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Project Log: Massive Complete 1971 Beetle Re-Restoration

Oppressa - June 5th, 2012 at 11:06 AM

[size=4]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.[/size]

blistered_bug - June 5th, 2012 at 07:34 PM

looks good mate, spewing it got rear ended

Oppressa - June 5th, 2012 at 08:38 PM

Quote:

Originally posted by blistered_bug
looks good mate, spewing it got rear ended

Work hasn't event started yet

Yeah the damage was terrible seeing as it happened 2 months after the last restore. But that was 10 years ago.

And this coming Saturday marks the beginning of the next phase. 3 months time and it's going to be a show-stopper

Camo - June 5th, 2012 at 10:51 PM

Quote:

Originally posted by Oppressa

3 months time and it's going to be a show-stopper

Not meaning to be negative, but just thinking about what you are about to embark on. That's a very quick way to blow $30,000+

Unless you are very well off financially, why don't you do some work yourself and save a bit. At least then you can say you built the car or had some input!

I'm sure it will be a show-stopper and we will all look forward to seeing the end result as we all love VW's.

Kev.

cam070 - June 6th, 2012 at 03:00 AM

Sounds exciting. Looking forward to progress pics.

Oppressa - June 6th, 2012 at 08:00 AM

Quote:

Originally posted by Camo

Quote:

Originally posted by Oppressa

3 months time and it's going to be a show-stopper

Kev

I understand what you're saying but tbh I don't have the tools, space, knowledge nor the want to do it myself. I will do the interior and engine but I have been saving for a while for this specific purpose.

Camo - June 6th, 2012 at 12:02 PM

Quote:

Originally posted by Oppressa
I don't have the tools, space, knowledge nor the want to do it myself. I will do the interior and engine but I have been saving for a while for this specific purpose.

Not enough space, I know that feeling. Great to see you have been saving to get what you want and know what is best left to the experts.

I think you would be surprised how easy the body comes off and the time frame it takes if you know what you are doing. (I only learnt when striping my car) You don't need a lot of tools to dismantle the car, but to carry out the repairs and modifications you want requires the correct equipment and knowledge.

If I can give you a hand with anything, give ma a yell. Glad to help if I can, just need the wife to give me a leave pass :lol:

As I said, looking forward to seeing your finished car :tu:

Kev

Oppressa - June 6th, 2012 at 04:58 PM

Wow, really appreciate the offer :tu:

Will keep you in mind if I get stuck!!

tasdex - June 7th, 2012 at 01:05 AM

Unlucky with the crunch.
Hope those at fault looked after the redo.

Oppressa - June 7th, 2012 at 11:26 AM

Quote:

Originally posted by tasdex
Unlucky with the crunch.
Hope those at fault looked after the redo.

They saw it as a right-off and no the payout didn't cover the costs. My 'friend' wouldn't pay the rest so I had to fork out a few thousand...

Oppressa - June 10th, 2012 at 06:10 PM

[size=4]Update 1

-Order placed for engine from Scat VW on 8 June
-Car was delivered to X Customs in Campbelltown
-While there I discussed with the owner some specifics of the job
-As well as the body mods mentioned in the OP, they will be installing new flush-mounted door handles. I haven't decided at this point whether I want the handle itself chromed or body-colour. The closest I could find to the design is these Aston Martin ones. Press a button towards the rear and the handle pops out. So entry will be keyless!

[/size]

Oppressa - June 25th, 2012 at 04:55 PM

[size=4]Update 2[/size]

Car is now pretty much stripped, body will be taken off the floorplan tomorrow and sent to be bead-blasted. Next week will be interesting as I'll be going down to X Customs to inspect the body after the blasting.
So lots of pics to come!

In the meantime:
-Scat VW finished the build of the engine and it has been shipped to Washington where the shipping forwarders (www.usatoaus.com) are. For those interested the receipt is below
-I have been ordering various parts which are below, specifically
Headlight chrome rings
Tail light chrome surrounds
New wiper arms
New Bosch wiper blades
Drift Iridium blue gauges to replace entire instrumentation. Exactly the ones in the below video (speedometer (KPH/MPH, odometer, trip meter, adjustable tyre circumference etc), tachometer, fuel, oil temp)
Drift is an Australian brand but interestingly it was cheaper for me to import the 'made in Australia' products from the UK (http://www.demon-tweeks.co.uk)!!!

http://www.youtube.com/watch?v=6iufSA_vmuE&feature=player_embedded

Camo - June 25th, 2012 at 07:46 PM

I like the gauges :tu: :tu:

Kev

Oppressa - June 30th, 2012 at 03:25 PM

[size=4]Update 3[/size]

Now it gets real! Went down to X Customs to see the body off the floor and check on the next steps. It was scary seeing my pride and joy in this state! Not only because it's bare but also because there is a fair bit to clean up.

-Body is ready for bead blasting, it's going on Monday
-The floor is going to be stripped and painted as well so a local mechanic will be removing the engine for me. When the floor is back from painting I will trailer it up to Sydney to install new engine and replace shocks then take it back down to X Customs the next day (but this can only be done once engine arrives anyway)
-Engine has arrived at the forwarder so I anticipate about 8 weeks for it to arrive in Australia
-I noticed a lot of rust along the base of the passenger side of the body (you can see some in the first photo). All of this is going to be cleaned up post bead blasting

That's it for now until I go back to see what the bare body looks like.
Serious question: anyone have an idea what a 10 year old 1835cc with twin Kadrons would be worth?

Camo - June 30th, 2012 at 04:04 PM

Please, go and remove the engine yourself unless he is doing it free. 4 bolts, accelerator cable and a few wires (easy) :yes: :yes: :yes: :yes: :yes:

If not maximum price $20-$30.

Kev

BorisBug - June 30th, 2012 at 04:46 PM

Love the down to your jocks rebuilds. will be keeping a keen eye on this one

Oppressa - June 30th, 2012 at 05:21 PM

Quote:

Originally posted by Camo
Please, go and remove the engine yourself unless he is doing it free. 4 bolts, accelerator cable and a few wires (easy) :yes:

If not maximum price $20-$30.

Kev

Okay will do. Appreciate the advice as usual.

Paulc1964au - June 30th, 2012 at 05:52 PM

wow going to be a huge build, looking forward to updates

mickya - June 30th, 2012 at 05:59 PM

Looking to be a big project! Very keen to see the final result!

May I ask where you got the wiper arms and blades from?

Oppressa - June 30th, 2012 at 06:04 PM

Sure...
Wiper arm (which I will prob be getting chromed):
http://www.ebay.com.au/itm/280888063897#ht_2313wt_1163

Bosch wiper:
http://www.ebay.com.au/itm/290717461589#ht_2259wt_1163

mickya - June 30th, 2012 at 06:07 PM

Okay great! Did these fit right on do you know, or is some mods necessary?

Oppressa - June 30th, 2012 at 06:08 PM

We'll see in a few months once the car is back together haha

Sorry I can't give any more info right now!

mickya - June 30th, 2012 at 06:17 PM

No worries mate! Dont need them right away, but ill see how you get on! Cant wait to find out the colour!

Oppressa - June 30th, 2012 at 06:19 PM

Quote:

Originally posted by mickya
No worries mate! Dont need them right away, but ill see how you get on! Cant wait to find out the colour!

Hehe it's a major secret right now

Let's just say it's going to be as far from stock as you can get!

Joel - July 1st, 2012 at 10:31 AM

Quote:

Originally posted by mickya
Okay great! Did these fit right on do you know, or is some mods necessary?

If your 68 still has the original wiper motor setup you'll need different ones.
71 and later used splined shafts, 70 and earlier had locking grub screws.

mickya - July 1st, 2012 at 02:48 PM

Thanks Joel! I've lost mine since stripping. Don't need them for a little while, so I'll post an ad later

Oppressa - August 25th, 2012 at 03:32 PM

[size=4]Update 4[/size]

Finally an update! It's taken a while because we have been waiting for the bead-blaster to have room to actually take it all away! It came back from blasting yesterday.

I thought the floorplan was going to need replacing however it's actually in very good condition! That's the good news... the body doesn't look too hot at all though. There is a lot of work that needs to be done. Previous (shoddy) repair work is now visible and it all needs to be fixed. The roof looks good at least LOL

I'm hoping to have the floorplan prepped this week so I can bring it up to Sydney the following week to fit engine, suspension, new brakelines, bushings and any other work that's easy to do with an exposed chassis. If I'm going to all this trouble it may as well all be done right!

The engine is due around 5 September so it should be great timing.

When I asked Aymen at X Customs how long left he said he hoped to be done in 5 weeks. I said "what do you mean by done?" "Completely finished" he said.

I'm unbelievably excited! I have been wanting to do this for a LONG time and now I have a rebuild of my favourite model of car and I can literally customise it exactly how I want! It'll be better than the day it rolled out of the factory and should be a shining example on the Australian VW scene.
I have a few decisions on parts/alterations to make over the next few weeks but it's a fun journey!

On with the pics:

The dash is going to be completely reworked. It will be minimal, functional and look superb.

Oppressa - August 29th, 2012 at 01:08 PM

[size=4]Update 5[/size]

Wheels selected and ordered from the US (6 week wait). For the look I'm going for they just had to be chrome. But I didn't want a ridiculous amount of it (ie too large or too many spokes).

So here they are! Dub Drone 5 in 16" x 7"
http://www.mhtwheels.com/mht-luxury-alloy-wheel.cfm?id=1448

I've also chosen what I think the tyres will be (right) compared to what was previously on (left). I wanted overall tyre/wheel diameter the same but slightly smaller profile so am going for 220/45 16:

Also in this update... new front discs have been ordered at 4x100 for the new wheels as well as a disc kit for the rear to replace the drums.

Birdman - August 29th, 2012 at 07:48 PM

They are obviously going to source a new body for you in order to deliver on that 5 week build date???

OZ Towdster - August 29th, 2012 at 07:57 PM

X2 or bucket load of new bog , one or the the 2