Kick Azz 1975 LaGrande Super Rebuild

[baxsie]

Starting way back (see: Getting naked with a heat exchanger), we have been trying to find a way around the heat (OG heat exchanger) or performance (big J tube) trade-off.

I think we have it.

We started with a quality heat exchanger from WolfsBurg West, and the semi-custom stainless steel flanged J tube that was supplied as part of our A1 exhaust.

From experimentation, we knew exactly where we wanted to cut to be able to get the old core out, and the new j-tube in:

We removed the factory folded seam by using the angle grinder:

Then peeling away the strip:

This exposes the core of the reproduction / repop heat exchanger. To their credit, there is the nice aluminum pour around the j-tube, but the finning is much less agressive than the factory, and the exhaust pipe is not convoluted:

A local sheet metal shop cut us 3/4" wide strips of 14 gauge sttainless sheet, which we then cut down to 3/4" squares using the chop saw:

Next came the ardous task of attatching the stainless-steel fins to the stainless steel J-Tube. Originally we attempted using the TIG. My TIG welds were horrible. My son made much nicer welds-quite beautiful, in fact, but the TIG welding process was brutally slow. After asking around, we found some 0.030 308 stainless MIG wire and a special gas that allows using the MIG to weld stainless. This made the process go much faster, although the welds are not quite as slick as my son's TIG welds:

Here is a picture of all the tabs welded on. There is an an equal number on the back side:

We used the torch and pliers to make the openinf in the skin bigger, and shape it around the J-Tube:

My son then brazed the skin closed again:

A quick bead blast:

We still had some Rust-Seal Motor Coater, so we prepped it with the Rust Blast etch and then shot it:

Hopefully that will give some decent heat this winter!
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1975 LaGrande Super Beetle Build Log / Farm boy hinge pin puller / Farm Boy Chassis Rotisserie
"I'm not getting older, I'm getting bitter."

[baxsie]

Got the heat exchangers assembled to the engine, most of the accessories connected:

Manifolds will have to come out for engine install, so they are still loose.
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1975 LaGrande Super Beetle Build Log / Farm boy hinge pin puller / Farm Boy Chassis Rotisserie
"I'm not getting older, I'm getting bitter."

[VWCOOL]

frak me, that now-hidden exhaust work is impressive. Two thumbs up, lads

[baxsie]

We had a local shop, City East Auto Body do the remaining collision repair, final body work and paint. The owners lives right up the road from us--we have known them for years.

I could not be more happy with the results. The paint is beautiful, the car is super straight. Here is a quick walk-around:

Body and paint history: previous body & paint posts:
Engine Tin painted, Body in Primer
Underside of body painted, reassemble body to pan
Collision repair on front of car

Here are some random in-progress pictures, generally in chronological order.

Test fit of hood and doors:

Wet sanding hood primer:

Doors & Fenders, still in the booth:

Body in the booth, before the clear:

Body out of the booth:

Hood Front Fenders And Doors On:

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1975 LaGrande Super Beetle Build Log / Farm boy hinge pin puller / Farm Boy Chassis Rotisserie
"I'm not getting older, I'm getting bitter."

[H2OSB]

Being a Super Beetle guy, I must say this is the greatest build thread evah! I really look forward to reading what you've done every time I see an update appear. Strong work gentleman! I also think it's outstanding that you've worked right along with your son!

I've done project cars for years and years, but I feel inspired when I see the superb work you've done particularly when one considers the numerous times you were attempting something for the first time (i.e. TIG...or even welding in general, if I read it all correctly.)

Keep it up. I look forward to your next update.

Mighty impressive!

johnL (aka H2OSB)
www.superbeetlesonly.com

[99XC600]

Amazing work. Just subscribed.

[baxsie]

VWCOOL, H2OSB & 99XC600: Thanks for the kind words and support. Appreciate it.

A few weeks ago, Mild Too Wild Upholstery completed the back seat and the door panels. We have had the Recaro Speed S seats for some time, but they recently put seat heaters in them. Nothing to see really, just a reference pic for the other photos following:

The door panels are upholstered in matching black and the micro-suede blue. We need to cut out for the speakers, and the door handle:

They made an entirely new back seat bottom and back, building and sculpting it from foam to a more modern "bucket" look, The stitching matches the front seats:

They reused the frame, latch and hinges. The back is an ABS panel. Once we have sorted out the rear speakers, we will decide if there will be a sliding panel for when the seat is down:

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1975 LaGrande Super Beetle Build Log / Farm boy hinge pin puller / Farm Boy Chassis Rotisserie
"I'm not getting older, I'm getting bitter."

[baxsie]

We had a local shop (Tripleplate Chrome) polish and chrome the "FUEL INJECTION" deck lid badge:

Really, the picture does not do it justice, it looks really great.
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1975 LaGrande Super Beetle Build Log / Farm boy hinge pin puller / Farm Boy Chassis Rotisserie
"I'm not getting older, I'm getting bitter."

[baxsie]

I am working on the vent wing windows.

I decided to get the aluminum chromed, after having some success chroming the aluminum "FUEL INJECTION" badge.

I grabbed a passenger-side bar, and a driver side bar, and headed down to the chrome shop. The guy there says "oh, stainless". I'm like "whaaaa?"

I have 8 wing windows, 4 passenger, 4 driver.

All four driver's side bars are all aluminum.

Three of the four passenger side bars are stainless, the last one is aluminum.

The only matching set is aluminum, so I am back to the chrome shop tomorrow to get a matching set of the extruded aluminum bars chromed.

Who would have guessed that there would be such an odd mix?
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1975 LaGrande Super Beetle Build Log / Farm boy hinge pin puller / Farm Boy Chassis Rotisserie
"I'm not getting older, I'm getting bitter."

[TX-73]

Excellent color choice

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My 1973 Standard Beetle Build SOLD
Click to view image

[Bashr52]

[VADave]

We cleaned and polished the shaft where the trigger slides:

What is the "trick" to getting the slide off this shifter? I have one that I want to take apart, but I don't want to damage it by doing something silly!
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1974 Standard - Jennie's Bug "Hanz"
Instagram HanzOnRoute66

2015 Harley Street Glide - David's ride "Franz"

[baxsie]

[VADave]

[baxsie]

We have been working on the doors. We used DynaPad for thermal and acoustic insulation above and below the beam, where we were pretty sure it would not interfere with the window. DynaPad is a vinyl mass loaded acoustic barrier foam, basically 1/4 inch foam, heavy vinyl, then another 1/4 inch foam. The DynaPad is installed with 3M 90 adhesive. Lower on the door we use RattleTrap, which is basically a thick (~0.070) rubber (tar?) pad with pressure sensitive adhesive on one side and foil on the other. And we used some chrome inner door handles, because they rock:

We installed the power lock actuators directly to the door, using 5mm screws, locknuts and a spacer to back it away from the flange:

To make the most of the power lock actuator's travel, we extended the lock arm a bit. This will give the actuator more authority over the lock mechanism. The upper (smaller) rod is a Z-bend in 3/32" stainless welding rod. The lower (larger) rod is 1/8" stainless welding rod, with a J bend at the actuator. The clamp is part of the lock kit.

Never one to pass by an opportunity for cheesy bling, we installed some "Ghost Shadow VW Logo Projector Lights". Keep in mind that the picture is taken in HDR mode in low light, so it is very flattering, but in anything but bright lighting, these look hella cool:

The projector lights are surprisingly complicated inside. Well, if they fail it just means there is another drain in the door, right?

In the "Any progress is some progress department", we installed the number plates. I have no idea what is encoded on the small one, but we got the paint off it, brushed it, hit it with some clear and riveted it on with some stainless rivets:

Hopefully the wing window bars will be done soon at the chrome shop, so we can complete the remainder of the door project.
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1975 LaGrande Super Beetle Build Log / Farm boy hinge pin puller / Farm Boy Chassis Rotisserie
"I'm not getting older, I'm getting bitter."

[Maddel]

[baxsie]

[NewTechnicIan]

Haha I like the VW logos, how are they wired? Turn on when the door opens?
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My 73 Standard build - It's painted! It drives under its own power! Time to get it wired and upholstered!

My 1679 Engine build.

[baxsie]

[talljordan]

The door switches probably cant handle the amperage those lights will demand, so I would recommend wiring them up using a relay, transistor, or MOSFET.
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1972 Super Beetle, Parked until adequate restoration funding is acquired in restoration!

Wanted: Male computer diagnostic plug end