Cleaning up engine bay

  wk20 - 28/12/12- 5 hours

Got another day on the car this week but was a bit of a slow day. Cleaned up the grease in the engine bay with some white spirit. There are a few spots of rust in the engine bay to clean up, made a start but need to get a smaller wire brush for the drill to get into the corners.

In the grill above the back of the engine lid i started to clean up the grime under the grill. When i started to clean i realised there was a lot of loose paint. Turns out to be a whole layer paint but it is really flaky, i am guessing because it was never keyed being so hard to get to. So with some little hand held wire brushes and a screw driver I have started to clean off the loose paint. It is going to take a while but i have made a start.
There is also a couple of spots of rust that need to be cleaned and treated.

The dark parts are where there is still loose paint to clean off.

Couple of rust spots to clean and treat.

Rear arch cont.. - Wk 20 - 23/12/12

This week was working on the rear arch, sorting out the section that the wing bolts onto. First I cleaned up all the bits of rust with the angle grinder to see what state they were in. There were 2 patches to cut out and replace

Sections marked up to cut out.

These were cut out with the angle grinder and then new pieces made. I did my first bit of welding on the car welding the nut onto the back of the plate for the wing. Then Rich welded in the patches and i cleaned up all the welds.

My first bit of welding for the car

Patches welded in and cleaned up

 As with all the bits of welding that we are doing at the moment I put a coat of zinc primer on to keep them protected and then when we have been around all the car will concertrate on making the body work A*

Rear arch metalwork - Wk 19 - 16/12/12

This week was back on with the body work on the rear arches now the valence is in.

First was quite a bit of work on grinding down the welds form the rear valance and cleaning up the last of the stonechip from the rear arches. The wire brush worked well on the stone chip. There has been a bit of repair work done at some point on the back. The good things is that it looks like the job was done really well. No dodgy filing or anything.

Rear arch cleaned up

On the passenger inner rear arch there was a little bit of welding needed. I cut it out and then Richard welding in the patch. I ground it back and it looks great. With all the welds cleaned back you can't even see where it was. I don't understand why you would want a patch welded on the outside when you can make it look like it was never there. It looks great

Weld in place ready for grinding

Weld ground down looks great

All the paintwork at the back was cleaned up, wiped down and then kurust applied. With this dry a coat of Zinc primer was applied to keep it all clean and rust free while the rest of the work was done. Everything is looked good and the last couple of blemishes from my first attempt at grinding will be covered once the stone chip and paint is on.

Zinc primer on, can't even see where the weld was

All cleaned up and zinc primer on.

Foam, Foam, Foam - wk17 - 1/12/12

With only a couple of hour this week to spend on the car I worked on removing some more of the foam over the rear arches. I equipped myself with the necessary tool, screw driver and wire formed to have a hook on the end.

Repeated prodding and pokingresulted in a large bowl of foam but thats only about half done

Bowl of foam

Still more to go but about 10inches out.

 

New rear valance - WK16 - 25/11/12

This week has been some good progress with getting the rear valance replaced.

First time using the angle grinder. I cut through the welds and then cut through the metal. The old rear valance came out in one piece. It came clear that this wasn't the original one but a replacement that has been put on, it had been replaced very well and a good job.

Old rear valance out

With the rear valance out it was time to clean off the old welds and clean up all the metal work. The metal work cleaned up well and there was only a couple of little patches of rust to clean up.

Me cleaning up the metal work

With all the metal work cleaned up it was time to fit the new valance. First I put back on the rear wings to line the valance up to. Then the rear valance was put in place and with a bit of work it fitted well. Rich wanted me to do the welding. I did a couple of practice spot welds but after 5 mins of welding i decided it was to soon to go on my car. Rich welded the rear valance in place for me.

New rear valance welded in place

 Although the new panel didn't weld great Rich did a great job on it and the welds are looking really good ready for me to grind them back and smooth them down.

Weld done ready for me to grind down

So it has been a really good day, I have learnt to cut and grind with the angle grinder. Old valance off and new valance on it a good days work. First panel complete

Cleaning up - wk 14 - 10/11/12

So with the beetle stripped down it is time to start to clear it up.

I spent the day scrapping off the under seal and hammerite from the passenger side front and rear wing. I didn't quite get it all done today but made a start and it is looking really good underneath.

On the rear inner wing there is definitely some repair work done so i might need to take this back a bit more to see what under the extra layer of paint.

I think that the later of hammerite that someone put on the inner arches at sometime has been it saviour to keep it so clean and rust free after 40 years

Looking good under the hammerite and underseal

Some filler and a coat of paint at the back of the rear wheel arch at sometime. Will need more investigation

Got a coat of smooth hammerite on wiper mechanism, you don't see it but it was a little rusty so worth giving it a coat for protections

Previous beetle - Boogie Bug

As my first car I also had a beetle. I loved it. It was a bright green beetle with boogie bug in big yellow letters on the back, used to advertise the local night club when they opened up. turns out it was a mis- match for parts wings and bumpers that didn't match the year. I think i learnt the most important thing about beetles from someone shortly after i got it. Make sure you have a cover on the battery or when someone sits on the back seat they might short the battery and the horse hair seat will catch alight

Looking back I must have been spoilt to have been allowed one as my first car bought for me. I know they weren't as expensive back in 2000 and they aren't exactly fast but its also doesn't make the most practical of cars for when you have just passed your test. Working nights having to try and drive it in the middle of winter when it was easiest to open the windows so the temperature inside the car was the same outside. But hey it was fun, and no-one else I know had one!

I ended up having to sell it in 2004 as I couldn't keep it as my daily car, it wasn't running well going to and from the station so it had to go. Now my new bug is the second car so I can drive it when the weather and journeys suits.

I had always wanted a purple bug with red flames, now I have the chance to do what I want to my project beetle I have out grown that thought. Now i want to go down the classic route with a twist, i please my new bug has standard wheel, standard running boards and the quarter light windows.

So here is my first bug,
 Cal look windows

Custom made door cards by Mum. Might be a hint to what to expect from my new bug

 Dressed up engine.

Few new parts - wk 13

This week I didn't do any work on the beetle as I went to a show instead to get a few bits and get some ideas.

Only picked up a few bits as it is still early days but I had a good look around to see what about and what show prices are like. Some pieces i need to pick up at auto jumble.

Bumper grommets, clips, handle seals and some wing nuts.

 Got some carpet, bargain price and really good quality BMW carpet none of the cheap stuff. Be good to make my own carpets out of, just need to work out how i'm going to edge it.

Carpet

Its been a long time since I have seen a lot of bugs together. I was a bit disappointed as there wasn't a lot there but I guess being end of season it was to be expected.

Still undecided on the colour. I like pale blue, cream and pale green still but all area colours that you need to find the right shade and if it is slightly off it could look really rubbish. I want to keep the outside true to the year (bumpers, wings, running boards etc) but with a few tweak such as clear indicator lenses. Inside, it is going to have a twist!

Fuel tank out - body unbolted - wk 12 - 28/10/12

Cheap petrol syphon purchased and well worth it. With a whole fuel tank to empty it was definitely needed. Managed to fill my daily drive up :-) bonus.

Fuel tank out with out to much trouble when it was empty

Fuel tank out

Next I disconnected the break lines and had a look around under the car. Looks ok, few little bits that will need attention with a few bits of rust under the car and a few bits that will need replacing.

Looks like the rubber is a little past it

The last job for the day was removing all the bolts that hold the body onto the chassis. This went well apart from one slip resulting in the first real injury of the build, a cut and very sore knee.

Next we need to work out how to separate the body so that it can be stored in one half of a double garage so need to be able to roll the chassis out from under the body

Strip down complete - wk 11 -21/10/12

So this week the strip down was complete.

First off was the bonnet. The aim was to take the fuel tank out and drain the petrol but when we checked how high the fuel was (the fuel gauge didn't work) it was right to the top and up into the filler hose so some will have to be removed before we can take it out.

The windows came out. All came out complete. The seals all need replacing after 40yrs, no point saving them, the front windows and quarter lights came out fine, most the seal and window parts are savable apart from new outside seal part needed.

All the windows out

Next the headliner came out, wasn't to difficult. Will see how it cleans up but will probably replace. The felting behind the fabric was all fine and i will be reusing it.

Headliner out

Finally the doors came off and were stripped down. All the window winder parts and locks were removed.

All stripped down

So the car is now stripped down apart from the petrol tank which will need removing next week. It was a very productive day, now I will need to start planning what needs doing next.

Continuing the strip down - wk10 - 14/10/12

This week I continued the strip down. The wings and side skirt from the drivers side came off, this was much easier then the other side to get them off.

Drivers side wings and side skirt off. 

Next I took out the wiring loom, although pretty much everything had been disconnected already this took longer then anticipated. The front came out easy feeding it through into the car but the back proved to be more difficult. From the engine bay into the car there was some high density foam stopping it. After a long time poking and using various home made tools i got enough out to get the wires moving and through. All the wiring look was out.

Next off was the last of the chrome trim and the wiper blades and mechanism

Trim, wipers, mirrors and wings off

Next week a few more bits to come off, petrol tank and windows out

Bumpers, lights and wings off - Wk9 - 7/10/12

This week I finished off getting the last of the sound deadening off the inside. Then moved to the outside, took off the taillights, headlights and indicators. All those can be saved though i might replace the rear lights as some of the plastic has started to perish over 40 years. Hopefully I go to a show soon and can have a look at what the cheaper replacements look like.

Front and back bumpers were next to come off. The bumpers are a little rusty in places but look ok. I am definitely more inclined to keep them, clean them up, re-chrome them and get new rubbers for them as they aren't cheap replacement ones.

Lights, wings, bumpers and trim strips off

Next off was the front and back wing on the left. Didn't come off to bad. They are both the original, the front was always going to be replaced and the back one will probably be replaced as i picked up some rear wings, new ones, cheap. The underneath of the wings and inside the arches seems to have an extra layer of paint, was a bit worrying at first but turned out that someone had at some point took the time to extra paint inside the wings and arches before under-sealing them.

Last thing to come off today was the chrome trim down the left side. Was much easier then i thought and we even managed to save a lots of the clips.

Here are the bits of rust on the left side that will need some work

Some rust to repair on the front end

Only one bolt are of the left side that will need repairing

Some welding needed on the panel near the rear swing arm

Interior & some new engine parts - wk7 - 30/09/12

This week I have continued to work on the interior. We took the dashboard out, quite a task working out where all the screws are that hold it on.

Dashboard out

Next was on to the sound deadening on the floor pan. This was something I wasn't looking forward too. I know it was stuck hard like tar onto the floor. I first scrapped of the top layer then used the heat gun to remove all the sound deadening.The floor looks good underneath, some surface rust to clean off and some bits that look like new.

Sound deadening all off the floor pan

This week I have also got some parts to go towards building the engine. All second hand. I have a crankcase, crankshaft, camshaft, conrods and replacement followers. Most other parts for the engine will now be bought new.

Well thats another 8 hours spent on the car and aching muscles

Stripping out the interior - wk 5 16/09/12

Next i moved on to stripping out the interior. All the seats were removed first, these are in good condition just a tear in the usual place on the back seat. I will be recovering the seats myself. Not exactly sure what i'm going for yet but i have some ideas but you will have to wait and see.

Next I took out the carpet and rubber matting. The carpet is in ok condition, the one behind the back seat is in great condition so might be re-used but the main carpet will be replaced.

The floor is looking good. There is a few bits of surface rust on the floor pan that should clean up ok. There is a bit of welding needed on the rear wheel well that has gone through.

Spot of rust that will need welding

Floor pan looking good apart from a little service rust in the wheel wells

 

Front foot wells with the carpet out, all very clean

Next I took of all the little bits and pieces, seat belts, gear gaiter, grab handles, sun visors etc. Gear gaiter went in the bin but everything else is good. The sun visors will be recovered.

I took the door cards off, again these are fine, the front ones i don't think have ever been taken off. I am going to cover these as i did with my last car, again i have ideas for these but you will have to wait and see.

Door cards off, plastic never been off before

  A check of the usual bottom of the door showed no rust in the bottom of the doors, pretty good considering they are 40 years old. Everything so far indicates a very well looked after car. 

Inside the bottom of the doors, no rust :-)

So that was a long day but got a lot done and really pleased with how it is coming along 

Cleaning tinware - Wk4&5 - 16/09/12

Last weekend and part of this weekend was spent cleaning up some of the engine tinware. I know i don't have a working engine yet and am still keeping my eyes for one in various places but there is no rush to get one i'd rather wait for the right one to come up.

The tinware has been cleaning up pretty well. There are a few bit of rust on a few pieces which will be cleaned up and treated before being painted. The clean tinware will now be put aware until i have an engine ready to rebuild.