63 Bug Project - My first classic VW

[bit_boy]

Greetings all. Been on here reading, researching, and shopping for a while and finally picked up my first classic VW. It is in overall decent shape, just needs a few things to get her on the road. I'm going to try and document my progress along the way.

I picked her up from a nice guy out in Tomball. It was listed on the classifieds here for a while and after much research and too much over-thinking, I decided it was "The One".

On to the pictures!

[bit_boy]

More pictures...

[bit_boy]

Rusty pans, but no holes through and through. Mostly surface rust as far as I can tell (already started prepping for rust inhibitor). Heater channels are intact.

[bit_boy]

Worst of the exterior rust.

Cool old sticker on the bumper (may keep it just for grins).

[bit_boy]

One of the things to repair on my growing project "to-do" list. PO had a little mishap towing the car to a swap meet a few months ago. Concrete at 50 mph is a pretty good abrasive!

Oh well... Tried to edit the original image, but the link is jacked so the edit isn't showing.

[bit_boy]

The car is pretty complete minus the seat covers, headliner, rear panels, etc. The PO had installed an adjustable beam, front disc brakes, new shocks all around, and a few other things.

The engine runs, but I need to hook up the fuel lines and get the tank fixed. It has some rust inside, so I may just get a new tank from JBugs. Unless someone has any comments on the process of using rust inhibitor and resealing it.

Have slowly been working on it as time permits. Have stripped all the remaining old tar board off the floors and the little left on the fender wells. I've also started working in the rust on the pans. Using various wire wheels and such I've found that most of the rust is surface rust. There are some thicker crusty areas, but I'm going to coat both pans with rust inhibitor.

Debating on what to do with the exterior paint. It's obviously been painted at some point in its life, as there is light blue paint over the front fender beading. I may try some method of paint removal to get back to the original Gulf Blue (I think that's correct for this year model).

But, that part of the project is lower down my list of priority. I really want to get it back together and drive it!

[61Ragster]

Yeah, keep that Navy sticker. Blue stickers indicate an officer and the guard at the base entry gate will automatically salute! A red (as I recall) sticker indicates an enlisted man's vehicle, and the guard will just wave you onward, since you are merely a low-life same as him (or her). You know an officer isn't gonna be pulling gate duty!
And before any of my fellow veterans out there don't recognize my sarcasm and want to take issue with my "low-life" reference, I gotta say I never got above E-4, and that was in '68.
Peace, and "Welcome, home, Brothers" to whomever that may apply.
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[url=http://www.vw-mplate.com/mplate2-12938.png]Click to view image[/URL]

[grandpa pete]

Looks like a nice solid base to start from
Which direction are you going in.....resto ....modified....drag car???
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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]

Right now I'm leaning towards a semi resto. All the interior paint is original and in good shape. I'll probably redo the interior, get the electrical in order, then drive it while I save up for the body work. I'd really like to get it back to the factory blue.

[andk5591]

Nice start - should be fun!
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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...

[63Ragtop NZ]

Looks like a nice solid base there bit boy, did he lose the rear wheel in tow?!
I really like the deep rims on the back, very cool.
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If you can't join them, beat them!

[bit_boy]

63Ragtop NZ, yes that's exactly what happened.

The PO said he installed type 3 drums on the rear to run 8" wide wheels.

I like the look as well.

My biggest fear is losing the momentum on the project, so I'm trying to work on it as I can, even if that means and hour here and there.

[grandpa pete]

Safety note : look into changing your single circuit brake system over to a 67 dual circuit master cylinder

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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 grandpa pete. The PO had already installed a dual circuit MC when he installed the front disc brakes.

I'm curious about the extra lines feeding into the top of the MC. Do those go back up to a reservoir at the stock location? Here's my current set up.

[grandpa pete]

this will show you where I replaced the 66 single reservoir with a stock 67 dual reservoir....
I wanted the easiest way to replenish the brake fluid AND if I have a problem in the future all the parts are readily available and I don't have to figure out what type of reservoir someone stuck on top of my master cylinder ( hint , hint , )

I don't see wires running to your rear brake warning switch ? why ?

The arrow on the pink tape points to where I secured the blue lines to the frame head using an existing mounting tab and a tye wrap
The white arrow is where I wrapped a piece ofblue hose around the brake line to avoid wear against the frame head

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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]

Good question about the wiring for the brake lights. I'll have to look into that further. I think most of the wiring is intact, but I know the headlights and tail lights are not hooked up. The rear fenders were removed and non-OG fenders installed at some point.

The PO gave me a couple of repair manuals that I've started reading (How to keep your VW Alive and a Haynes or Chilton). A little daunting for someone that has never dealt with a car of this vintage, but I'm up for a challenge.

I do like your install of the larger reservoir in place of the small original. Very neat and tidy job on the lines and wiring. Hope you don't mind if I copy your idea!

[bit_boy]

Made a little progress on the Bug. Did more grinding/scuffing on the floors to get ready for the rust killer application.

Removed the pedal assembly which looks like I'll need to take apart. I need to replace the brake pedal spring, strip the old paint and repaint the parts.

I've done more digging into what type of master cylinder is on the car. It actually looks like a dual MC that might be used on a buggy or sand rail. It also only has one brake light switch on it.

I'll order a '67 dual MC, brake lines, brake light switches and reservoir to make the conversion complete.

Oh, and it looks like I'll need a new main brake line that runs front to back. That's looking a little crusty!

** Sorry for the flip flopped pictures. Not sure what's going on with that. They look fine on Photo Bucket! **

[jzjames]

What kind of " rust killer application" you gonna use on the floors?
Word of caution; you may be less than happy with Por15. That stuff is bogus in my opinion. Your floors are relatively solid, I wouldnt recommend "rust killer" stuff. I doubt the floors will ever be left soaking in moisture again.

[bit_boy]

I'm using an industrial two part epoxy. Probably overkill for this application, but it was free thanks to a buddy that works in the chemical development area of a major oil/gas/chemical company.

I may also coat the inside of the fenders and under the gas tank for more exposure to the elements. Curious to see how it holds up.

[bit_boy]

Progress since the last post!! My new brake MC and parts came in late last week. Disassembled the pedal assembly and have been cleaning parts. Pulled the engine and tranny to replace the damaged bearing housing and install new axle seals. Inside of one drum was wet with oil. Looks like I may need new gaskets for the side covers as well, based on the oily build up. Some of it looks like undercoating over spray, but I haven't tried scraping it off yet. Oh, and I'm working on removing all the tins while the engine is out so I can get rid of that horrible green color!! Gag!