upright - Corvair Power - Stability & The Beetle - Handling - Parts Information
Follow the link to BUY THIS BOOK @ Amazon: How to Hot Rod Volkswagen Engines
John Muir, Tosh Gregg and Peter Aschwanden
ISBN 1-56991-310-1
First published in 1969, this classic manual of automotive repair equips VW owners with the knowledge to handle every situation they will come across with any air-cooled Volkswagen built through 1978, including Bugs, Karmann Ghias, vans, and campers. With easy-to-understand, fun-to-read information -- for novice and veteran mechanics alike -- anecdotal descriptions, and clear language, this book takes the mystery out of diagnostic, maintenance, and repair procedures, and offers some chuckles along the way. This edition features new information on troubleshooting, new photos, and an updated resource list.
Follow the link to BUY THIS BOOK @ Amazon: How to Keep Your Volkswagen Alive 19 Ed: A Manual of Step-by-Step Procedures for the Compleat Idiot
Table of contents:
Chapters: How to use this book - How works a Volkswagen - How to buy a Volkswagen - Tools and spare parts - How to drive a Volkswagen - Flat tire! - Engine stops or won't start (and orientation) - Red light on! (Oil red light) - Maintenance (3.000-Mile): Valve adjustment, timing, tune-up, lubrication, distributor, carburator, fuel injection, tune-up checklist, ignition timing chart - Volkswagen doesn't stop - Shimmies and shakes (front end) - Slips and jerks (clutch) - Grinds and growls (transaxle) - Engine overhaul - Know-how: Mechanic's Information and Data, Table of Torque - Within the law (lights and sounds), wiring diagram - Hi-performance modifications - VW Mania - Parts suppliers - How to keep your Volkswagen alive forever - The grab bag - Electrical impulses - changes and new ideas - The dread auto-trottel - Trouble, trouble, trouble
Jim Tyler
ISBN 1-903706-90-4
This manual is your complete guide to all aspects of Volkswagen Beetle restoration including chassis, body, engine, suspension, steering, brakes, electrical equipment, interior and exterior trim.
Step-by-step instructions. Around 700 color photographs. How to make replacement panels. How to weld. How to use filler and how to paint.
Follow the link to BUY THIS BOOK @ amazon: How to Restore Volkswagen Beetle: Enthusiast's Restoration Manual Series (Veloce Enthusiast's Restoration Manual Series)
Part of the table of Contents:
Chaper 2. Mechanical Restoration & Repair: Workplace and Tools - Safety - Avoiding Trouble - Engine Tests and Removal - Height Restriction - Engine Strip, Inspection and Rebuild - Inspection - Crankshaft Grinding - Rebuild - Pistons and Cylinders - Cylinder Heads: Refit - Cylinder Heads: Repair - Rocker Gear - Valve Guides - Modifications - Head Overhaul - Lapping Valves - Rebuild Continued - Fuel Pump - Tinware - Topcoat Paints - Engine Electrics - Coil and Condenser - Distributor - HT Components - C/B (Contact Breaker) Points - Rotor Arm - Timing - Static Timing - Dynamic Timing - Dwell Angle - Vacuum Advance - Engine Won't Start - Diagnostics - Is there a Spark? - Low Tension Circuit - High Tension Circuit - HT Leads, Distributor Cap, Plugs - Fuel - Running In - The Fuel System - Fuel Tank - Fuel Tank Sender Unit - Fuel Lines - Carburetor - Specifications - Inlet Manifold - Clutch - Clutch Fork Shaft - Clutch Spares - Clutch Fork Shaft Rebuild - Gearbox (Transaxle) Removal and Refitting - Swing Axle Cars - Diagonal Arm Suspension Cars - Gearbox - Brakes - Overview - Rear Brakes - Front Brakes (Drum) - Front Brakes (Disc) - Master Cylinder - Bleeding the Brakes - Suspension/Steering - Front Suspension - Torsion Bar - Beam Axle - Front Suspension - McPherson Strut Type - Rear Suspension - Swing Arm Suspension - Diagonal Arm Suspension - Wheel Bearings - Steering - Steering Wheel and Column - General Electrical System - Overview - Restoration and Electrics - Battery - Lights - Fuses - Windscreen Wiper Rocker Replacement - Rocker Removal - Refit - Starter Motor - Generator - Voltage Regulator - Heat Exchangers and Exhaust - Heating System - Final Setting Up - Carburation - Transmission - Brakes.
Chaper 3. Bodywork and Trim Restoration: Premises, Tools, Skills and Equipment - Welding Equipment - Using a MIG Welder - First Steps with a MIG - Other Tools and Equipment - Use and Abuse of Body Filler - Using Body Filler - Panel Beating - Panel Repairs - Rust Proofing - Restoration - Car Condition - Paint and Underseal - Seat Removal - Seat Repair - Rear Seat - Front Seats - Fixed Glass Removal - Window Aperture Repairs - Windscreen Refit - Headliner Removal - Headliner Replacement - Door Removal - Door Strip Down - Door Panel Repair - Door Rebuild - Wing Removal - Wing Repair - Wing Replacement - Running Boards - Bodyshell Welded Repair - Rear Inner Wing - Rear Bumper Mounts - Front-End - Overview - Luggage Bay Lid Removal/Replacement - Flitch Replacement - Flitch Repair Panels - Spare Wheel Well - Removal of Bodyshell from Chassis - Floor Pan Repair/Replacement - Floor Pan Repair - Combined Floor Pan Halves/Heater Channel Replacement - Heat Channel Replacement - Frame Head - Front Crossmember (Toe Board) Replacement - Rear Crossmember (Heel Board) Repair - "A" & "B" Post Repair - Refit Bodyshell to Chassis - Quarter Panel Repair - Window Aperture - Luggage/Engine Bay Seal Retaining Strips - Flitch Top Rail Repair - Using "Donor" Car Panels - Paintwork - Painting Equipment and Facilities - Types of Paint - Preparation - Under the Wings - Finishing Touches - "Boxing Up" - Chromework - Interior - Case History - Update - Professional Restorers - Sad But True.
Follow the link to BUY THIS BOOK @ amazon: How to Restore Volkswagen Beetle: Enthusiast's Restoration Manual Series (Veloce Enthusiast's Restoration Manual Series)
The remaining small pieces of undercoating can be removed with white spirit and a piece of cloth. This is the result:
Next came the sander to remove al the remaining paint.
For the last pieces of rust I used the sandblaster and a chemical rust remover (by turtle wax). The result is nice.
Some close-up pictures of the heater channels.
Old and new heater channel.
First all spot welds which connects the cross connection to the luggage shelf have to be drilled out.
Drilling out the welds is a lot of work. Make sure that you use a drill that is big enough to drill out the entire plug weld. A 6 mm drill turned out the work very wel. After you drill out all the welds use a chisel to separate both sheets of metal.
With a little help of a hammer the heel board falls free.
Check his site @ http://www.geocities.com/MotorCity/Speedway/1367/beetle.html
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Check their site @ http://www.myvwsite.com/
]]>First you have to take precautions to prevent the body from deforming after you cut away the heater channel. I decided to weld a steel pipe in the door frame.
First cut is made just in front of the B post. I decided to start with an angle grinder.
Next came the A post. Make the cut just behind the A post.
Now cut away the rear piece of the channel. The cross section give a nice view of the damage.
First cut around the sections which are plug welded. Then drill out the plug welds to remove te remaining pieces of the rear section.
Now I can remove the front section.
This piece is more difficult to remove, I have to be carefull not to cut the good metal.
Visit his site @ http://myweb.cableone.net/rdoolin/vw/
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Visit his site @ http://souza.coastalcustoms.com/
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Nice pics with lots of text.
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Lots of pictures and a lot of text.
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The floorpan is magnificent!!! Wow!!
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Nice '70 beetle with lots of pics.
]]>Nice '74 beetle project with lots of pictures.
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Rating Good. Professional looking website with easy naviation to all their products. They ship internationally to Canada and the UK. You can order at their website. There are photos of most parts. You can see prices in 4 diffrent currency's.
Visit their shop @ www.cip1.com
Intro on their website:
"Cip1.com / California Import Parts LTD. has been servicing Classic and Vintage Volkswagen enthusiasts for over 25 years and we have been the #1 Classic VW parts website since 1996.
IN STOCK. Cip1.com keeps the largest selection of Classic VW parts & accessories in the world. In stock means we have these parts available for immediate shipment.
SHIPPED. We have the fastest and most reliable automated warehousing and shipping system in the industry. This means your order is shipped sooner when you deal with Cip1.com.
CUSTOMER SERVICE. We know that Customer service will keep our customers coming back. Our team of Classic Volkswagen experts have over 100 years of experience to help with any question."
Volkswagen parts, VW parts at Discount prices! Beetle, Ghia, Bus, Free Shipping.
]]>Website Rating Average: High quality engines (with great colors!!). Finally they have upgraded their website!! The website is filled with lots of pictures with great details about the engines. You can't buy through their website (you can only contact by phone or email).
Worthwhile to take a look.
Visit their site @ www.bergmannvw.net
]]>Rating good. They have updated their web shop to current standards. All standard brands and parts are available, all parts are presented with a picture. You can order through their website. The Engine and Gear calculator are helpful tools. They accept Visa, Mastercard, American Express, Discover, Pay Pal etc. UPS and United States Postal Service for shipping. Worthwhile to take a look.
They have removed their event photos (Bug-o-rama, Sand sports super show, va classic, bug in, etc.)
Visit their shop @ www.vwparts.net
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Rating Good. Nice looking website, good pictures of all products. The products are a little bit expensive. In the tech info section you can find tech drawings of a beetle to find the right parts. Gallery and links page are comming soon...... They accept Visa, Mastercard and Discover. Free shipping on all orders exceeding $199.95
Visit their shop @ www.appletreeauto.com
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Rating Poor. Turn Key performance engines. Supplier for: Bugpack, CB performance, Scat and Empi.
Limited amateuristic looking website, only a montly flyer with prices, no real webshop.
Visit their website @ www.strictlyforeign.com
]]>Visit their website @ www.kustom1warehouse.net
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Rating Average. The website gives you a lot of information about their product. However it's not a webshop. You can download their catalog
Visit their website @ www.scatvw.com
You can find information about the following products.
Engine Kits Volkstroker III
Volksracer
Volksracer Race-Ready
Long Block Engine[+] Engine Cases Killer Dry and Wet Sump
Case & Accessories
Oil Pumps, Sumps & Acc
Special Tools
[+] Crankshafts Flange Crankshafts
Dowel Pin Crankshaft
Forged Crankshafts
Cast Crankshafts
Connecting Rods
Clutches & Flywheels
Type IV-914/4 & Porsche
Big Bore Piston Kits
Hi-Rev Camshafts & Acc
Hi-Rev Lifters/Push Rods
Adj. Push Rod Tubes
Hi-Lift Valvetrain Comp.
Hi-Lift Rocker Arms
[+] Cylinder Heads Split Port & Accessories
Pro-Port +Hi-Rev
Hi-Lift Valve Covers
[+] Fuel Systems Carburetor Kits
Intake Manifolds
Carburetor Fuel Pumps
Air Cleaner Elements
Oil Cooler
Aluminum Crank Pulleys
Tight Fit Fan Shroud
Exhaust System
Electrical System
Trans Mount
Differentials & Gear
Transmission Comp.
Frontends
Wheels & Disc Brakes
[+] Exterior Accessories Bolt-On Accessories
Buggy Accessories
Body Seal
[+] Interior Accessories Drag-Fast Shifters
Procar Seats
Kits & Accessories
Rating good. Great shop with lots of parts. They have all the standard brands. They accept Visa, Mastercard, Discover and American Express creditcards. They ship with UPS.
Visit their shop at www.mooreparts.com
From their website:
"Moore Parts Source is your online headquarters for air cooled Volkswagen parts and accessories from daily driver to off-road and highperformance. We are committed to keeping your Volkswagen alive, may it be street, strip, or off road. We stock thousands of parts on hand for stock restoration, custom street, drag racing, off road bajas, and high tech sandrails. Our excellent sales staff and technical support team are second to none! Each member of our staff is an expert in the field of air-cooled VW's and can assist you by providing product installation tips and procedures, as well as suggesting additional parts that may be needed to properly complete your project."
This is on the menu:
**OFF ROAD SPECIALS**
**STREET SPECIALS**
AN Fittings & Hose
Cables
Clutch & Transmission
Electrical Accessories
Electrical Components
Engine Accessories
Engine Adapters & Kits
Engine Components
Exhaust Components
Exterior Parts & Accessories
Ignition Components
Intake & Fuel Components
Interior Parts & Accessories
Mounting Tabs & Brackets
Off Road Accessories
Sand Rails & Accessories
Sealants & Lubricants
Suspension, Steering, Brakes
Tires, Street & Off Road
Tools, Tow Bars & Manuals
Wheels & Accessories
Rating Good. Known for their excellent exhaust systems for VW beetles. It's not a webshop but a parts search database with a dealer finder. All with good quality photographs. Also great quality Disk Brakes
Visit their site @ www.acindustries.com
Click on more to see their location
On their website:
Products:
Brakes
Engine
Exhaust
Restoration, Repair, Tools
Steering And Front Suspension
Transmission
Brands:
A.C. Industries, Inc.
Aftermarket
JaTech
Tri Mil
Tri-Mil Industries
Rating: average. This webshop features a lot of interesting parts, with pictures of most of them. But the interface is not very friendly. Their categories are Beetle, Super Beetle, Ghia, Bus, Type3 and Thing.
visit their shop @ www.mamotorworks.com/acvw
Click on more to view their location.
So.Cal Imports is a well kown partsshop. They have a wide variety in parts, including a the common brands (Engle, Weber, Tri-Mil etc.). Prices are relatively cheap. They ship worldwide (UPS). All parts can be found at the webshop.
Visit their shop @ www.socalautoparts.com
Click on more to view their location
My strategy on removing the rust was: first use a wire-brush, second use a random orbit sander, third use the sand blaster, fourth use a chemical rust desolver (Fertan) and last spraypaint with zinc spray.
This is what the shelf looked like after using the wire-brush and the random orbit sander.
Next came the sand blaster, however the sheer size of the luggage shelf (and the limited amount of air in my compressor (100 litres) made me focus on the worst parts. This is what the result looked like.
Next came the Fertan, this is a biological substance with bonds with rust. By sealing the rust the oxygen component is removed therefore stopping the corrosion process (at least that's what the sales brochure tells me). I hope this works or else I can start all over. This is what the shelf looks like after applying the Fertan.
I'm not quite sure about the Fertan so I'll wait some time before applying the zinc spray.
]]>This is what the chassis looked like in the last couple of months.
After removing the green plastic I could see what the rain has done to the remainder of the floor pans.
A fresh layer of bright orange rust smiled up to me.
Let's first remove the front beam. This is what it looks like after I removed the dirt and the big chunks of rust.
Now let's remove the gearbox and the rear axels. Most nuts were rusted tight but no bolts were broken in the removal process.
Both floor pan halves were cut out with an angle grinder. This is what's left of the chassis.
Now it's time to drill out all the spot welds. After the last pieces of the floor pan halves are removed the new one's can be cut to fit the chassis. But that will be in another post.
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If we proceed to the inside we see more strange repairs. The complete inner panel seems to be replaced.
But why should you replace this panel? On the oudside there is rust but no sign of collision damage. This weld also suggests the complete inner panel has been replaced. You can see that the metal on the left of the weld isn't original.
I wonder if I should cut out the panel just to see what's behind. One last picture regarding this mystery the odd dent above the rear window. It's hard to see on the photo so I added a black line to outline the dent.
It's not a very good picture, but this is a very weak spot.
The luggage shelf is completely rusted but is just a thin layer of rust. The wheel arches are very much rusted, and have some serious holes in them. I need a few repair panels to fix this.
The bottom right side of the rear window turned out to be pretty good. Just the factory water hole but nothing else.
Also a really bad piece of rust can be found at the bottom left side of the rear window seal. This is quite a usual spot for rust.
You've already seen the left and right side of the wheelarch and the luggage shelf. But here are some more pictures.
Both heater channels are in poor condition. Both on the inside and the outside.
Another piece of classic rust, the spare wheel well. But easy to replace.
The floor pans can be fixed, but if you want to do it right both have to be replaced.
First I had to strip al the parts. So the bodyshell was light enough to be lifted and moved to the workshop. The removal of the doors, windows, hood, etc. was easy.
That's how the dashboard looks like after everything is removed (unfortunately I could not remove the steering shaft).
After separting the bodyshell from the floorpan the body was put in the workshop (it's a little small, but hey it's the only place I got).
The rear suspension was (primitively) fixed on the left side. The right site however is one big hole!!!
Some pictures of the right rear suspension mounting points.
The front looks relatively good, the front beam has little rust. I can get a better look after removal of the beam.
All the classic rust area's were in poor condition. The heaterchannels were poorly repared, the luggage shelf was covered in a thick layer of rust, the spare wheel well was rusted through, etc. etc.
Some extra pictures just to give an impression:
Both heater channels need to be replaced. The left one is already repaired with some patch panels. But I want to new ones.
A lot of rust around the rear right suspension mounting bracket.
Don't know what happened to the packedge shelf. It's just one big chunck of rust (not to many holes though). On the right you can see the patchwork. I'm gonna replace that with new replacement panels.
How the project started:
After I moved from Rotterdam to a small village in the south of the Netherlands the opportunity arose to start-up an old hobby: restoration of VW Beetles!! Not the expensive nice ones but the old rusty ones. After some nosing around on the Internet I found a nice project.
It's a 1967 1500 beetle. The previous owner started the project but gave up along the way (a better opertunity was presented to him). After the Herbie movies you start to look at beetles as living beings so I couldn't let it die. The shell was already seperated from the floorpan and some area's were repared. But most of the car was in poor condition.
The dashboard looks very nice though. Apart from a radio it is complete.
The front hood is the 67 down long model. The rear decklid it the semi long model.
Now it's time to move the beetle to my place.
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