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My 1968 Bug Build
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Bradgt74
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PostPosted: Sun Dec 22, 2013 7:00 pm    Post subject: My 1968 Bug Build Reply with quote

Hey guys....I've been in the Bay forums for a few years, but just picked up a 68 Bug. It's pretty solid and the price was fair, so I convinced myself to start another project Wink It has been lowered the ghetto way, as it's missing the front lower torsion rods, and the shocks have been removed all the way around. This thing must have bounced down the road pretty bad.

My plan is to replace the rusted out pans, improve the suspension situation, fix the brakes, and install an engine. I'll post progress, but I'll tell you now this will probably be a slow project.

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1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
notchboy wrote:

You were drinking last night, weren't you Shame on you
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Joel
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PostPosted: Sun Dec 22, 2013 7:34 pm    Post subject: Re: My 1968 Bug Refresh Reply with quote

Are you gonna leave the body as is or paint it?

Bradgt74 wrote:
It has been lowered the ghetto way, as it's missing the front lower torsion rods, and the shocks have been removed all the way around. This thing must have bounced down the road pretty bad.


You gotta wonder WTF is going on in peoples heads when they do that sort of thing.

Hey man I can't drive my car anywhere but it looks cool just sitting in my back yard..... Rolling Eyes
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Bradgt74
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PostPosted: Sun Dec 22, 2013 8:10 pm    Post subject: Re: My 1968 Bug Refresh Reply with quote

Joel wrote:
Are you gonna leave the body as is or paint it?


For now I'm going to leave the paint. The roof has a nice patina starting where the primer is starting to show through. Green is the original color, but there has been some paint work done over the years. Depending on how much body work I end up doing may sway my decision on paint. (blend versus complete spray)
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1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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You were drinking last night, weren't you Shame on you
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sb001
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PostPosted: Sun Dec 22, 2013 8:33 pm    Post subject: Re: My 1968 Bug Refresh Reply with quote

Bradgt74 wrote:
It has been lowered the ghetto way


So you picked it up from someone off E. Lake Street? Razz

J.K. - I love Minneapolis!!
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Bradgt74
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PostPosted: Mon Dec 30, 2013 8:26 pm    Post subject: Reply with quote

SB001- Hit me up next time you're in town.

I started the teardown on the front beam. I confirmed there were no torsion bars in the lower beam, and the upper beam only had 4 Mad Here you can see the stupid threaded rod that was keeping the lower control arms in place.
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The lower left control arm's needle bearings were shot, which scored the cylinder pretty bad. I could smooth out the scoring, remove the bad bearing, and use a bushing at this corner, but then I think I better just source a used control arm and new bearing. Agree?
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My lower arms have these holes to deal with. Should I just weld a cap on the ends? Do the inside of the control arms ever seem to wear out? I'm a bit concerned from having just 4 torsion bars in the upper beam may have caused some excessive wear or "bow tieing".
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Time to track down some parts for the beam including new ball joints and shocks. Any suggestions are welcome.
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1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
notchboy wrote:

You were drinking last night, weren't you Shame on you
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jzjames
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PostPosted: Mon Dec 30, 2013 11:56 pm    Post subject: Reply with quote

I saw these on Craigslist, might ship?
http://seattle.craigslist.org/tac/ptd/4262605769.html
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Bradgt74
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PostPosted: Sun Mar 16, 2014 2:13 pm    Post subject: Reply with quote

It has been a cold and busy winter, which is bad news for project progress. I have been collecting parts, studying my books, and finishing my "honey do" list so I can get some garage time started!

I found a front trailing arm on Samba classifieds to replace my worn out one. I pressed out my old balljoints and pressed new ones in. I'd never done this before, but let me tell you...it took most of what my 10 ton hydraulic press could do. I took the boots off when I pressed the joints in to prevent damage to the boots, and used large sockets to mate up with the arm and joints. The pics without the boots show the importance of matching the notches in the arm and joint. The joint only has full movement in one direction. I installed balljoints with added movement capabilities since the bug will be lowered via adjustable beam.

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I have a solid long block available, but I still needed to source cooling tins, carb, intake, etc so I found a complete engine on craigslist. Come to find out it was owned by the same guy who sold me the bug. Laughing I'll be swapping all these items over to my engine.

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_________________
1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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You were drinking last night, weren't you Shame on you
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Bradgt74
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PostPosted: Sun Mar 16, 2014 2:25 pm    Post subject: Reply with quote

Oh, I did want to mention I found out the front torsion caps on the trailing arms are removable if you didn't already know. They simply pop out. This will make it easy for me to weld up the holes left from the leaf eliminating rod, and will allow me to confirm my leaf receiving profile in the trailing arm is in good shape. I was concerned they could be damaged by the PO using only a few leafs versus the full 10.

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_________________
1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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You were drinking last night, weren't you Shame on you
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Bradgt74
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PostPosted: Thu Mar 20, 2014 7:33 pm    Post subject: Reply with quote

I was originally going to install Avis style beam adjusters. I proceeded to grind the two recesses that captures the center torsion bar retainer.

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Once these were removed, my next step was to grind a slot for the Avis adjuster bolt to rotate through. (where the center torsion bar set screw is) I was also going to have to weld patch peices where the two recesses once were. At this point, I'm thinking this style adjuster seems to be more work than the weld in style, so I ended up ordering the weld in adjusters.
After marking a 3" horizontal line through the center set screw hole, I cut a two inch section from the middle of the beam.

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In this picture, you can see the weld in adjuster on the right, the Avis style in the middle, and the part I sectioned out on the left.

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


You obviously want to weld one in at a time to retain a straight beam. I'll be installing the top adjuster tomorrow, then it will be time to reassemble the beam!
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1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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Bradgt74
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PostPosted: Sat Apr 05, 2014 6:37 pm    Post subject: Reply with quote

I got both adjusters welded in. I started preping the beam for paint and found some rust holes at the bottom of the shock towers. The bottom drain holes were clogged which accelerated the rusting. I cut rot out:

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And welded in new metal.

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Once the beam was repaired, I cleaned it with a wire wheel, scuffed it with 220 emery cloth, etched it with metal prep, then two coats of Silver Masterseries.

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


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I will be painting everything flat black tomorrow, then assemble later in the week.
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1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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dubjeep
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PostPosted: Sun Apr 06, 2014 4:37 am    Post subject: Reply with quote

Nice work on the beam; it looks good.
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Bradgt74
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PostPosted: Sun Apr 13, 2014 6:32 pm    Post subject: Reply with quote

I painted the beam, replaced one of the beam bearings, packed all four with grease, coated all torsion bars with new grease, and got it assembled.

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I needed to replace my pans. I also didn't have a title for the bug. Both were issues, but not roadblocks. New pans would be ~$300 and filing for a bonded title in MN could run a couple hundred plus a pain in the ass worth of paperwork.

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Low and behold, my daily Craigslist creeping exposed a 68 pan with title and solid floors. Very Happy This route would save me money and time!

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_________________
1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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You were drinking last night, weren't you Shame on you
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Bradgt74
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PostPosted: Sun Apr 13, 2014 6:39 pm    Post subject: Reply with quote

I got to work cleaning up the pan via wire wheel. I did find a handful of areas that needed metal patching, but it wasn't more than a few hours of work. I'm almost done prepping for primer / Masterseries:

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


I'm not sure if I should coat the whole thing with Masterseries, or just the rustly pitted parts. I'm a bit concerned with adhesion issues on the clean metal.
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1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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You were drinking last night, weren't you Shame on you
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Bradgt74
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PostPosted: Sun Apr 27, 2014 2:46 pm    Post subject: Reply with quote

I scuffed the clean metal with 220 emery cloth then wiped it down with metal etch. I applied 2 coats of Masterseries. My next step is to seam seal, then 2 coats of chassis black.

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

_________________
1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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You were drinking last night, weren't you Shame on you
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Bradgt74
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PostPosted: Sun Apr 27, 2014 3:04 pm    Post subject: Reply with quote

I thought this over for quite some time, and decided to purchase another bug body to use on my build. I was growing attached to the green 68, but when I removed the floor pans, I discovered the heater channels to be in pretty bad shape on the bottom. My luggage shelf needed to be replaced, and my door sag was also something I would have to fix. Sad

I found a really solid 73 body. The heater channels are great and the door close nicely. The only welding I will need to do is by the back window due to death foam.

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


I'm bummed out that the body and pan won't both be 68s, but I suppose I can use the green deck lid and rear fenders and tail lights which will give it the older look.

So to sum up my build thus far, I started with a green 68, which is turning into my parts car. I am now using a different 68 pan and 73 body. I am a strong advocate for having a parts vehicle when working on a project, I just ended up purchasing in a different order. Smile

Who knows how this project will end up!!
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1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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Bradgt74
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PostPosted: Tue May 06, 2014 6:44 pm    Post subject: Reply with quote

I applied two coats of Masterseries chassis black via brush. It took alot longer than spraying, but it was easier to do in my crowded garage.

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


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


Next, I'll be bolting up the front beam, transmission, running brake lines, cables, etc. Assembly is definitely the most enjoyable part of a project. At this point, I have parts everywhere, and it is a good feeling seeing stuff come together Very Happy
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1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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Bradgt74
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PostPosted: Tue Dec 16, 2014 7:24 pm    Post subject: Reply with quote

It's been a while...better post an update. I had to put the Bug on the back burner this past summer so I could build a detached garage.

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Built some saw horses and got the body lifted off the ground.

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There was a sigh of relief when I was able to confirm my front beam adjusters were in a pretty good spot. Fender wheel gap looks pretty good.

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

_________________
1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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Bradgt74
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PostPosted: Tue Dec 16, 2014 7:36 pm    Post subject: Reply with quote

Started sorting the wiring out. Most of it's there, but there will be some splices and all that needs to be replaced. The green donor should have what ever I need on the wire side.

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I'm going to use the 68 steering wheel, but I need to sort out the washer column lever, as it contacts the wheel.

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


I've got a replacement apron. I'll be cutting this one out and attaching a removable replacement.

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

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1970 Westfalia http://www.thesamba.com/vw/forum/viewtopic.php?t=379526&highlight=1970+westy
1968 Beetle http://www.thesamba.com/vw/forum/viewtopic.php?t=579992&highlight=
1987 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=762500
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PostPosted: Thu Dec 18, 2014 7:44 am    Post subject: Reply with quote

Popcorn
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PostPosted: Thu Dec 18, 2014 8:11 am    Post subject: Reply with quote

very nice.
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