Project Log: Massive Complete 1971 Beetle Re-Restoration

Oppressa · 2012-06-05T01:06:55+00:00

Didn't notice a project forum so posting here. Feel free to move, mods. Model: 1971 Volkswagen Beetle Brief History: 1999 - Purchased 3rd hand Nov 2001 to February 2002 - Stripped to bare metal and sprayed in Honda Super Sonic Blue Pearl February 2002 - Wheels and tyres replaced April 2002 - Not-at-fault accident. Front and rear damage, engine damaged beyond repair June 2002 - Everything resprayed except for the doors. New 1835cc engine with Weber carb (later replaced with dual Kadron carburettors) Since that time, the interior has been reupholstered and the stereo has been through many iterations. Time and the elements have since taken their toll on the paint and so the time has come. I have been deciding for a few years what to do - new car vs another restoration. I want to keep the bug so a full restore it is! After months of searching for panel beaters and getting quotes, I have finally chosen X Customs to do the restore. They are the same workshop that restored the volks.com.au Beetle: From Saturday 9 June 2012 they are going to: strip the car remove the body from the floor plan body will be bead-blasted, all rust removed replace floor plan, all rust removed remove rain gutters - have only seen this done on very few cars before in the States and even fewer in Aus. Should clean the lines up and look superb a few body minor adjustments - remove spray nozel on bonnet (never used in the 13 years I have owned the car) and not hooked up anyway, remove and seal up all air vents on the dash (the ventilation system was removed in 2002 anyway), seal other random dashboard holes, seal all screw holes not used for rear license plate respray (paint will NOT be revealed to anyone until it is sprayed) replace all glass except for windscreen replace all door, window and between-panel rubbers replace other various parts with new rebuild Estimated practical time is 3 1/2 months. At the same time as the restoration, I will be ordering from Scat VW a turn-key 0 Mile 1915 engine with twin 35mm Solex carburettors, C35 Scat cam and Scat 200mm clutch. I will be ordering the engine ASAP and have shipped by sea hopefully arriving around the restoration completion. I will install it as well as some blank brake discs and rear drums for new wheels & tyres. Much more to come.

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 20 Jul 2013, 2:15 pm

#963798

Update 40

Update 40... a memorable one... COLOUR!

The body has been bolted onto the floorpan permanently
Bonnet interior and engine bay has been painted
Doors are on for blocking/measurement
Inside of bonnet and engine lid are PAINTED! So today the colour is revealed!!!

These shots were taken earlier in the week and show the black basecoat parts such as roof, foot wells, bonnet and engine bay:

And now... the pics from today! Here we go folks!...

What's that in the background?... a tinge of colour?!

Why yes! Kameleon KF06 Gold to Silver

The rear beaver panel. After discussion with other paint shops we have decided that the panel has to be modded before all of the engine work is done and the muffler is installed. So it's going to have to be a best guess at to how much it should be raised. I'll measure and research this week

Just LOOK at those lines!

Body bolted to the floor now

Doors are coming back off, this is just measuring and checking. The inside of them will be painted first and then they will be refitted and painted while on the body. Best for kameleon

This thing is going to look mean!!!

I don't know which I like more... the lines or the bonnet in the background

A view through the door of the paint booth

Masking all the fenders to prepare them for stone guarding

And some gratuitous colour shots

And what the hell, a video too!

1971 VW Beetle
Currently being restored - click here

Aussie Dubbin Fahrvergnugen

895 posts · joined Jul 2008 · 20 Jul 2013, 2:33 pm

#963800

Great work fella. Must be loving that final stage of painting where it starts to actually be laid. The pics tell a thousand words. Thanks for sharing soo much detail. I sanded my blue bug many moons ago, and got a pretty reasonable paint job too, but seeing this reminds me of the countless hours in prep!!!!!!!!!
Should be a valuable car based on the body and prep work alone

'68 BUG build(Racing)
http://forums.aussieveedubbers.com/viewtopic.php?tid=85509
69Baja
http://forums.aussieveedubbers.com/viewtopic.php?tid=88798
Manx(MaxFX)
http://forums.aussieveedubbers.com/viewtopic.php?tid=88799&page=1#pid826884

beetleboyjeff Custom Title Time!

1,790 posts · joined Feb 2009 · 20 Jul 2013, 3:28 pm

#963806

Those shiny colours will look AWESOME on a bug. The rounded lines always look good in metalics, and with no gutters etc. yours will look even better I reckon.

Actually, I reckon it will look like a Christmas beetle. :-)

From your ole' mate Jeff

Paulc1964au Custom Title Time!

1,627 posts · joined Mar 2010 · 20 Jul 2013, 5:16 pm

#963811

this is going to be such a beautiful car

/url]Streetwise Aircooled Volkswagens
My 69 Bug

Craig Torrens 6 times Australian, 7 times State Hillclimb Class Champion

8,040 posts · joined Jan 2003 · 20 Jul 2013, 6:02 pm

#963815

You wont want to drive it !

ian.mezz I never said, I could write or spell

3,913 posts · joined Sep 2004 · 21 Jul 2013, 6:23 pm

#963922

Craig Torrens wrote:You wont want to drive it !

that happens a lot 🥲

😂🤪😂🤪😂
car forums. where a lot of peoples good intentions end up taking a good old car off the road forever never ever to see the road again. 🥲

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 21 Jul 2013, 6:40 pm

#963923

Haha. I'm building this baby to drive and enjoy!

1971 VW Beetle
Currently being restored - click here

nils Fahrvergnugen

971 posts · joined Jan 2008 · 21 Jul 2013, 8:05 pm

#963929

NICE!

Quit calling rust patina

simohagz Casual Dubber

38 posts · joined Mar 2013 · 21 Jul 2013, 8:17 pm

#963932

Hey mate, project looks amazing.
Are you getting your suspension work/brakes etc done by O&S or do you have another specialist?

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 21 Jul 2013, 8:28 pm

#963935

simohagz wrote:Hey mate, project looks amazing.
Are you getting your suspension work/brakes etc done by O&S or do you have another specialist?

Hey, thanks. Once painted it's going onto a tow truck to my mechanic who has worked on VWs for about 50 years. He and I will fit all the mechanics then back to O&S to finish it all off

1971 VW Beetle
Currently being restored - click here

5lam AKA: BlackBug

520 posts · joined Mar 2006 · 22 Jul 2013, 10:48 am

#963974

Dang! This is cool!

Custom doesn't come in a Box

Super1302 Officially Full-On Dubber

361 posts · joined Jul 2008 · 24 Jul 2013, 9:39 am

#964168

Hats off to you for your persistence, obviously this is a great piece of work, be great to see in the flesh 🙂
Well done.
👍

simohagz Casual Dubber

38 posts · joined Mar 2013 · 24 Jul 2013, 1:58 pm

#964175

Oppressa,

What are the specs on the engine you ordered? Or is it a secret?
Looks like a good price for the turnkey, very interested to see how it all turns out once installed!

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 24 Jul 2013, 2:03 pm

#964176

simohagz wrote:Oppressa,

What are the specs on the engine you ordered? Or is it a secret?
Looks like a good price for the turnkey, very interested to see how it all turns out once installed!

Hey, see Update 2 which was about the 5th or 6th post, first page. I uploaded the full invoice. Note that is US $.

Also went back through old emails and found:
How many carburettors and which brand/model/size? We normally build them with a pair of 35mm solex
What alternator brand/model/size? We build them with an AC 60 amp alternator
What cam/size? Normally with our C35 Scat cam

1971 VW Beetle
Currently being restored - click here

simohagz Casual Dubber

38 posts · joined Mar 2013 · 24 Jul 2013, 2:38 pm

#964178

Thanks for that. Sorry for all the questions!

From the look of it I assume its running a stock style ignition system?
Also from your earlier posts I gather that you bought the headers/muffler seperately (which by the way looks awesome)

Is there anything else you needed to buy or is it ready to bolt up to your trans?

Looks like you got smashed on customs fees on the gearbox, was it a similar situation with the engine? So far its looking like you got a sweet deal!

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 24 Jul 2013, 2:45 pm

#964179

Yeah the headers and muffler I'm excited about!

Your questions about bolting together will be answered in about a month after I'm well into the mechanical stage!

Yeah the transmission customs fees were shocking. DB Shencker was the shipper and it all cost a bomb (not the shipping but using them to get the shipment out of the airport and onto Australian soil)!
The engine via sea shipping was much cheaper (relatively speaking taking the size into account). Breakdown of the charge from usatoaus.com:
Shipping: 450
Duty: 224.40
GST: 474.56
Total: 1148.96

Oh and Scat's charge to ship the engine to usatoaus (in Washington) was $108.

1971 VW Beetle
Currently being restored - click here

pfillery Insano Dub Head

734 posts · joined Dec 2011 · 26 Jul 2013, 8:40 pm

#964370

Oppressa wrote:Haha. I'm building this baby to drive and enjoy!

Driving it is fine. Just don't park it.

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 27 Jul 2013, 2:45 pm

#964424

Update 41

Some good, some bad...

Good:
-Everything is pretty much prepped for paint
-Headers and muffler positions were tested because we'll need to paint the rear beaver panel at the same time as the rest of the car. We had planned to fit all the machnics, then mod the panel after based on where the muffler protruded. I decided to mod it in a similar fashion to what I had originally done years ago, cutting some off the bottom and rounding off the corners
-Door handles pained and test fitted, they needed to be painted separately to ensure paint coverage

Bad:
-I decided that before paint, I wanted to test fit the old suspension (just because it's lieing around and I didn't want to fit the new parts yet) with one of the new wheels at the front. You guessed it, doesn't fit. So work is on hold for the moment while I source some of these and I can test fit to make sure we won't need to mod the fenders 😬
http://vwparts.aircooled.net/MAXX-STRUT-Adjustable-Lowering-Strut-Kit-71-73-SB-p/maxx-strut-kit-3-bolt.htm

Someone has fitted them here and you can see the size difference compared to standard struts/springs
http://www.superbeetles.com/performance101/may2.htm

I'm guessing 2 weeks before they arrive and are fitted and we can move on...

2 shots from earlier in the week

And today

The modified rear beaver panel. Not 100% complete, some areas to refine. Looking good though!

My first glimpse at how the colour change will look 😀 Flush door handles fitted

And a quick vid

1971 VW Beetle
Currently being restored - click here

Bizarre Moderator The artist formerly known as blue74l

12,789 posts · joined Aug 2002 · 27 Jul 2013, 6:19 pm

#964436

if i am reading the chart right they are 16" x 7" ET 40

that is the same as a rear Porsche Boxster

The front Boxsters are 6" ET 50

Your wheel will be only 3mm less clearance inside but 23mm wider compared to the Boxster

So with the Maxx strut. Your sweet there.
But..................It will be tight on the guard.
It will depend on what tyre you are going to run.
I would be suggesting a 205 50 to try and keep it tight.

You may need to "roll" the guard.

Futue te ipsum!!!

Bizarre Moderator The artist formerly known as blue74l

12,789 posts · joined Aug 2002 · 27 Jul 2013, 6:21 pm

#964438

I have a spare 17" x 7" ET 40 if you want to borrow it to do some test fits

If you look at my Members rides you will see a photo with that wheel - the black Evo Fuchs

Futue te ipsum!!!

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 27 Jul 2013, 6:21 pm

#964439

Bizarre wrote:if i am reading the chart right they are 16" x 7" ET 40

that is the same as a rear Porsche Boxster

The front Boxsters are 6" ET 50

Your wheel will be only 3mm less clearance inside but 23mm wider compared to the Boxster

So with the Maxx strut. Your sweet there.
But..................It will be tight on the guard.
It will depend on what tyre you are going to run.
I would be suggesting a 205 50 to try and keep it tight.

You may need to "roll" the guard.

Thanks for the input, much appreciated, Bizarre. That's what I'm thinking which is why I don't want any body/paint work continuing until we have it all tested and measured!

1971 VW Beetle
Currently being restored - click here

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 27 Jul 2013, 6:23 pm

#964440

Bizarre wrote:I have a spare 17" x 7" ET 40 if you want to borrow it to do some test fits

If you look at my Members rides you will see a photo with that wheel - the black Evo Fuchs

Thanks! I'll have another attempt once the struts arrive and let you know!

1971 VW Beetle
Currently being restored - click here

Joel Now containing 100\% E-Wang

9,368 posts · joined Feb 2006 · 28 Jul 2013, 9:30 am

#964478

Oppressa wrote:Someone has fitted them here and you can see the size difference compared to standard struts/springs
http://www.superbeetles.com/performance101/may2.htm

Bare in mind that Ryans Super is a 74 and has a different front end to yours, the 2 bolt like his adds 20mm track width per side and they have slightly wider guards to match.

With yours having new replacement guards you would be wise dry fitting the rims and guards before painting as they all seem to be different width aftermarket.

But if your rims are 7" et40 like Bizarre mentioned you'll have a pretty good fit depending on the tyre size you choose.

Mine is 3 bolt like yours and has German 71 Super front guards, I've got 7" et40 on it at the moment with 205 tyres and they are very close, any lower and I'd probably need to lip the guards

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 28 Jul 2013, 9:31 am

#964479

Hey Joel. What size rims are yours?

1971 VW Beetle
Currently being restored - click here

Joel Now containing 100\% E-Wang

9,368 posts · joined Feb 2006 · 28 Jul 2013, 9:32 am

#964480

Depends on the day of the week but those ones are 17x7 et40

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 9 Aug 2013, 8:30 pm

#965929

Update 42

So the wheels seem okay with the new front springs/struts.
I have decided that most/all of the mechanical work will be done at O & S Restorations as opposed moving back and forth. The suspension, tyres, wheels and brakes prove to be a bigger headache than I originally would have thought now that we're up to that stage.

Everything is currently on hold until a big order from CIP1 comes in which includes most backend suspension parts and as well as items needed for the drum to disc conversion.

Once those parts arrive, I'll be transporting the engine, transmissions and everything else mechanical/electrical that I have purchased to the workshop where we will lay everything out and check that we have all the parts.

I'll also have to purchase a tyre or two simply to test (then if it's okay order four more). If the tyre works with the suspension, brakes, calipers, torsion bar setting (I'm ordering one of these amongst other things https://www2.cip1.com/ProductDetails.asp?ProductCode=C26%2D501%2D200) and the torsion bar setting itself works well with the weight of the engine installed THEN we can proceed.

So a few more weeks of waiting, sorry people!

Old vs new to show the size difference. Note everything you see in the pic excluding the new parts on the floor will be replaced with brand new items. We just installed old gear to test the wheel size with the struts/springs.

1971 VW Beetle
Currently being restored - click here

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 25 Aug 2013, 2:53 pm

#967608

Not an official update, just some news.

Still on hold while I wait for all suspension parts to arrive so that we can get it rolling (and therefore check wheels, suspension and tires) before paint.

I ordered and received all of this last week
1 of : ACC-C10-4300 - URETHANE TRAILING ARM BUSHING KIT - DOES BOTH SIDES - BEETLE 69-79/GHIA 69-74/TYPE 3 69-74/THING 73-74
US $27.95
1 of : C13-5588 - EMPI - BRAIDED STAINLESS STEEL BRAKE HOSE KIT - MADE IN THE USA - SUPER BEETLE 71-73 - SET OF 4
US $79.95
1 of : C26-501-200 - REAR TORSION BAR ADJUSTER - WELDING REQUIRED - ALL BEETLE / GHIA & BUGGY FLOOR PANS OR CHASSIS
US $85.45
2 of : KYB-KG5529 - KYB GAS-A-JUST SHOCK REAR EA - BEETLE 52-79 / GHIA 56-74 / BUS 55-67 / TYPE 3 62-74 / THING 73-74
US $119.90
1 of : VHD-N-3416-8 - TAPERED MOUNTING BOLTS - FOR ACC-C10-4100 SUPER BEETLE DISC BRAKE CALIPER BRACKETS - SOLD SET OF 8
US $5.95
10 of : VHD-N10-2544 - BOLT - 10MM DIA. - 25MM LONG - SOLD EACH
US $29.50
2 of : VWC-113-501-231 - REAR STOCK CV STUB AXLE - NEW - BEETLE/GHIA/TYPE-3 WITH I.R.S. - LEFT OR RIGHT - SOLD EACH
US $87.90
2 of : VWC-133-411-333 - OE GERMAN - SWAY BAR BUSHING CLAMP - SUPER BEETLE 71-79 - SOLD EACH
US $25.90
2 of : VWC-311-615-107-8A - BRAKE CALIPER - BEETLE 66-79 / GHIA 66-72 / TYPE 3 66-2/71 (GENUINE VARGA BRAND) SEE NOTES
US $149.90

There's more to order but I didn't want to go over the $1000 because of import charges and they have also run out of torsion adjusters.

This week the front suspension will be added (all new parts except for the lower control arms which will be restored). Hopefully soon after the rear parts will all be in stock at CIP and I can order them, fit up the rear then finally paint *sigh*

1971 VW Beetle
Currently being restored - click here

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 30 Aug 2013, 9:19 am

#968147

Update 43

Front suspension fitted, brakes are on. Two types of tyres have been fitted to two of the wheels so we can test size and fitment. Pics of the tyres and wheels will come next week. All parts that I have purchased have been taken to O & S Sportscar Restoration including new engine and transmission.

One issue we have discovered is that the wiring loom I purchased is for a left hand drive. Discussing if it's better to get one made from scratch in Australia or alter the one I have. O & S their altering costs will be more than buying new anyway.

More parts on the way. Candy for now:

Lower control arms are the only parts at the front that are not new, they have been sandblasted and painted

1971 VW Beetle
Currently being restored - click here

Oppressa Officially Full-On Dubber

367 posts · joined Oct 2002 · 7 Sep 2013, 5:47 pm

#969055

Update 44

Tyres and wheels have been fitted and tested. I'll be honest and say I was disappointed when the tyre guys rolled out my rims with the tyres on. The wheels looked small and the rubber too tall. But once fitted on the car I'm very pleased! I could have gone 17s but it just would have caused issues because they would have been 7.5" wide instead of 7.

It was between these two tyres:
Toyo 195/50/16
GT 205/45/16

In the pics below, the 195 is on the front. I would have preferred to use the 205 (for obvious visual reasons) but clearance from the springs would have been too fine so I'm buying 4 more Toyos this week (because I bought 5 of the Dub wheels). Turning circle is 100% too which is a relief. I was worried it would have to be restricted.

First lot of pics are from earlier this week when we were trialling both tyres. Obviously there is no weight in the car hence the stance, particularly at the rear! Second lot is from today with the 205 removed so I can return it for a refund. Plan from now is: finish building the rear suspension this week. Then into the paint booth the week after!

On another note, after reading my thread, 3 Aussieveedubbers.com forum members are taking their rides to O & S Sportscar Restoration (2 are already there). Drumming up business! It's so good to see a quality restorer on the Sydney scene. They should change their name to O & S VW Restoration!

Centre cap not fitted but they look sweet with them attached!

Today:

Looks HOT from this angle! So happy with the shaved handles, wheels and removed rain gutter.

1971 VW Beetle
Currently being restored - click here

SuperOwen Fahrvergnugen

868 posts · joined Jan 2009 · 7 Sep 2013, 6:03 pm

#969060

Nice wheels, a bit like 16" boxster 5 spokes but chromed. The boxsters always look good so they should be fine.