Super Beetle resto custom project

[number3]

This is a project car we picked up a few years back and finally decided to tackle.  Although it had been sitting under shelter while in our possession it seemed that it was in better shape when we picked it up in Vancouver then now.  Aren't they all. 
Started tearing this apart March 8, 2010 so some of the project has been completed already.  Will catch up with posting in the next few days to get this project current.

Plans call for a complete restoration with mild bits of customization thrown in.  4 wheel disc brakes, lowered struts, adjustable spring plates will be thrown at the pan.  The engine will be a 1835cc power plant with stock fuel injection (hopefully).  Paint, interior, and new convertible top will also be tackled as we progress.   All work other then the convertible top will be handled by AVR Import Specialties and GLI Autowerks in the valley.  Convertible top will be handled by Custom Creations.

This is what we started with.

Yes that is a Brazilia in the back ground.  Future project.

A real barn find.

Marathon wheels anyone?

Front trunk.

Area behind dash.

The original fuel injected engine.  Will be replaced with an 1835cc but stay fuel injected.  Lets see how that works.

And finally the pan shot.

[Bruce]

The engine will be a 1835cc power plant with stock fuel injection (hopefully). 

I think that's pushing your luck.  I think you should go 1776, that's been done before.

[number3]

The engine will be a 1835cc power plant with stock fuel injection (hopefully). 

I think that's pushing your luck.  I think you should go 1776, that's been done before.

Bruce
In your experience what is the limiting factor of the stock fuel injection system?

[Bruce]

Airflow through the intake system.

[number3]

Airflow through the intake system.

Thank you

[number3]

Once the body and pan were split everything was sent out to get blasted.  The pan looked solid before we sent it out but when we got it back we realized that both pans needed replacing due to multiple pin holes and a few bigger holes.
Before

After

Wasted a few dollars sand blasting sheet metal that ended up in the recycle bin but sometimes you go backwards to move forward.

Finally finished cutting, grinding and drilling out the spot welds.

Front bulk head needed some welding as well.  The tunnel was crammed full of nuts, plastic, wood, foam that was all used as a nice nest for a mouse. 

After fixing the bulk head and welding in the pan halves.
Bottom side

Bottom side

We applied a light rock guard coating on the pan underside.  Same material will be used on the inner fenders as well.  Material is paintable and adds a little more protection then just paint.  Top of side pan received a final coat of primer and is now ready for paint.

Top side

Side view

[number3]

After pan was primered pan top and bottom was covered in gloss black paint.



Clean pan was moved to the show room at AVR to start next phase.  Installation of rebuilt transmission, four wheel disk brake set up, new bushings, brake lines and adjustable spring plates.  Wheels will be 5 x 130 bolt pattern for Porsche type wheels.

[number3]

With the pan work being handled in between the real days work the body was sent out to get blasted.  Without getting into the pros and cons of blasting versus dipping we where happy with the end result.

 

Front trunk area

Inner rear quarter

Rear luggage area

Dash and windshield hoop

After blowing off all the media and giving it a quick clean off body was put into self etching primer.



Now comes the slow tedius body work consisting of some rust repairs, dent work and primering.

[Jeremy]

Good progress. Keep the pics coming.

[Geoff]

lookin nice! it's coming together quick!

[number3]

Car is coming along nicely.  We are further ahead then the pictures show and am hopeful to have this completed for the GCVWS.  I guess we will see.

The front needed a new skin.


One side channel needed a repair for the running board attachment.


Inner strut needed a couple of patches as well.


And after weeks of working on the body the shell is finally painted in the factory colour called River Blue.




And finally it is placed back on the pan.  Now comes the best part in my opinion.  Reassembly.

[85fastlane]

Looks incredible guys, hope to see it next week!

[Jeremy]

Great work guys. And fast too. 

[Randy]

  Lookin' Forward to seeing it at the show.

[number3]

Been working feverishly trying to complete for this weekend.  I expect it will be there but not 100% completed.

Front trunk area during assembly.


Rear quarter inner panel. 




Front seats finally assembled.


Front dash / foot well area


And finally a side profile


That will be it until next week when it will receive the final touches and a good cleaning.

[Geoff]

That was the fastest resto I think I've ever seen! Nice work.

[number3]

That was the fastest resto I think I've ever seen! Nice work.

It helps when you have a big family you can draw from.

[number3]

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