• From: B.C.Canada
  • Registered: 2005-01-26
  • Posts: 2,610

Topic: '71 Super restoration

Well I finally started restoring my bug. I bought it in Oct. 2006 with only 64,000 miles on it but sun damaged due to sitting 14 years in a semi desert. I have all the original paperwork and it was completely stock and unmolested. It had one owner, a women, who bought it new and only took it to the dealer for work. It still has the original Continental spare tire, never used.

She stopped driving it because she hit a deer and damaged the front left fender and door. After sitting for years she had the fender replaced, welded the lower door hinge, pounded out the door skin and gave it a crappy paint job. Also got a tune up.

I got it and changed fuel and vapor lines, cleaned up all the electrics, got new seats to replace the sun damaged ones and got the engine running really good. Had to do some repairs on the heat channel bottom plate and rocker panel mounting strip. So I drove it every day all year for 4 years trouble free except for small stuff. It was great in the winter because the stock heat worked well and it has a working gas heater and came with 4 studded snows.

I stopped driving it about two years ago. The muffler went, the rust that there was, was getting worse of course. I didn't have a garage though and didn't want to attempt this in my driveway. My shop in the basement wasn't that big either and was filled with Beetle and bus parts.

Now I've moved to a house, in Vancouver, that has a detached double garage lined with H/D shelving. I'm sharing the house with my friend and fellow ACVW fanatic. He has a '77 Westy and I have an identical '78 Westy.

I've already completely disassembled the Beetle, including the engine. Pretty much every thing that comes off is off except no need to separate the body as the heat channels are OK. There are rust holes at all 4 corners and behind the charcoal can is a large hole into the engine compartment. Floor pan is solid.

Now if you guys can just tell me how to put it all back together I'll be good to go!

The beginning>

http://i43.tinypic.com/2jdmjp0.jpg

http://i43.tinypic.com/149s7zr.jpg

http://i41.tinypic.com/1z4hbut.jpg

http://i43.tinypic.com/351gvnk.jpg

The dis-assembly>



http://i40.tinypic.com/jfkfw5.jpg

http://i42.tinypic.com/30clo2u.jpg

http://i41.tinypic.com/2uqkjvc.jpg

http://i43.tinypic.com/11uwaw8.jpg

http://i43.tinypic.com/i55194.jpg

http://i40.tinypic.com/69nay1.jpg

http://i44.tinypic.com/2ijsyad.jpg

http://i42.tinypic.com/ajuomt.jpg

The pic below is rust due to poor repair of deer damaged area. I will need the front section of the heater channel with the defrost nipple.

http://i43.tinypic.com/2ce5b4j.jpg

http://i41.tinypic.com/nq8v85.jpg

http://i40.tinypic.com/28kjais.jpg

http://i43.tinypic.com/6i47dw.jpg

http://i42.tinypic.com/2njhx7m.jpg

The assembly>

http://i39.tinypic.com/35hfts4.jpg

The white repair panels come from my previous Beetle, a '73 standard with swing axle rear end. Canadian model. Waste not want not.

http://i44.tinypic.com/30nkf1d.jpg

http://i42.tinypic.com/dlkrys.jpg

I'll be relying on my friend Robert Bentley but he doesn't know everything so stay tuned for questions.

jim

'71 SB(DD only 79K(now 84K miles) & '78 FI Westy (project)
PO of '65 Beetle in '69, '70 Crewcab & '70 Ghia in '77
'71 Super inside rear vents now available
http://www.openroad.ca/volkswebbin/view … p?id=85915
  • From: Cincinnati, Ohio
  • Registered: 2005-09-10
  • Posts: 2,336

Re: '71 Super restoration

I like the photo of the trunk area.  The duct tape on the fresh air box, the "wall to wall" carpeting wink...and is that the gas heater on the right side of the trunk photo?  That "beast" runs on gasoline...right?

Some of the other photos with the rust just above the pan area look a bit scary.  That heavy duty shelving is sure coming in handy for all the parts during disassembly! smile  That new metal in the final photos looks pretty good!

Glad to see you made the "big leap" into the restoration...good luck! smile

- Nick

1979 Super Beetle Convertible
  • From: somewhere over the rainbow USA
  • Registered: 2006-07-26
  • Posts: 1,889

Re: '71 Super restoration

I sure hope you labeled everything wink
Time to get a learning on that  there welder you own.
ask away on the questions, I have a few refurbishments under my belt as do others.

burrhead

A wise man makes his own decisions, an ignorant man follows public opinion.
  • From: B.C.Canada
  • Registered: 2005-01-26
  • Posts: 2,610

Re: '71 Super restoration

I've done everything but bodywork on Beetles and buses. Bodywork is different because you have to be creative. I don't use labels anymore. I know what every part is and where it goes and these pictures and others are my insurance if I do forget the order of reassembly. I memorized all the Beetle and bus wiring diagrams long ago. I may not be too smart but I have a crazy memory.

jim

'71 SB(DD only 79K(now 84K miles) & '78 FI Westy (project)
PO of '65 Beetle in '69, '70 Crewcab & '70 Ghia in '77
'71 Super inside rear vents now available
http://www.openroad.ca/volkswebbin/view … p?id=85915
  • From: South Africa
  • Registered: 2004-11-11
  • Posts: 46

Re: '71 Super restoration

Wow she sure is holy ! Im also not much of a bodywork person myself , but one has to start somewhere! Good luck with the build.

'Keep on Rollin'
  • From: somewhere over the rainbow USA
  • Registered: 2006-07-26
  • Posts: 1,889

Re: '71 Super restoration

jamesdagg wrote:

I don't use labels anymore. I know what every part is and where it goes

Hope this statement does not come back too bite you wink   You ARE getting up in age  smile
Just  ask Sir Yancey.

burrhead

A wise man makes his own decisions, an ignorant man follows public opinion.
  • From: B.C.Canada
  • Registered: 2005-01-26
  • Posts: 2,610

Re: '71 Super restoration

This is actually the least "holy" 40 year old car I've seen. Course I've never been to Texas or Arizona. The floor is completely solid and heat channels only need the bottom plate and front tip of the drivers side inner channel.

I can't forget. I'm blessed and cursed with a photographic memory of my entire life back to 4 years old.

jim

'71 SB(DD only 79K(now 84K miles) & '78 FI Westy (project)
PO of '65 Beetle in '69, '70 Crewcab & '70 Ghia in '77
'71 Super inside rear vents now available
http://www.openroad.ca/volkswebbin/view … p?id=85915
  • From: Canada
  • Registered: 2004-03-27
  • Posts: 630

Re: '71 Super restoration

burrhead wrote:
jamesdagg wrote:

I don't use labels anymore. I know what every part is and where it goes

Hope this statement does not come back too bite you wink   You ARE getting up in age  smile
Just  ask Sir Yancey.

Zing!

Yeah, I've seen a lot worse than that come back from the dead...but you've still got your hands full.

I can't give much personal advice on welding, and you've probably seen some of those well documented restoration threads over on The Samba...great source for tips and inspiration.

Biggest piece of advice from personal experience is to practice, lots, before starting on the car.  Use weldable primer to protect hidden pieces, and do butt welds unless the original metal was overlapped.

1979 Type 1 Convertible                                       1976 Scirocco (For Sale!)
1971 Type 1 Semi-Automatic Super                       1968 Type 1 Sedan
1961 Type 1 Sedan
1957 Type 1 Sunroof

Der Bugmeister's Website

  • From: B.C.Canada
  • Registered: 2005-01-26
  • Posts: 2,610

Re: '71 Super restoration

Lucky for me all the rust holes are not visible from the outside. The fenders were all good but one and I have a replacement. I can also buy all the panels I need, so very little fabricating. Also my friend is a H/D mechanic apprentice and is learning to weld. I have used my MIG and did OK. I'm not ready for welding a panel in where it's visible though but I need to learn because my '78 Westy is next and it does have lots of rust visible from outside.

jim

'71 SB(DD only 79K(now 84K miles) & '78 FI Westy (project)
PO of '65 Beetle in '69, '70 Crewcab & '70 Ghia in '77
'71 Super inside rear vents now available
http://www.openroad.ca/volkswebbin/view … p?id=85915
  • From: Cincinnati, Ohio
  • Registered: 2005-09-10
  • Posts: 2,336

Re: '71 Super restoration

jamesdagg wrote:

The floor is completely solid and heat channels only need the bottom plate and front tip of the drivers side inner channel.

This is sort of surprising (at least with what I've seen).  Usually the floors go first...or at least at the same time as the heat channels...and other fender well rust.

Does it look like the floors were repaired/replaced previously?

- Nick

1979 Super Beetle Convertible
  • From: B.C.Canada
  • Registered: 2005-01-26
  • Posts: 2,610

Re: '71 Super restoration

Every bugs story is a little different Nick. With only 64,000 miles and sitting in the semi-desert it could very well have had no rust, except for a couple of unusual things.

The front left wheel well and the front end of the heater tube with the defrost nipple, were damaged when the deer was hit. A poor repair was done with aluminum and rivets and no sealant.

The bottom plate of the drivers side heat channel was rusted from the inside out. Water got in the corner of the window or the fresh air box and ran down the A pillar destroying the paper tube and forming a puddle in the heat channel, on the bottom plate not in the heat pipe. It eventually rusted it's way out at the lowest spot.

The hole on the right side of the engine compartment is entirely due to the charcoal canister. There was mud trapped between it and the wall.

Other than the deer damage at the front left no body work has been done and the engine has never been out. The floors only had some surface rust even under the battery.

I plan to remove all the glass since the rubber is all cracked anyway and so I might as well replace the headliner. It has one tear that I did bringing home parts and it's a bit dirty around the edges. And then the paint job will be so much better with the glass out. I'm returning to the original color. I'll POR 15 the underside as I've done to a couple of buses.

I just haven't decided if it's worth removing the dash. What do you guys think? Is there any advantage to removing the dash for painting? The front footwell area and under the dash are like new.

http://i40.tinypic.com/eimrug.jpg

http://i41.tinypic.com/2qbt6h5.jpg

jim

'71 SB(DD only 79K(now 84K miles) & '78 FI Westy (project)
PO of '65 Beetle in '69, '70 Crewcab & '70 Ghia in '77
'71 Super inside rear vents now available
http://www.openroad.ca/volkswebbin/view … p?id=85915
  • From: somewhere over the rainbow USA
  • Registered: 2006-07-26
  • Posts: 1,889

Re: '71 Super restoration

I would not remove the dash unless it is bad or if you are going too paint around it. OG is better than the crap out there. Doesn't look like they painted the int. other than the doors?
Removing the windows always looks better than masking off around them especially changing colors.

burrhead

A wise man makes his own decisions, an ignorant man follows public opinion.
  • From: Cincinnati, Ohio
  • Registered: 2005-09-10
  • Posts: 2,336

Re: '71 Super restoration

jamesdagg wrote:

The front left wheel well and the front end of the heater tube with the defrost nipple, were damaged when the deer was hit. A poor repair was done with aluminum and rivets and no sealant.

The bottom plate of the drivers side heat channel was rusted from the inside out. Water got in the corner of the window or the fresh air box and ran down the A pillar destroying the paper tube and forming a puddle in the heat channel, on the bottom plate not in the heat pipe. It eventually rusted it's way out at the lowest spot.

The hole on the right side of the engine compartment is entirely due to the charcoal canister. There was mud trapped between it and the wall.

Jim,

It does sound like this Beetle has had an unusual life.  Most of the air-cooled VW's I've seen, worked with, and owned...have "lived" in the snowy midwest & East coast United States where the roads get salted pretty heavily during the Winter...and so the vehicle's pretty much rust from the bottom (pan)...and then the rust works it's way up (heater channels, rocker panels, fender wells, "firewall" area, luggage area behind the rear seat on a beetle, etc.).  Man that salt just EATS away unprotected metal...like termites thru wood!!!

The body on your Beetle appears to be in pretty decent shape smile...from what I can see in photo #1...except for some of the rust on the rear fender (just above the chrome trim piece).

Good luck with the project...

1979 Super Beetle Convertible
  • From: Canada
  • Registered: 2004-03-27
  • Posts: 630

Re: '71 Super restoration

Removing the dash is easy, and non-destructive.  You're going this far, I'd pull the dash off as well.

Just remember if you pull the windshield, you can save the glass or you can save the rubber...but you can't save both.

1979 Type 1 Convertible                                       1976 Scirocco (For Sale!)
1971 Type 1 Semi-Automatic Super                       1968 Type 1 Sedan
1961 Type 1 Sedan
1957 Type 1 Sunroof

Der Bugmeister's Website

  • From: somewhere over the rainbow USA
  • Registered: 2006-07-26
  • Posts: 1,889

Re: '71 Super restoration

Der Bugmeister wrote:

and non-destructive.

Even the delicate area around the glove box?

burrhead

A wise man makes his own decisions, an ignorant man follows public opinion.