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Author: Subject:  Project Log: Massive Complete 1971 Beetle Re-Restoration
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posted on May 13th, 2014 at 07:35 AM



Quote:
Originally posted by simohagz
Agreed.
I am the owner of the Gunmetal Grey '68 under restoration at O&S and I can attest that the work is top notch.

I had been intending on doing a project log similar but time constraints have meant I now have a MASSIVE backlog of photos/work done to share at some point in the near future.

Alan, the ghia looks great. Love the headlights.


The 3 O&S VW owners :)

Agreed, the Ghia lights look brilliant! I saw the new engine has arrived for the bug too :D You've actually caught up to me it seems simo! I need to purchase the Dynamat now.




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posted on May 13th, 2014 at 01:34 PM



Quote:
Originally posted by Oppressa
Quote:
Originally posted by simohagz
Agreed.
I am the owner of the Gunmetal Grey '68 under restoration at O&S and I can attest that the work is top notch.

I had been intending on doing a project log similar but time constraints have meant I now have a MASSIVE backlog of photos/work done to share at some point in the near future.

Alan, the ghia looks great. Love the headlights.


The 3 O&S VW owners :)

Agreed, the Ghia lights look brilliant! I saw the new engine has arrived for the bug too :D You've actually caught up to me it seems simo! I need to purchase the Dynamat now.


Haha, I wouldn't say that, my gearbox is still sitting in pieces and no work on the electricals yet!
I just came back from visiting the workshop, stoked with how my engine turned out, looks "stealth" in keeping with the overall build.

Cant wait until it is finished!

With the dynamite, turned out cheapest to get it from Ryda online. That is assuming you want the genuine Dynamat branded stuff. I got 2 of the bulk packs and as you probably saw, the boys have put it EVERYWHERE! Hopefully it quietens down my little engine in the back a little...
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posted on May 31st, 2014 at 05:51 PM



[size=4]Update 58[/size]

So I've been sick with shingles hence the lack of any updates (pro tip: don't get shingles. ever). Anyway:

-Dynamat XTREME 10455 applied to firewall, sidewalls, doors and ceiling (floorpans will be done later)
-Front and rear bumpers have had some small imperfections repaired and then rechromed
-Headers, J pipes and muffler have been modified for best fit (including adding the missing flange to the headers)
-Bracket has been fabricated and installed to properly mount and secure the muffler. Once this was completed, the whole lot was sent to be ceramic coated (the factory job didn't look good enough :D)

http://i.imgur.com/DgFse5J.jpg

http://i.imgur.com/EJEq40B.jpg

http://i.imgur.com/4lL8MOp.jpg

http://i.imgur.com/tsjeAVd.jpg

Mods done. Before ceramic coating
http://i.imgur.com/gqNTRQ2.jpg

Ta daa!
http://i.imgur.com/mVTA8oJ.jpg

Installed
http://i.imgur.com/PAV57Sh.jpg

http://i.imgur.com/7NP5ISb.jpg




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posted on May 31st, 2014 at 07:55 PM



Looks awesome...
Never had shingles... was wondering how your build was going, hope your well now buddy! Cant wait to see this thing on the road.
Just 1 Q:
Can you let me know who did the rechroming? Need to get my bumpers done and I dont live far from the panel shop doing your work.
cheers Jamie




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posted on June 2nd, 2014 at 08:00 AM



Quote:
Originally posted by GottaSplit
Can you let me know who did the rechroming? Need to get my bumpers done and I dont live far from the panel shop doing your work.
cheers Jamie


Hey, it's not nearby!
All Metal Bumpers in Ingleburn




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posted on June 2nd, 2014 at 04:11 PM



Oh ok...cheers for that. I have been put in the direction of All Metal Bumpers previously... looks like I am driving to Ingleburn.
Hope your well.
Jamie




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posted on June 2nd, 2014 at 04:38 PM



Thanks for the wishes. Feeling much better. I've heard it can last for a month or 2 but I'm pretty much over it all a week and a half after it started. Very grateful though!



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posted on June 2nd, 2014 at 04:47 PM



Great to hear... I thought your car was at a panel beater in Cromer(?) on the Nth Beaches... think Im going to have to read your thread again! (Probably would've anyway...)



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posted on June 2nd, 2014 at 06:21 PM



It was anyhow - O & S Sportcar Restorations. I had some work done there last year.



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posted on June 12th, 2014 at 01:20 PM



I think your missing a plate that goes on floor near clutch pedal ??
did they weld the roof where they cut the rain guard off ??




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posted on June 12th, 2014 at 02:56 PM



Quote:
Originally posted by ian.mezz
I think your missing a plate that goes on floor near clutch pedal ??
did they weld the roof where they cut the rain guard off ??


Do you mean this one? All under control.
http://i.imgur.com/v3R4iP0.jpg 

Yes it was welded and then lead-wiped where the gutter was removed




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posted on June 12th, 2014 at 04:53 PM



Quote:
Originally posted by Oppressa
Quote:
Originally posted by ian.mezz
I think your missing a plate that goes on floor near clutch pedal ??
did they weld the roof where they cut the rain guard off ??


Do you mean this one? All under control.
http://i.imgur.com/v3R4iP0.jpg 

Yes it was welded and then lead-wiped where the gutter was removed


There is a cool youtube clip of that process :D




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posted on June 14th, 2014 at 01:32 PM



[size=4]Update 59[/size]

-Rear drive shafts greased and fitted
-Front sway and most of the front suspension and steering has been completed
-Breaks, hoses and lines fitted (not complete)
-Oil filter will be mounted above the transmission so a bracket has been fabricated, primered and painted
-Accelerator pedal and cable fitted, brake pedal assembly built

http://i.imgur.com/8YFfuex.jpg

http://i.imgur.com/bTfeT1F.jpg

http://i.imgur.com/WWRQTeO.jpg

http://i.imgur.com/pm299yb.jpg

In here above the transmission (but on the other side) is where the oil cooler will be mounted
http://i.imgur.com/u3neV29.jpg

http://i.imgur.com/7kH3W4r.jpg

http://i.imgur.com/1bnwKq1.jpg

http://i.imgur.com/74AyW8c.jpg

http://i.imgur.com/82sjwzD.jpg

http://i.imgur.com/IxYHwse.jpg

http://i.imgur.com/asgnsXq.jpg

http://i.imgur.com/hzHxLE8.jpg

If you're paying close attention, you'll notice that the accelerator cable has been fitted!
http://i.imgur.com/mdueHmj.jpg




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posted on June 19th, 2014 at 05:34 PM



It's aliiiiive!

https://www.youtube.com/watch?v=SOjPCIZ4itk 




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posted on June 19th, 2014 at 07:12 PM



Nice! :cool:

you're so close to driving that brand new beetle out of the workshop




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posted on June 19th, 2014 at 08:29 PM



Awesome! Just went through the whole thread, absolutely awesome job mate!



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posted on June 19th, 2014 at 09:08 PM



Quote:
Originally posted by SebastienPeek
Awesome! Just went through the whole thread, absolutely awesome job mate!


Thanks man. It certainly makes for a rollercoaster experience looking back on it!




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posted on June 20th, 2014 at 08:25 PM



I think that you will have to fit the tie rod ends from the bottom as those shocks sit really low and steering arms may rub on the under body
Also the bottom of the ball joints may need cutting off so it doesn't rub on the rim




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posted on June 24th, 2014 at 08:46 PM



[size=4]Update 60[/size]

Huge amount completed, coming along at breakneck speed now:
-Manufactured front brake hoses and organise parts for fitting steering
-Assembled steering arms and damper to assess clearance for new front brake hoses. Manufactured and route new brake hoses from wheels to brake
-Steering column disassembled, blasted, primered, painted
paint
-Speedo cable fitted, speed sensor fitted
-Removed plate from oil sump, drilled 9.5mm tap thread and fit oil temperature sender for oil temp digital gauge. Tested
-Assessed type of fuel sender in tank in order to calibrate new digital fuel gauge, measured resistance from empty to full and found T1. Calibrated fuel gauge full to empty, set alarm, low fuel level at 20% and tested ok
-Assessed fitment of vehicle speed sensor. Cleaned fuse holder and relay assembly
-Test light circuit for use of new switches with old low/high beam relay, ordered 2 + 30A relays to modify electrical circuit
-Test hazard light, turn signal circuit. Not possible to work with old relay, f
Fit new relay and test operation ok
-Test wiper circuit and adopt to new switch
-Fitted exhaust and new custom bracket
-Fitted headlights
-Manufactured oil hoses outlet and inlet. Fitted oil hoses, adjusted and order parts for heat shield
-Fitted alternator belt

http://i.imgur.com/YY1VlkI.jpg

http://i.imgur.com/4SvDFIw.jpg

http://i.imgur.com/CMjwQt6.jpg

Oil filter mounted above transmission
http://i.imgur.com/lJHcfMG.jpg

Some of the new heat shielding on the pipes
http://i.imgur.com/JKb2k3K.jpg

http://i.imgur.com/JczoOWV.jpg




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posted on June 24th, 2014 at 08:48 PM



Quote:
Originally posted by ian.mezz
I think that you will have to fit the tie rod ends from the bottom as those shocks sit really low and steering arms may rub on the under body
Also the bottom of the ball joints may need cutting off so it doesn't rub on the rim


Ahh yeah everything will be tested bit by bit. It won't leave the shop unless I'm happy with it all.




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posted on June 24th, 2014 at 09:09 PM



Quote:
Originally posted by Oppressa
Quote:
Originally posted by ian.mezz
I think that you will have to fit the tie rod ends from the bottom as those shocks sit really low and steering arms may rub on the under body
Also the bottom of the ball joints may need cutting off so it doesn't rub on the rim


Ahh yeah everything will be tested bit by bit. It won't leave the shop unless I'm happy with it all.

is that oil filter far away from the drive s haft for when the drive shaft moves up and down??
hard to tell in the picture.
No Long now and you will be back on the road. :tu:




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posted on June 29th, 2014 at 02:27 PM



Quote:
Originally posted by ian.mezz
is that oil filter far away from the drive s haft for when the drive shaft moves up and down??
hard to tell in the picture.


Here you go ;)

http://i.imgur.com/EWGgT7E.jpg




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posted on August 29th, 2014 at 09:38 PM



[size=4]Update 61[/size]

There's been a big break in the build as O&S had to prepare other cars for conourse. Work picked up again this week:

-lots of wiring work
-coverplate made for fusebox and fusebox mounted
-central locking wiring and actuators being installed
-handbrake installed
-fuel tank fitted
-steering box finally installed
-heat shield around exhaust finished

http://i.imgur.com/EINqqMR.jpg

http://i.imgur.com/KiAv7CK.jpg

http://i.imgur.com/CL8zga1.jpg

http://i.imgur.com/jIUnW10.jpg

http://i.imgur.com/kZTaR0z.jpg

http://i.imgur.com/XHyvwJo.jpg

http://i.imgur.com/0vn1TfD.jpg

http://i.imgur.com/VfQhxzz.jpg

http://i.imgur.com/pSOaE2v.jpg

Mmmmmm yeah... :) Completely stock Beetle stuff here!...
http://i.imgur.com/XiQ0dOZ.jpg




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posted on August 30th, 2014 at 08:07 AM



It's really great to see shops still putting that level of work in, and to that end people willing to pay for that level. Hats off to you sir.



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posted on August 30th, 2014 at 09:32 AM



Looking great dude, is that rear caliper leaking in the pic? What are you using on the floors for sound deadening? More of the same?



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posted on August 31st, 2014 at 06:13 PM



This will be an amazing car when finished
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posted on September 2nd, 2014 at 05:48 PM



hey mate one question i have about the central locking, when or if the battery goes dead and you have the doors locked how do you get in?
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posted on September 2nd, 2014 at 08:26 PM



You'd be able to stick a jump battery on the starter terminals to give it a bit of juice. (You can get to that from the outside of the car)



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posted on September 3rd, 2014 at 07:32 PM



where did you get the insulation over the j pipes and the blanket over the back of the engine?
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posted on September 5th, 2014 at 10:12 AM



Quote:
Originally posted by tayloredvw
hey mate one question i have about the central locking, when or if the battery goes dead and you have the doors locked how do you get in?


2nd little motorbike battery and a dual battery switch in engine compartmemnt to at least supply power if something was to go wrong. It will be charged by a VSR (Voltage Sensitivity Relay).




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