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My Wedding Transportation (Maybe)

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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Topic: My Wedding Transportation (Maybe)
    Posted: 08 March 2018 at 4:50pm
Hi, this is my first post. I'm going to log the rehab of my '70 1500 beetle here. I'm getting married in June this year and have promised my bride to be that my beetle will be my transport on the big day

Here it is in all it's glory


Everything you see was done in the early '90s by the previous owner. I forget how long I've owned it, must be about 20 years. In that time I've fixed it a bit, driven it a bit and parked it a lot


Sadly, although the p.o. threw money at the car he didn't know much about them and did no work to it himself. So it was in very poor condition when I got it. It should really have been scrapped but I was young and full of enthusiasm. So I fitted pans and heater channels and repaired the bulkheads and fixed all the stuff that you can't see. Unfortunately this left all the exterior panels with massive amounts of filler in them from the expensive respray the p.o. got done. I knew it was going to cost a fortune in repair panels and I was worried that I might not get it spot on, so in the back of my mind I was thinking about re-shelling it. So once in a while I'd check ebay, gumtree and facebook

I spotted this on facebook and had it bought it for £350 the next day. It's an '85 Mexibug



The plan is to use the red bug as a donor for the Mexi shell and then put the Mexi shell onto the '70 pan

While I was waiting for the Mexi to be delivered I made this. It's mostly salvaged from the huge trampoline we had in the back garden that got destroyed in a storm


I tested it by moving my T4 into the corner of the garage




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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 08 March 2018 at 5:00pm
After a jet wash I was able to see what I'd bought a bit better
Original factory fit quarters


Factory horn, still on its bracket




Original, but rusty, metal



Edited by whamcars - 08 March 2018 at 5:06pm
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Post Options Post Options   Quote malky39 Quote  Post ReplyReply Direct Link To This Post Posted: 08 March 2018 at 5:35pm
Sound like you will have you time filled from now until June
☺️. I too will be using my bug as transport to my wedding this year also in June
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Post Options Post Options   Quote gayle Quote  Post ReplyReply Direct Link To This Post Posted: 08 March 2018 at 8:23pm
Take it the floor of the mexibug is gubbed then? Good luck for this project :)
Highly medicated for the safety of the masses
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 08 March 2018 at 9:35pm
I’m going to be busy. That’s for sure. I hope yours is in better condition than mine

Edited by whamcars - 08 March 2018 at 9:54pm
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 08 March 2018 at 9:54pm
Originally posted by malky39

Sound like you will have you time filled from now until June
☺️. I too will be using my bug as transport to my wedding this year also in June


Good luck. Have you got a build thread?
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 08 March 2018 at 9:58pm
Originally posted by gayle

Take it the floor of the mexibug is gubbed then? Good luck for this project :)


The pan’s not too bad. I managed to sell it on eBay. The pan on the red bug has had a lot of work done on it. New brakes, drop spindles, new steering box and a narrowed beam. Plus it’ll speed up the conversion from lhd to rhd
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Post Options Post Options   Quote malky39 Quote  Post ReplyReply Direct Link To This Post Posted: 08 March 2018 at 10:08pm
Originally posted by whamcars

Originally posted by malky39

Sound like you will have you time filled from now until June
☺️. I too will be using my bug as transport to my wedding this year also in June


Good luck. Have you got a build thread?


No build thread, wouldn't be much to show Ed might disagree though, my bug is running and usable it more bits I want to sort rather than they are really need to be done. Rusty spots, ride height sorted and if funds allow the interior sorted aswell. MOT is first on the list as it due next week
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 09 March 2018 at 7:19pm
Can anyone tell me how to edit photo's? I've got a duplicate in one post that needs to go

TIA

Time to split the body from the pan


So close


Down safely. I can move it with one hand now


I'm very happy with the condition of the body. It's a little rusty but it's had next to no work done to it. The same can't be said for the pan, which has been "repaired"




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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 09 March 2018 at 7:33pm
I couldn't figure out where I should start with the metal work. In the end I decided to remove the rusty front bulkhead. Looking at the options I could fit a poor quality pattern part or pay for a genuine vw part which would need converting to RHD anyway. so I decided to try and repair and convert the one that's already on the car

The drilling of many holes


I shouldn't have drilled along the top. I should have cut the boot floor about an inch behind the edge so that it coulkd be seam welded back in. But I only figured that out after I'd got the bulkhead out


I ground these welds down with a finger grinder. I don't know of any other tool that would have done such a neat job. It's one of my favourite tools


So close, but the school run stopped me in my tracks. Ah well there's always tomorrow

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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 09 March 2018 at 7:54pm
It's out. It looks fit for the skip. Years ago that's where it would have ended up but not today


Cleaned


I decided to start with something easy. Pitting and rust holes on the top rear. Trying to weld up holes like these is a recipe for extreme frustration. So I removed the bit that's sticking out



Inside it looked like this


Repair piece made


Once I was ready to weld I gave the inside of the box section a good clean then a couple of coats of Screwfix cold galvanising spray


It's been a while since I did any tack stacking. A couple of them look quite nice. The rest are just ugly. Oh well I'll get better as I go on


Done

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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 09 March 2018 at 8:14pm
This is the outer edge of the bit that sits on the napoleons hat, where it joins the heater channel



Checking I've still got a right angle



The other side of the bulkhead base has a lot more rot. So I'll remake it in sections


The camera battery died so I just cracked on


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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 09 March 2018 at 8:23pm
There were a couple of areas of rot right in the middle of the bulkhead so I tackled them both at once

Hole


Patch. This little bit of metal took forever to make. I understood what I needed to do but without a shrinker/stretcher I couldn't figure out how to make the metal do what I wanted


In the end I used the pick end of a hammer on a dolly and gave it about a million hits


Some big gaps to fill but I’ll get better


The payoff for all that effortBig smile

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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 10 March 2018 at 12:56pm
The second repair to the middle of the bulkhead


Nearly there


I managed to grind right through the patch while I was smoothing out the welds. I had a go at filling the holes but I just made more holes. So I made a filler piece and welded it in. And then I ground right through that too. I ended up cutting the whole mess out. The smooth bit is the filler piece


I decided to do something else as I was getting wound up by the mess I was making



My first line was too low. By going higher I could get rid of hidden rot and the mess over on the left



That turned out pretty nice. It will only need a couple of mm of filler to get it flat. I try to do no filler repairs but I'm still learning and I don't always get it right




Edited by whamcars - 10 March 2018 at 12:58pm
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 10 March 2018 at 1:22pm
I've given up on the bulkhead for the time being. I ground through it again! It seems the bulkhead is made from 0.6mm steel. Add to that the fact that I haven't picked up a welder for about six months and it was bound to go wrong

I decided to have a look at the engine bay. It still had the factory tarboard fitted. So I had no idea what was lurking


P1060536 by snedboy sneddon, on Flickr

I thought about keeping the tarboard but it was a bit chewed up



That looks alright. I removed the tags that held the tarboard on




The body had been stored on trestles before I got it. Looks like the engine bay sides took the weight




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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 12 March 2018 at 12:35am
I moved round to the nearside rear wheelarch. I wanted to make sure the wing mounting flanges were good so I ground the paint back and found mostly good metal


There was a broken bolt in the bottom wing mount



I've given up on stud extractors. I must have tried loads over the years. They're usually a waste of time. Just get the drill bit centered and then go up the sizes until you can get the correct size tap started in the hole



Looking at the front of the arch there was a fair bit of corrosion. So I started cutting


I ended up with a hole that needed three different bits of metal to fill it


First bit in


Second bit in. I realised I hadn't made the first bit big enough so I added a bit. I couldn't find a decent pic of this area on the net and I didn't take a pic before I chopped it. I looked in my other beetle but it's so rotten, it's literally coming apart at the seems. In the end I cleaned back the seam sealer on the other side of the car and used that as a reference




Attempting to recreate the factory welds


The completed repair. The weld blobs are from the factory so I kept them




Edited by whamcars - 12 March 2018 at 12:39am
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 12 March 2018 at 1:05am
I got stuck in to working on the car without really thinking about what I was doing. So I decide to do a bit of prep work. When I welded up the red '70 the glass ended up like sandpaper with all the grinding flash. I tried to polish the marks out but it was still a mess

Sections of old paddling pool pinned to the window rubbers. I tried gaffer tape but it just wouldn't stay put. The headliner will just have to fend for itself
  


At the same time I removed the door trims. Inside the doors looks amazing. Not a spot of rust

Dirty but not rusty





Edited by whamcars - 12 March 2018 at 1:14am
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Post Options Post Options   Quote KennyC Quote  Post ReplyReply Direct Link To This Post Posted: 14 March 2018 at 7:39pm
1985 Mexican, 1200cc, in that colour (looks like LA7Y Zinngrau/Pewter Grey) with those wheels and a grey headlining....
That looks like a rare special edition “50 Jahre Kafer” “Jubilee Beetle”
One of 3150 built to commemorate the last Beetle officially sold through the VW dealerships in Europe.
Did you say the chassis sold?? (I saw it on eBay)
These cars came with Golf GTI steering Wheels, Golf GTI style trim on the seats and green tinted glass...
There’s less than 10 in the UK I’m told....
If you’re on FacePest, check out the “50 Jahre Kafer” page
Will be worth more when finished in it’s original spec I’d guess
Have fun in the garage :-)
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Post Options Post Options   Quote 93fxdl Quote  Post ReplyReply Direct Link To This Post Posted: 15 March 2018 at 1:12pm
A good source of info on repairing panels
http://forum.retro-rides.org/thread/70135/panels

All done using basic equipment
Ttfn glenn
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Edited by 93fxdl - 15 March 2018 at 1:14pm
If it ain't broke, fix it till it is. If you can't fix it with a hammer, you've got an electrical problem. Lack of funds is the mother of ingenuity
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Post Options Post Options   Quote gayle Quote  Post ReplyReply Direct Link To This Post Posted: 15 March 2018 at 1:14pm
Agree on the LA7Y paint code. It's the same as my Scirocco
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 16 March 2018 at 8:07pm
Originally posted by KennyC

1985 Mexican, 1200cc, in that colour (looks like LA7Y Zinngrau/Pewter Grey) with those wheels and a grey headlining....
That looks like a rare special edition “50 Jahre Kafer” “Jubilee Beetle”
One of 3150 built to commemorate the last Beetle officially sold through the VW dealerships in Europe.
Did you say the chassis sold?? (I saw it on eBay)
These cars came with Golf GTI steering Wheels, Golf GTI style trim on the seats and green tinted glass...
There’s less than 10 in the UK I’m told....
If you’re on FacePest, check out the “50 Jahre Kafer” page
Will be worth more when finished in it’s original spec I’d guess
Have fun in the garage :-)
Ken.
(Lockerbie)


I think you're right. A lot of what is on the "50 Jahre Kafere" page matches what's on the car. Unfortunately the pan is sold and I don't drive LHD cars so it won't be going back to original
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 16 March 2018 at 8:10pm
Originally posted by 93fxdl

A good source of info on repairing panels
http://forum.retro-rides.org/thread/70135/panels

All done using basic equipment
Ttfn glenn
tinbashing


That is a good source. Here's a couple more

A total metal master

https://www.garagejournal.com/forum/showthread.php?t=182565

Inspiration for anyone welding a beetle

https://www.thesamba.com/vw/forum/viewtopic.php?t=629294&postdays=0&postorder=asc&start=0&sid=f4c3cff73dbec11c7ec82b7390f36184
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 28 March 2018 at 5:01pm
I haven't posted for a while. I've been having a nightmare getting my taxi through it's Hackney test. Anyway there has been some progress on the beetle

The next bit to be fixed


Rot cut away to reveal more rot


I won't cut any more out until I'm happy with the fit of the first repair panel
 

Ready to fit


I had to cut the quarter panel to gain access to the rotten inner panel

 
spot welds drilled out


Inside the quarter was nice and clean


Second repair patch made


Patch number three. This is for the side the running board mounts to


It just needs the captive nut for the running board welded on


I could see that the jacking point reinforcement was a bit crusty so I cut away part of the heater channel closing plate to gain access


The jacking point reinforcemnt is rusty but saveable


Saved




Edited by whamcars - 28 March 2018 at 6:53pm
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 03 April 2018 at 7:58pm
Heater channel wire brushed back to shiny metal. The black pitting will get a coat of Aquasteel rust converter


When I think I'm ready for primer I wipe down with a clean white cloth. Judging by the colour of this it needs more scrubbing with celly thinners
 

With everything cleaned and primed I lined the jacking reinforcement up with the holes in the sill


Checking the alignment


Zapped. It took a lot of heat to plug weld this properly



Edited by whamcars - 04 April 2018 at 3:45pm
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Post Options Post Options   Quote whamcars Quote  Post ReplyReply Direct Link To This Post Posted: 04 April 2018 at 3:51pm
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Checking the running board lines up with the new captive nut

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