'69 Retro-custom bug project - VZi, the UK's largest VW forum, community and sales

Surfbug · 29-12-2007, 09:25 AM

Thought I'd start this thread to show, and keep track of my bug project progress. I am quite far into the repairs now, and have a few plans to make things different. It is my first beetle and I have learned so much by carrying out the work myself, and also picked up loads of tips from VZi.

I bought this 1969, 1500 beetle from a guy in Portreath, Cornwall. Paid £130 off Ebay.

Some pics of it on the way back to Penzance.

Surfbug · 29-12-2007, 09:33 AM

Started to strip the car. I kind of ploughed into it so quickly, that I did'nt really notice how much rot there was. Although not too bad, it was still alot of work ahead. I started ordering and fitting panels before I completely stripped it.

One of the worst things was the amount of badly repaired rust from over the years.

Surfbug · 29-12-2007, 09:35 AM

Surfbug · 29-12-2007, 09:40 AM

Next step seemed to take ages, as I work overseas, and only get a small window of time when I'm home to get jobs done. First thing metal work wise was to separate the floor pan from the body. It was not a case of just unbolting it. The heater channels had been plated and welded solidly all the way down, so took a while to get the body off.

Body off, I had a pair of pan halves waiting to be fitted.

Surfbug · 29-12-2007, 09:44 AM

One side cut off and ready to accept passenger side pan.

Repaired this piece before fitting the floor.

Before:

After:

One side done, now the other.

Surfbug · 29-12-2007, 09:54 AM

Floor pans finished and etch primed:

Couple coats of shonechip paint on the underneath and 2K black top coat:

Surfbug · 29-12-2007, 09:57 AM

Welded in a new frame head too, but forgot to take any pics

Also attacked the gearbox with the wire brush after I cleaned the rest of the chassis

Surfbug · 29-12-2007, 10:02 AM

Purchased this engine as well, as the car did'nt come with one. It's a 1300 TP, although I think I will try to upgrade it to a 1600 ish at some point. My main concern for now is to start the metal work on the body.

Surfbug · 29-12-2007, 10:10 AM

At this stage, I decided to tackle the heater channels. Again no pics....soz. Got the old heater channel cut out after bracing the doors, and realised that the lower piece of the rear quater was loaded with filler and rotten. Also lower A post was shot.

The repair panel I got for the botton of the rear quater was shit, and after re-inspection decided to spend out on a complete rear quater, due to more terrible repairs on the inner arch too.

Surfbug · 29-12-2007, 10:13 AM

Quater fitted. Really good fit, and not as difficult as I thought it would be: