How to chop your Beetle by Clark Customs

Clark Kustoms · Posted: Wed Mar 04, 2009 9:34 pm Post subject:

Image may have been reduced in size. Click image to view fullscreen.

Now cut the rear window area away.

Heres the other side trimmed already.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:45 pm Post subject:

You can just slide the rear part of the roof section into the quarter panel.
walk around the car look at it from all sides.Theres no sure way to measure this area, i used a hole for the trim
and just went strait up.
Just to get an idea from side to side. You just have to stand back and make the rain rail flow.
Note how the middle of the rain rail is strait with the bottom of the car.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:49 pm Post subject:

Mark where the rear window sections go then set them aside.
The rear roof section is next, you can use the section you cut off or in this case i used a oval section.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:56 pm Post subject:

Later ill cut through both these pieces once i get them lined up.

I trim the inside of the rear window areas so they will over lap the oval section.

I can fill the inside later where the gap is.
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Clark Kustoms · Posted: Wed Mar 04, 2009 9:59 pm Post subject:

Once i look it over for the correct flow of the rain rail and line up the marks from when i lined up the rear window
sections. I cut through both sections and weld it in a few spots.
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don.ville · Posted: Thu Mar 05, 2009 1:08 am Post subject:

Now I have a much better appreciation for the work that goes into a chopped top.

I thought it was much easier. (Cut, bend, weld).

Press on teacher, press on.

BTW: You still have the Barndoor Ice Cream looking like your avatar? When you gonna get a move on it?
You should pitch it to Ben&Jerry's for a promo vehicle. they'd prolly buy it and make you finish it. Smile

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66busman · Posted: Thu Mar 05, 2009 9:26 am Post subject:

Damn Chris, great work! Thanks for the tutorial!
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IRCutman · Samba Member Joined: April 11, 2007 Posts: 5

Follow your projects on VR.com...
This is great work...
more, more, more...
My 72 daily may not be safe after seeing this.

Clark Kustoms · Posted: Thu Mar 05, 2009 9:04 pm Post subject:

You can see here how those 'b' post being taller helps. It comes in contact with the roof
skin and if you cut both sides the same it will help you center the roof. If you use a roof skin from a different car
than it could be cut larger than the new opening, saving work later. Im not so lucky.
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Clark Kustoms · Posted: Fri Mar 06, 2009 4:52 pm Post subject:

Now that all the pieces are in place , walk around the car and make sure it looks right. It can be adjusted at this point.
Roll it out in the street, look at it from far away.
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Clark Kustoms · Posted: Fri Mar 06, 2009 4:54 pm Post subject:

I like to over lap this part, just in the middle.
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Clark Kustoms · Posted: Fri Mar 06, 2009 4:57 pm Post subject:

Now tack the roof in place. I held some strips under the gaps in the roof
sprayed them with paint then trimed the paint line for a tight fit.
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Clark Kustoms · Posted: Fri Mar 06, 2009 5:01 pm Post subject:

I like to jump around from side to side, welding in spots no bigger
than a 1/4''. Screw the row of nickels, just keep the heat down.
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Clark Kustoms · Posted: Fri Mar 06, 2009 5:03 pm Post subject:

You can see the cut i made next to window lip to (narrow) the post.
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Clark Kustoms · Posted: Fri Mar 06, 2009 5:08 pm Post subject:

I like to scrub the welded area with w wire barbque brush as i go,
makes it easyer to see what is welded and what isnt.
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Clark Kustoms · Posted: Fri Mar 06, 2009 5:09 pm Post subject:

Mirror delete...
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Clark Kustoms · Posted: Fri Mar 06, 2009 5:11 pm Post subject:

This is the post from the other side, it has the curve i need for this side.
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Clark Kustoms · Posted: Fri Mar 06, 2009 5:11 pm Post subject:

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Clark Kustoms · Posted: Fri Mar 06, 2009 5:14 pm Post subject:

Heres the inside gap filled...
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Clark Kustoms · Posted: Fri Mar 06, 2009 5:18 pm Post subject:

There you go, grind and grind and grind some more. Dont over heat
the metal with the grinder. Go find a baja and give a new look...

Cool

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How to chop your Beetle by Clark Customs
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