Hi all, I finally worked up enough guts to do a 4" chop on a bug.
24 years earlier I payed a pro to do this job, on my pride and joy 1970 bug. Long story short it came back in bits 😬.
Had a go about 5 years later with good results. 19 years have passed and I have started, finally.
Enjoy
Fat Boy ·
pic's didn't load I'll try again
Fat Boy ·
some more
Fat Boy ·
sorry about the order
Fat Boy ·
enough for now 😁
helbus ·
Jobs like this make you lay awake at night thinking about what order to do the next steps. Yeah?
dragsters for life ·
looks cool
i was the guy at ricks the day you got the blue roof clip, you were tellin me the story on the day
cool that its finally getting done
ill be watching this one
Fat Boy ·
helbus wrote:Jobs like this make you lay awake at night thinking about what order to do the next steps. Yeah?
I know what you mean. Lie in bed waiting for the next day, to get to cutting. Fun stuff let me tell ya.
Regards
Fat Boy
Fat Boy ·
dragsters for life wrote:looks cool
i was the guy at ricks the day you got the blue roof clip, you were tellin me the story on the day
cool that its finally getting done
ill be watching this one
Good to hear from you again. Stay tunned.
I would like to get the bug regoed. getting mixed messages from different people. The rta seems to think that the 4" chop is going to be too much for street or rod reg. Any help in this department will be very helpfull.
Time for more pic's.
This is current stage.
dragsters for life ·
neat chop, sits nice
5lam ·
Killin it! Looks great
theVman ·
Just as "dragsters for life" says .... very neat chop alright.
Want to share the setup measurements and angles?
Fat Boy ·
It's not as hard as you think vman. Please keep in mind that I have no experiance in any body work, I'm a plasterer and a Taxidermist by trade. Shit this is the 2nd time in my life that I have used a mig😵💫. Most of the job can be done with a 4" grinder clamps and a mig. I think the most important thing is the flow of the lines, a good eye comes in handy.
I'm more than happy to post the entire process, f up's and all. All the info is easy to find on the samba and Volksrod, just punch in chop top and it will do your head in 🤪
Fat Boy ·
I managed to find the only pic I have of my original bug. She was white when I purchased her, I didn't know how to drive anything but an auto, f#@kin girl I know😂 so getting home was fun. The only thing I changed was the paint, for all those holden buffs I chose VK SS blue.
Nearly sold the bug to buy a Xp coupe Tubbed and all the bells and whistles. Decided to keep the bug and chop the roof the rest is as they say history...😠
Regards
Fatty
DubbyFan ·
Fat Boy wrote:It's not as hard as you think vman. Please keep in mind that I have no experiance in any body work, I'm a plasterer and a Taxidermist by trade. Shit this is the 2nd time in my life that I have used a mig😵💫. Most of the job can be done with a 4" grinder clamps and a mig. I think the most important thing is the flow of the lines, a good eye comes in handy.
I'm more than happy to post the entire process, f up's and all. All the info is easy to find on the samba and Volksrod, just punch in chop top and it will do your head in 🤪
Looks great, I too would be happy to see the entire process
if that is not too bold. So did you use three roofs in total and the oval rear? Looking forward to seeing the rest of this one, thank for sharing Fat Boy.
Fat Boy ·
Gday dubbyfan, I decided to use three roofs to avoid having double welds. You don't really need three entire roof sections. As in the pic's I used the original roof for surround leaving them wide, as to compinsate for the added width when dropped. I picked up a 53 roof and rear clip, used the b pillars and and rear window, probably could have used that skin and put in a couple of filler pieces but decided to get the red roof as a throw over. the red roof tappered down too sharp at the rear and created two humps at the weld joint. I decided to cut out those areas and put in filler's anyway.
jack schoot ·
looks great, will be a nice looking car when its finished
Kombi_Rescue ·
one of the best chops I've seen...looks great at all angles...credit to the effort cheers steve
Flintstones ·
you've got a good eye to get the lines looking right.
This is one of the nicest chops I've seen as the proportions look right.
Cheers
D
Fat Boy ·
Thanks for the thumbs up 👍 guy's. Wasn't always smooth sailing though.
When I got the oval clip home on closer inspection the rust had eaten all the way up to the vents so bad that I ripped the boot lid hinge's off by hand. So I decided to use the inside of the original bug and the outer skin of the oval. Seemed like a good idea at the time but turned out to be two full day's of scratching my head.
Regards
Fatty
Fat Boy ·
some more rust 😂
ran5 ·
looks cool
Fat Boy ·
Hi all, had a bit of time to kill, so I decided to build a rotisseri for the bug. Makes life alot easier for those shitty jobs under the bug.
Regards
Fatty
Fat Boy ·
some more
Fat Boy ·
A little scary let me tell ya.
Flintstones ·
lucky you did the chop first, looks like it just made it.
does make the job so much more pleasant to work on.
Cheers
ran5 ·
very cool, so ur in melb?
DubbyFan ·
Wow lovin this build, well done Fat Boy and thanks for sharing!
DubEnthusiast ·
Wow. Your doing an extremely good job. Keep it up 😀. Im keen to see this when its finished 🙂
Fat Boy ·
Thanks for the input fellas.
ran5, I'm in the north of Melb. Must catch up when the two bugs are finished.
Regards
Fatty
PHAT BUG ·
Wow that's looking awesome!! I'm loving the oval rear clip.
It great to see the different ways people go about achieving the same result 🙂
Mine is fully engineered with a 100mm chop, also in the report it states the deats have been dropped 75mm. Athough at this stage they need to come down a bit more as (being 6'3") I've had a crook neck since getting it on the road, haha.
It's all worth it!!
Would love to see all the chopped bugs lined up one day so we can compare 😉
vdubbles24 ·
Fat Boy wrote:It's not as hard as you think vman. Please keep in mind that I have no experiance in any body work, I'm a plasterer and a Taxidermist by trade. Shit this is the 2nd time in my life that I have used a mig😵💫. Most of the job can be done with a 4" grinder clamps and a mig. I think the most important thing is the flow of the lines, a good eye comes in handy.
I'm more than happy to post the entire process, f up's and all. All the info is easy to find on the samba and Volksrod, just punch in chop top and it will do your head in 🤪
I agree. I did my first chop on my volksrod truck. I made plenty of mistakes but they are all fixable. I'm learning as I go. Just part of it.
Looks good.
Fat Boy ·
Gday all, been a while but finally got some time and decided to start removing all the rust.
As always if you can see a little then there's probably alot more you cant see.
I was lucky enough to pick up some heater channels from e bay, the rest of the replacement panels are on their way from JUst Kampers. They seem to be a great mob to deal with, I'll keep everyone posted on the situation.
Enjoy the pic's
Fat Boy ·
some more
Fat Boy ·
and more
Fat Boy ·
more
Fat Boy ·
Hi all,
Just received my new panels from Just Kampers, I very impressed with the service they provide, would recommend to all.
Hope this helps anyone thinking of taking on a similar job to what I'm attempting.
Regards
Fatty
Fat Boy ·
A few more
annosL ·
That looks good work, thanks for pics
Fat Boy ·
As far as luck goes I never seem to have alot when it comes to vw's, 😂 but I must say that the volksrod god's must be happy with me, because I picked up this baby today for what I consider a bargin.
Quick run down
Lowered front beam
Fully re built as far as shock's, rubbers and bushes
4 x disc brakes
Original pan no rust
Fully treated with por
Gene berg shifter
IRS suspension
New brake lines
Every thing has been done. Saved me at least 6 months work and about $5000 in parts.
Total price $1200.00
Regards
Fatty
Flintstones ·
Great score!!
what are the axles from? no weak link there!!
Cheers
D
dragsters for life ·
hells yes
Fat Boy ·
Hi all,
Been a while but the sun is out and work has stopped for a few weeks, so I thought I would get the welding done on the inside of the bug. I also picked up my W deck lid.
As you can see I managed to turn an old door into a new interior.
Hope you all had agreat Xmas and New year.
Enjoy the pic's
Regards
Fat Boy
benny_acko ·
Loving this build!Great work - keep it up and looking forward to following the progress
Fat Boy ·
Hi all, been a while. I decided to replace my doors as the rust was more than I was happy to deal with. So I decided to have a play. Finally got the Lambo hinge to work after cutting half the poor bug to pieces. Looks ok but I have decided to go with a suicide system instead. I don't want the bug hinges just have to decide on weather I go traditional Suicide or conventional door with hidden hinge. Always happy to hear from you guys. Let me know your opinions.
Regards
Fat Boy
PS Just Kampers now have complete doors for sale for early bugs 😉
Fat Boy ·
Another
Fat Boy ·
It's that time of year again!!! This will be my third year on my Volksrod...Enjoy
DubbyFan ·
Lovin this, great stuff Fat Boy
essex ·
that Lambo door idea is way out there! good stuff, look forward to seeing pics of the suicide doors
helbus ·
If you have the Lambo door working well can you leave it. Or is it a bit agricultural?
Fat Boy ·
G'day Hellbus, They look sweet, but it has a few issues. Not easy to get in and out due to the chop, the door comes very close to the body, which will end up damaging the paint work down the road. I had to remove the entire A pillar to get the hinge to work and this leads to door seal issues. Plus the engineer nearly slapped me when I showed him the pic hahaha. When the bug is finished she will be fully registered so I want everything to be simple and user friendly.
Regards
Fat Boy
bugmaniaar ·
Hey there.
Just wondering?? Maybe a stupid question..
When people do chops how do you get window glass to fit?
Cheers CC
Fat Boy ·
G'day, In the early bugs, all the glass is flat except for the rear. They can be cut to size. The rear window can be an issue, I think a lot of guys use a Perspex. I dealt with this issue by using an oval window out of an earlier model.
Regards
Fat Boy
roverv8bay ·
G"day all. Tha axles are either 1600 180b o 240k Datsun they are perfect set as the have a curve on the spline that's stop lock up on th up & down movement I used them in my 327 chevy powered triumph 2500 because the originals used to bind & destroy the diff. I may end up using them in the rear of ECLECTIC if I run into cv bind once it's lifted
ernie
helbus ·
Yeah, flat glass is easy. Any glass place can make up toughened float (flat) glass to a template. About $600-700 to make a set for a Beetle, whether stock or chopped. The rear would have to be perspex, or the expensive option is to cut out of a laminated windscreen the same curve ($600-1000 if you can find someone to do it) or you can get glas made, however a mould would have to be made to curve it, so 1 glass would cost thousands. Perspex is acceptable, and could cost less than $50. We have many cars at work with perspex rear windows from factory.
Fat Boy ·
With the rear glass, I ran into issues when I chopped my 1st bug years ago as it's a curved piece of glass. With this chop I decided to go for an oval window grafted into my 60 bug. That window seems to suit the chop perfectly that along with a W deck lid should set it right off.
Fat Boy ·
Hi all been a while! I was looking forward to working on the bug over the Xmas break but my father fell very ill and after he passed I wasn't in the right frame of mind to get stuck into the bug. While I spent time with dad he asked how the bug was going, even though he lived overseas he was always interested in my bug. As a VW was one of my 1st cars!!!
While overseas I found some old pic's of my original VW boy did that bring back some memories. I'll post them up once I scan them.
So as you can tell I have picked up two new doors and the work will begin very soon. Got these through Just Kampers they came from the UK I'll let you all know what I think of them once I start cutting them up lol 🥲
Fat Boy ·
And again!!
Fat Boy ·
Felt good getting the grinder out again 😉
Fat Boy ·
Getting closer
Fat Boy ·
Closer look!!
Fat Boy ·
Hi guy's finally got those new doors swinging!! To be honest I'm liking the stock look with the chop on the doors more and more 😉
Fat Boy ·
Put the long weekend to good use!! Spent it adjusting A pillars lol and getting the new door tops done. Picked up my guards as well ! Happy days
Fat Boy ·
A few more pic's
Boozo ·
coming along nicely 🙂
Fat Boy ·
Spent the day adjusting the decklid to suit the chopped and leaned roof!!! Been a while since I've had to think this hard lol
Fat Boy ·
More
Fat Boy ·
More
essex ·
Good to see the progress,
DubbyFan ·
This is cool, great work!
Fat Boy ·
Finally got all the major welding done!!! Now off to the sand blaster. Over 3 years to this point 😉 Enjoy
lou0060 ·
fat boy you deserve a medal! bloody awesome!
Doug Sweetman ·
This is rapidly turning into my dream bug.... Awesome skills and great to see it from start to finish
Boozo ·
Looks awesome. What colour are you painting the beast?
Fat Boy ·
I have been doing a lot of thinking on the paint!!! I'm leaning towards a Brandy Wine and maybe some flame work!! Either Black or Ghost flames! I would love some input and pic's if you guy's have any 😉
Fat Boy ·
Hi all this was the 1st time in 3 years I have been able to start some body work!!! Just filling the welded areas but it's good to give the welder a rest 😉 Enjoy
Fat Boy ·
Few more !!
x275 ·
looks awesome dude. Great job
cnfabo ·
That is FAT!!
LUFTMEISTER ·
Looks hard. Good work. 👍
helbus ·
It is real mind excersize working out all of the angles and gaps of panels isn't it? I work every day making body panels for cars that are widened in the outer body panels by 30, 40, 50mm per side. It takes some thinking time to be able to make it look like it was made like that from factory.
adlbeetle66 ·
👍👍
Keep the pics and progress coming!
beetle_nut ·
Nice work mate.lookin good.
Fat Boy ·
Hi all been a while but we are still here!! Hope you all had a great New Year.
Finally got the time (one day) to get some work done on the bug.
Fitting the body to the pan before I start on the suicide door set up.
Hopefully I'll be working on her a little more often till she's finished!! Enjoy
Fat Boy ·
More
Fat Boy ·
more
Fat Boy ·
A little more
Bizarre ·
"there was movement at the station for thw word had passed around.........................."
great stuff............. looking forward for progress
Fat Boy ·
Sitting perfect!!!
Fat Boy ·
One day soon 😉
Fat Boy ·
Bizarre wrote:"there was movement at the station for thw word had passed around.........................."
great stuff............. looking forward for progress
Cheers Bizarre !!!
1303Steve ·
looking good
Fat Boy ·
Getting all the ugly bits, to look respectable
Fat Boy ·
Rust removal!
Fat Boy ·
Primed
Fat Boy ·
Cleaned, sanded and degreased!!! The joys
Fat Boy ·
That's me for today! Cheers everyone
Fat Boy ·
Re fitting the support at the correct height!
Fat Boy ·
Nothing ever fits lol!!
Fat Boy ·
Not too bad a weld for a Taxidermist hahahahahaha
Fat Boy ·
I have been putting this little job off for a while, glad it's done!
Fat Boy ·
Ready to lay down some primer!! Then get stuck into some body work!! Enjoy
Fat Boy ·
Metal prep!
Fat Boy ·
Final wash!
Fat Boy ·
1st coat epoxy primer!
Fat Boy ·
Just like new!
Fat Boy ·
After final coat of epoxy!!
Fat Boy ·
No longer a rust bucket 😉
Bizarre ·
brilliant!!!!
bugmaniaar ·
👍👍
Fat Boy ·
Spent the afternoon removing the filler I had put on a couple years back!!! I won't be using filler on bare metal again!! As this project has taken a while I was lucky enough to see what happens to metal under filler. 1st the filler could be knocked off in chunks as it seems to have lifted and secondly I discovered surface rust under the filler. I was told by a custom panel shop that this would happen, that's why I decided to put the bug in epoxy primer as to seal the metal! The metal was prepped properly but as it was explained to me that the metal will always sweat and create a film under the filler this creates an air pocket for rust to start. I'm no expert but I always listen when an expert has something to say 😉
Fat Boy ·
Knocked this off with a chisel and has rust bleeding through the welds. Always in the garage never been wet!!
Fat Boy ·
Got the pan seal in place used sika flex just on the floor side! Thanks to some tips on this great forum.
Fat Boy ·
Most of the bolts are in! That was fun lol......Will get the remaining few once she's up on some tyres... Then it's suicide door, alignment time. Ps is there a tightening sequence for the body?? Cheers
Bizarre ·
This is gunna be sweet!
Fat Boy ·
Looking ratty 😉
Fat Boy ·
Autoloc hinge kit!
Fat Boy ·
Let the cutting begin 😉
Fat Boy ·
1st fit!
Fat Boy ·
Nice lines only took 6 hours lol That's just testing 🙁
Fat Boy ·
I now know why they are called suicide doors!! Hope it's worth the effort!!
Fat Boy ·
Looking more like a rod everyday... Still a long way to go 😉
Fat Boy ·
Time to straighten everything up!!
Fat Boy ·
These tabs are a life saver 😉 Helps keep the door in place so you can mark the hinge pockets on the inside of the door!!!
Fat Boy ·
Some bracing to stop the door flexing and adding a bit of strength!
Fat Boy ·
Altered hinges to allow for window glass to operate properly!
Fat Boy ·
Added heavy brace to square up hinge pocket and reduce flexing, will add a couple more braces running from the upright back to the wheel arch...
Fat Boy ·
Close up of the set up! A couple more braces and she will be right 😉
1cut808 ·
WOW. Mega Keen.... Looking good... Keep the updates rolling please
hewey ·
Nice work, and beautiful lines on that chop
DubbyFan ·
Any updates, loving this car!!!!!!
wombatventures ·
Looking good Mate!
Fat Boy ·
Hi Guys/Girls been a little busy sold our place building a new home with a bigger workshop!!! Got the bug out on the road sort of lol She's tiny hahahaha
Fat Boy ·
Looking for ideas for bumpers!! Here she is resting till the workshop is built!
1cut808 ·
Workshop? DAMN, that sea container is bigger than my shed!!
Fat Boy ·
After a 7 year break, it was time to dust off the old girl!!
Looking forward to all the inspiration from you Guys/Girls, hoping to get to paint stage by the end of 2024.
Ps 7 years was just enough time to get ready to tackle the second door! Luckily for me its only got 2 doors 😂