63 Bug Project - My first classic VW

[bit_boy]

The starter also seems to be a victim of undercoating over spray...

And I can't seem to find a replacement shock that matches this part number anc color. I've searched all the auto parts websites (O'Reilly, Auto Zone, Advanced Auto) as well as Amazon and such. Looks like Wolfsburg West is the only company that offers a stock type shock in red (but the part numbers don't match: 111513031G vs. 738330).

The parts list keeps growing! But, I have to admit, I'm having fun.

[grandpa pete]

While you have the brake system apart ; look into replacing the front and rear soft lines ....They can break down internally and you won't know until it won't stop
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63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

[bit_boy]

Thanks for the tip! It looks like all the soft lines were updated when the front and rear brakes were upgraded. But, I will certainly double-check them!

[andk5591]

On your shocks - if you want red - just repaint them.
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D-Dubya Manx clone - 63 Short pan,1914.
Rosie 65 bug - My mostly stock daily driver.
Woodie 69 VW woodie (Hot VWs 7/12).
"John's car" 64 VW woodie - The first ever
Maxine 61 Cal-look bug - Cindy's daily driver.
Max - 73 standard Beetle hearse project - For sale
66 bug project - Real patina & Suby conversion
There's more, but not keeping them...

[bit_boy]

Wow. Can't believe October has blown by. As usual I haven't done as much with the Bug as I would have liked.

I was able to get the pedal assembly rebuilt, but that had to be delayed until I had the correct return spring.

I started pulling the engine tins to strip and repaint. Tried sanding and scuffing with a wire wheel, but that took too long. Glad my company has a bead blaster they let me borrow on down time. The ugly green is going bye-bye!

Going with VHT wrinkle finish, just to try something different.

I found a shop in the area that was able to replace the damaged bearing housing. They also installed new trans cover seals, new wheel bearings as well as new axle seals.

Now the crud removal is in progress. Hope I can get it painted in the next few weeks.

[bit_boy]

Dang! Those pics look huge! I know I resized them... Hmm.

[offshores]

Cool project!!!

[bit_boy]

Thanks! Just doing what I can, when I can.

[ThingBeast]

Bit boy, what part of Houston are you in? I'm in the Sugarland area. I have a great mechanic that can do things that may be too difficult for the less experienced (like my electrical). Also, don't get discouraged working on the bug, keep it up little by little. That's how I've done working on my 61 Gulf Blue bug, 1 step at a time and now I'm done to the last stretch of getting my seats redone. If you want, you can do a work party date at your house and several locals would love to swing by and give you a hand and knock out a bunch of work in a day....

[offshores]

I hear that. I had a pretty good stretch of doing stuff on my project and then it just came to a stop. No time for it. Looking forward to getting after it again soon. Good luck on yours and I'll be looking forward to the updates.

[bit_boy]

ThingBeast, thanks for the offer to help. It is appreciated. I'm on the north side of town near the Woodlands. I've tried to find mechanics and part suppliers either in my immediate area or close to my office (290 @ West Little York). But, it's been difficult. I hadn't thought about a work party. That sounds like a great idea, just need to get the wife to agree to it! LOL.

Thanks for the encouragement guys. I do get bummed when I can't get out to the garage. I try to look at it from the "How do you eat an elephant?" view point.

[ThingBeast]

bit boy,
Call Kermit at KAR parts. He has a great selection of parts for your bug, His number is 832-843-1616 and he is at:
2646 Greens rd
Houston 77032
He is over by Bush Airport. I go to him whenever I need something quick and can't or don't want to wait on CIP1 shipping me something. The mechanic/body shop guy I use is in Pasadena. He is a great source for work you don't want to do or can due to lack of experience. I can get you his phone number if you wish, just let me know...

[bit_boy]

Awesome! Thanks for the tip! I'm in that area all the time. Good to know there is a classic VW parts shop on my side of town.

[bit_boy]

Was able to take some time off over the holidays and luckily I had a few days to work on the Bug.

Finished cleaning the tranny and finally got it painted as well as reinstalling the brakes.

Installed the new valve covers and some of the repainted cooling tin.

Installed the new tranny mounts and got the tranny mounted.

Almost ready to install the engine.

Installed new engine bay seal and got the engine in... FINALLY!!

[bit_boy]

Also started fitting the 67 brake reservoir and working out those details. Looks like I will have to trim the hard lines from the reservoir to route the lines over the top of the front beam.

I started getting all the electrical hooked back up to the engine last night. Broke a green wire off the distributor that goes to the coil. My DOH! moment for the evening. The brittle wiring is having me rethink whether or not I should get a new wiring harness and rewire the car.

Got the belt back on the alternator and noticed it sounds like the fan is rubbing on the inside of the housing for about 50% of rotation. Hate to take all that back apart but more worried about it binding when the motor is running. Grrr...

[jzjames]

Like it! Youre going to keep the original paint.
The fan rubbing on the shroud can sometimes be fixed by just loosening the generator on the stand and pushing or pulling on it to mount it just a few mm in a different position.

[vwnut1]

Excellent progress in a short time period. The car appears to be pretty solid and rust free for the vintage, excellent choice.

I like how you are starting with the brakes, suspension and drivetrain before starting on the "cosmetic" portion of the project, the rest will be down hill from here. Did you end up pulling/reinstalling the the engine and tranny by yourself?

I had great success using Eastwood's Rust Encapsulator on my floor pans. I used a wire brush attachment on my drill, made sure the surface was cleaned properly, and then applied 2 thin coats of the product. I would suggest a respirator when applying because of the strong solvents used in the product. Keep thse pics coming and looking forward to following your build.
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1957 VW Oval Resto Mod

[bit_boy]

[bit_boy]

vwnut1, I had a friend help me pull the engine and transmission. But, reinstallation was done by my with the help of my 9 year old son. I'm so glad he wants to help me work on the Bug!

My biggest gripe would be the floor jack I have didn't have enough lift height. I had to remove the fan shroud, carb, and alternator to be able to slide the engine out from under the car. But, it's all going back together fairly well.

I know I can't make as much progress as fast as some can on their projects, but I'll try to keep taking pictures and updating the (re)build.

[bit_boy]

I've been able to make some progress since my last post. I've installed a new throttle guide tube, hooked the cable up to the carb and rewired the points. I've also finished the strap for the new MC reservoir, but no pics of that yet.

I picked up a new gas tank last week, but found the lip is a bit wide and will need some trimming to fit properly. Had hoped to save the stock tank but proper restoration is not in the budget at the moment.

My biggest "Yippee" moment was being able to get the floors painted. YES!! FINALLY!! Mixed up the rust killer paint and applied it yesterday. One more step off the checklist. (And, yes, it is as thick as it looks. Not so much "painting" as it was "spreading". )