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My 1970 Vw Bug build
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kyleader
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PostPosted: Fri May 20, 2011 10:54 pm    Post subject: My 1970 Vw Bug build Reply with quote

Well I figure it is time to create a build thread for my bug. I bought it in March 2011 and have been slowly working on it over the weekends when I have had some spare time. The future goal will be Baja Bug but for now I will be restoring it and fixing everything up.

Day 1:
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I then began to fix everything that I found to be, lets just say, interesting…
I washed, waxed, and slay barred the bug the first weekend. I also changed the engine oil to Castrol SAE HD30, and the tranny oil to Castrol Hypoy-C. I then fixed the window wipers and got the water to spray and from there I drove it everywhere (having a blast!) and started making notes of what I wanted to replace/fix.
Misunderstood which side the tranny fill plug was on, but snapped a pic of the Koni shocks I found on the rear of my bug:
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Some misc beautifying:
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Also sprayed the vent down with black Krylon after sanding off the white over spray.
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I then sanded down some cancer spots and ended up REALLY getting it all out…
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On that back side of that body panel the factory VW rubber insulation mat was looking nasty + rusty, so I took it off and scraped all that plastic off. *Need to get pics.

These holes were where the passenger side mirror connected to the door: Yes, they were drilled INTO the door.

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Pic of the wiring from when I bought it:
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After about a week or 2 of driving, my bug started to accelerate poorly and eventually wouldn’t start in my driveway. Time to boil out the carb (There was no inline fuel filter at the time).
I went to the local VW store and bought the rebuild kit for my Weber 32/36 DFAV carb, then realized I should buy some other stuff as well.
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Carb rebuild kit, EMPI intake seals, EMPI filter (the one that came with it was BLACK and no matter what I could not seem to get it anywhere near clean). I also bought some distributor wire organizers.
Here it was before I took it off:
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My current jetting:
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And afterwards, at night. I sand blasted the intake body (Empi brand) as well.
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After re-adjusting the idle and fuel mixture screw she was running smooth. Time to de-ghetto other items.

These bad boys are the ‘spider mirrors’ online and looked pretty bad IMO.
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The fix: Factory VW mirror…
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Then… These burnt wires started the giant wiring diagnosis that has consumed many of weekends.
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There were 2 wires burnt allllll the way through the bug up to the hood. I wired in 2 new wires for the time being and drove it around like that (still no brake/blinker/running/ or reverse lights).

Ahah! I found the wiring diagram for my beetle so the fixing began.
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My friends and I got everything to work except the blinkers actually blinking- however when I tried everything with the parking lights on everything got messed up/reversed so I drove my truck for the following week until I had more time to work on it.
What do you know, it rains for 2 days…
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I kept tinkering with the wiring and began to realize I couldn’t stand looking at my engine bay with this spray glue residue all over the place.
Before:
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After about 20 minutes:
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After a good week:
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I still have tons of cleaning to do in there, but I think it looks much better.


Fast forward until today and I got my Wolfsburg West package.
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1 passenger side window regulator, 2 rubber window channel lift mats, 2 outer German window scrapers, 2 inner German window scrapers, 2 new pedal covers, hood release cable (Mine broke when taking out the glove box), emergency flasher switch, headlight switch, WW flasher relay, light switch cap, dome light bulbs, gas door release handle, and I bought a dome light online as well.

The passenger door with the panel off: *Beginning to clean*

I finished up the emergency switch wiring: I cut off the old connection, put new one son with a built in weather guard, and used shrink-wrap as well.
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Guess which is new for the next 3 photos!
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And a nice pic of the previous craftsmanship: Note that the dome light was ‘smleted in the middle. And when turned on- it sparked and blew a fuse.

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And that catches us up to today. I find it entertaining to watch other people update their bugs, so I hope you enjoy my build as well.
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str8buggin
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PostPosted: Wed May 25, 2011 3:01 pm    Post subject: Reply with quote

Seems likes it's coming along great. Does your dome work? I'm trying to get mine to and I can't get it figured out, I have power going to the wires but can't get the thing to turn on.
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Nirvana92
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PostPosted: Wed May 25, 2011 3:38 pm    Post subject: Reply with quote

any new updates? im interested to see how its coming along....i get to work on my '70 all day tomorrow finally!!! Very Happy
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kyleader
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PostPosted: Tue Oct 18, 2011 12:45 pm    Post subject: Reply with quote

WOW! I sure did lose track of updating my thread... Probably because I’ve been working on her so much Smile.

Lets see... I left off with a tarp over my bug and the electrical almost finished. I should also note that EVERY screw/bolt that I removed for the door parts I replaced with Stainless Steel Smile

*Resuming...


I finished installing new switches. Hazard and Headlight
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Found lots of 'weird' wiring..
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Cleaned up my Generator wiring, and added a stainless Steel generator clamp.
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After driving her around confident in the electronics, I started to realize how loud she was... which turned into one BIG project! That's right... Dynamat!

Here's the driver side door all factory sound insulation etc.


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Here it is after I sanded off all/any rust, removed ALL grime, and primered:
Clean:
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The Brown Primer was for 'rusty' metal, which it hardly was at the bottom but I figured since this is where any rain would collect if it were to drain down, it wouldn't hurt.
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And the end result:

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I of course did it to the passenger side door as well:
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Paint:
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Last edited by kyleader on Tue Oct 18, 2011 12:50 pm; edited 1 time in total
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kyleader
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PostPosted: Tue Oct 18, 2011 12:48 pm    Post subject: Reply with quote

I guess I forgot to take pics of the Dynamat on the door! Sad. I guess you’ll have to believe me lol.

After installing the Dynamat I proceeded to install the new window regulators, felt liners, window scrapers, wing window seals etc etc.
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I also sanded down anything that I was to re-use such as the felt liner holder:
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And primered/painted them to keep them fresh for ages to come:

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While working in the door area I fixed the door knob so it actually stays in place!
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I then installed new door panel clips and rubber retainers.
Doors… check!



Well, like most of my projects, they turn out to be much more involved... A couple more Dynamat orders and I was ready Smile

Rear luggage area with the factory carpeting etc removed:
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That board stuff was the biggest pain to remove and clean up!!!

I then sanded it ALL down to locate any rust etc (One small rusty area the size of a pea-fixed).

I guess the only pics I have are of it half painted when I realized I forgot to take complete pics :X
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I used the horizontal factory gap in the firewall as an X-axis, and measured points on one side then mirrored them over the middle (Y axis) to create a perfect fitting Dynamat strip:

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For the rear luggage area I first laid down Dynamat Original: *Note the ‘slices’ I used to fill in the gaps a bit.
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kyleader
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PostPosted: Tue Oct 18, 2011 12:50 pm    Post subject: Reply with quote

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After laying down the Original I then put the second layer on (Dynamat Extreme) :

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I went as high as I could without destroying the headliner fabric:

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And a teaser:
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Yup! I went ahead and did the quarter panels as well!
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All done:
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And she was happy for a while… but I had more plans for her J

Cleaned up/polished eyelids:
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Note to self: Do not misplace the mirror gasket!!
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Dynamat was so very well WORTH IT! I found a pretty good deal on the Door Kits (12sq. ft). BTW guys, the door kit is perfect for the length of our doors, no trimming required and no excess- literally perfect! I LOVE how quite it is now Smile

Guess who found the old one much later…

I have MUCH more to update, but I am about to head to school. I’ll update the rest soon, and will keep up with my thread better!
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mrbigmax
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PostPosted: Tue Oct 18, 2011 6:25 pm    Post subject: Reply with quote

Keep up the good work. You used the term craftsmanship. Don't you mean "craftsman$#&*?"
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buysell
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PostPosted: Tue Oct 18, 2011 9:50 pm    Post subject: Reply with quote

Applause Excellent work!
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fivelugshortaxle
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PostPosted: Wed Oct 19, 2011 3:06 am    Post subject: Reply with quote

Please don't ruin that car by turning it into a damn Baja......go buy a rail.
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42x37.5 ported heads...dual springs
Dual Dellorto 45's
Bugpack 1 5/8 merged header w/ single muffler
Bosch 010 distributor
Straight cut cam gear
1.5 quart deep sump

Parts bought...assembly started.
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kyleader
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PostPosted: Wed Oct 19, 2011 9:49 am    Post subject: Reply with quote

fivelugshortaxle wrote:
Please don't ruin that car by turning it into a damn Baja......go buy a rail.


Only time will tell. I'll tell you this though, the more i've been restoring the harder it is to think about cutting her up. More updates today!
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smokey503
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PostPosted: Wed Oct 19, 2011 11:16 am    Post subject: Reply with quote

Not sure or not, but is that one of those red clear distributor caps? If so, you might want to change it to a stock one. I hear those are pure garbage.

Would you mind letting us know how much you spent on Dynamat please?
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kyleader
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PostPosted: Wed Oct 19, 2011 2:21 pm    Post subject: Reply with quote

I have been writing down EVERY purchase onto a list, as well as holding receipts and contact #’s, as well as trying to find Factory manual pages etc. I’ll look up the Dynamat for you shortly.

Lets see… I guess nobody realized only one of my running boards had the chrome strip? Not only was the rubber tops cracking beyond repair but the bottoms were quite rusty. As luck would have it, my friend and I went to the local junk yard and there was a complete bug there, with some goodies I wanted.

My fuel gauge doesn’t mark the reserved as red, and I found a gauge that had the red marking so I pulled that, just to mix it up for awhile (Though I still haven’t put it in).
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Aluminum Running Boards! I just got done cleaning the right side to compare with the left. They had 2 layers of over spray in some places! After realizing how much they go for new, I didn’t hesitate to purchase them at a fraction of the cost.
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After removing my factory running boards I sanded, primered, and painted the channels that the running boards are attached to.
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I used electrical grommets vs. the factory rubber washers :
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The end result:

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I have been debating on painting the top of the running boards black, then sand the tops of the ridges so the aluminum contrasts with the paint.
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75smith
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PostPosted: Wed Oct 19, 2011 2:39 pm    Post subject: Reply with quote

very nice, now I need to go work on mine Very Happy

I would personally paint the boards black and sand down the tops, I think it looks better(tip for sanding-take a 2x6 about 8ft long put a strip of sandpaper down lengthwise across the middle of the 2x6 and run the running board lengthwise down the 2x6 so you get even sanding)
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DrummerDaveB
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PostPosted: Thu Oct 20, 2011 10:05 am    Post subject: Reply with quote

Looks Great!
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kyleader
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PostPosted: Mon Oct 24, 2011 3:03 pm    Post subject: Reply with quote

I figured it's time to update you guys.

At this point in time I was looking for more performance, and with my background in dirtbikes, quads, and Nitro remote controlled rc, it was time for a carb.

As im still unsure as to which direction I will go, I stayed with a single carb (less fuel slosh = better for bumps etc). I found what you could say was a GREAT deal on a Zenith 32NDIX P010 carb with the plenum manifold.

Dirty:
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Reviewing the jetting that came with it:
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I then bought the choke block off kit from Air Cooled Engineering (ACE).
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I then sandblasted the iron base, then painted with Satin Rustoleum:
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After the correct jet sizing from 356 carb rescue, ACE block off kit, a TON of cleaning, and a rebuild kit:
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Unfortunately the seller thought his accelerator pump was the short one (needed for single carbs), but it turned out to be the longer one. Here's a pic of the short vs. long one. Luckily the short one that came with my carb was still in good condition so I re-used it.
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Ready to go! With a sandblasted plenum manifold AND poly urethan black manifold couplers. I also installed new fuel lines from the metal line off the chassis to the fuel pump, and to the carb. I protected the metal line at the firewall with some fuel line as well as precautionary measure. I mounted the fuel filter right after the metal line from my chassis. Does anyone know which brand this manifold is? Deano possibly? There is a Z printed on the base where the carb bolts on.
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Installed! With a K&N filter of course Smile
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I then cleaned up my old carb and put her up for sale:
Weber Progressize 32/36 DFAV
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At the same time as the carb install I knew my 205T distributor would not work with my carb setup (vac advanced)... so after talking to Glenn Ring on this board, I bought a beautiful Bosch 019 centrifical advanced rebuilt carb.
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I then installed the Petronix Electronic ignition inside it:
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After all of this I was more than happy with the performance gains. It revs out quicker (steeper slope) and the only limiter was now my 1600 Smile.

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A little offroad action Razz
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oxfordethan
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PostPosted: Mon Oct 24, 2011 7:53 pm    Post subject: Reply with quote

mrbigmax wrote:
...You used the term craftsmanship. Don't you mean "craftsman$#&*?"


Exactly how I feel about some of the things I've done to mine. LOL ! Going in my sig line. Like mrbigmax said, "Keep up the good work." Looks great. I'd love to have the mags.
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'69 Bug being rebuilt
http://www.thesamba.com/vw/forum/viewtopic.php?t=374620
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kyleader
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PostPosted: Mon Oct 24, 2011 9:28 pm    Post subject: Reply with quote

oxfordethan wrote:
mrbigmax wrote:
...You used the term craftsmanship. Don't you mean "craftsman$#&*?"


Exactly how I feel about some of the things I've done to mine. LOL ! Going in my sig line. Like mrbigmax said, "Keep up the good work." Looks great. I'd love to have the mags.


Their growing on me, at first I wasn't too much of a fan but i'm liking them more and more everyday.

They are called Shelby Mags correct?
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xsocalpbx
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PostPosted: Mon Oct 24, 2011 9:38 pm    Post subject: Reply with quote

Looking good bud, any plans on new wheels? suspension?
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kyleader
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PostPosted: Tue Oct 25, 2011 9:55 am    Post subject: Reply with quote

xsocalpbx wrote:
Looking good bud, any plans on new wheels? suspension?


I find the stock steelies with paint to look quite nice, but I am still unsure of what direction I wish to go with as far as suspension goes. Having a lowered bug would be cool, though I'm already scrapiung my exhaust as she currently sits.
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kyleader
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PostPosted: Wed Nov 02, 2011 9:09 pm    Post subject: Reply with quote

I removed my deck lid extensions, so the deck lid actually fits flat now:
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AND installed a brand new decklid spring, WOW does that make life easier!
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I did these mods to make the next mod MUCH easier Smile
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