How to chop your Beetle by Clark Customs

Clark Kustoms · Posted: Tue Mar 03, 2009 11:27 pm Post subject:

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Heres the inside cut line...You could just lean the rear
window down buy cutting a pie section out behind the
rear side windows, but it doesnt line up as nice at the
decklid area.
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twinwindows · Posted: Tue Mar 03, 2009 11:47 pm Post subject:

What about keeping the window per portioned to the rest of the windows I.E. shortening the rear glass height and you wont have the deck lid problem.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:07 am Post subject:

That would work as well. In fact this car will be a volks rod and
the decklid can be at any position, but a fendered car would
need that area angle stock. You would need to leave the vents
and chop the window.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:15 am Post subject:

Now theres no turning back. Start at the front and note where i cut the
posts.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:21 am Post subject:

Now cut off the tape sections and in the previous photo you can see
a mark in the middle of the door post to be cut.

Note... The roof gets wider as it gets lower so everything spreads apart.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:48 am Post subject:

After you cut the tape sections off save them.
Note the relief cut in the post so its the same width as the roof post.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:53 am Post subject:

You can see i used the 'a' post section i cut off as a guide. Now the front sections are both the same in position and 3 3/4'' lower.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:55 am Post subject:

Heres a good way to hold the middle together and you can see how much
the roof get wider.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:56 am Post subject:

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Clark Kustoms · Posted: Wed Mar 04, 2009 10:02 am Post subject:

Heres how much the front section moved forward. Now i use the doner
roof section and transfer this amount over to it.
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Clark Kustoms · Posted: Wed Mar 04, 2009 10:06 am Post subject:

4 1/4'' from the 'b' post forward is the tranfered amount from the car.
Cut it a little big and grind it back to make a tight gap.
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Clark Kustoms · Posted: Wed Mar 04, 2009 10:12 am Post subject:

See where my thumb is , that line is where the car is cut.
I cut the doner section higher, i'll show you why later.
Also the section is cut about 14'' long, but it will need to be cut back later,
its easyer to tell where to cut that area when its welded to the car.
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Clark Kustoms · Posted: Wed Mar 04, 2009 10:15 am Post subject:

Resist the temptation to make it a truck just to save work. Laughing

The rear sections need to go now.
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Clark Kustoms · Posted: Wed Mar 04, 2009 10:18 am Post subject:

The rain rail is your guide. The body line on the top of the roof can
be tweeked with filler later although it sould be close.
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Clark Kustoms · Posted: Wed Mar 04, 2009 10:26 am Post subject:

Note how i just tack things in place.
Thats so i can move it around is i need to.
Also i cut the door tops apart and lined the rear section up as well.

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Clark Kustoms · Posted: Wed Mar 04, 2009 9:08 pm Post subject:

Now i marked the 'a' post at the point where i cut the door.
Now i hold a door top from a doner door. I cut the 'a' post area of a doner door at the same place i cut the
door on the car.

The top of the doner door is cut about 4 3/4'' past where the door on the car is cut. The idea is to fill the gap
in the door left at the top with this longer piece. Now i mark where the doner door piece ends.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:13 pm Post subject:

Now set the piece aside and close the door and mark the door where the donor section ended.
Cut square, it will make less work later.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:22 pm Post subject:

Here you see where i cut the door to make it thinner.

Inside too.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:23 pm Post subject:

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Clark Kustoms · Posted: Wed Mar 04, 2009 9:29 pm Post subject:

By marking the posts this way you end up with more flat area.
It keeps the rain rail strait 2'' more.
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