Deserter Series 1 build

[BIGMIKEY]

With the chassis now a roller I started fitting the body. As far as I know this buggy was an original build before the guy I bought it from disassembled it. It then sat for years until I got it. The body is actually pretty clean as far as hackery goes. There are holes to fill which is typical but don't seem to be any extras. It had a top at one time evidenced by the holes for the snaps. Little repair needs to be done except the unfortunate engine access "Hood" cut in the back. I will get to that later.

After sitting for decades not bolted to a chassis the body mount lips edges were twisted up some and curled inwards. Had to deal with that.

When I set the body on the chassis I saw it wanted to kick off to the left exposing too much tire sidewall on the right front and not enough on the left. Can't let that go.

I saw the body was hitting the right torsion bar cap. It was also pushing the body forwards and the area over the Napolean Hat would not line up. I opened up the body in front of the torsion cap to allow it to straighten out.

There was a sizable gap over the rear crossmember too. I used the stock holes in that area to draw the body down. It bolted down pretty evenly all around.


I had to "Persuade" the body at the napolean hat to take on the shape of the chassis in those areas using long bolts in the front and drawing it down gradually. There were a few crackles and pops but it settled in and it evened up nicely. Carefully applied heat fom a heat gun helped ease the body back into shape.

To get the body centered over the tires I put a shim between the body and the napolean hat to raise it up enough to move the body enough to make tire stickout even. There are 4 holes at the front of the pan, two on each side. I used 2 of those holes, one each side and drilled up through those holes and through Buggy body flange. I took two long 5/16" bolts and nuts with big washers to ease the body down a bit at a time.

I used some braces and clamps to get everything in place.

The exsisting holes in this previously mounted body mostly lined up with the holes in the new floor pans after I used levers and braces to get the body unwarped then bolted it down. I had to push the body outwards on the drivers side to get the body mounting flange to align with the pan rail.

Now all the tire stickout is uniform.

The right rear fender had warped and curled inwards from sitting for decades. i put these wood shims in and heat cycled it over the course of months to try to restore the proper shape.

Mike T
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BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[Murphy's Law]

Good job, Mike! I'm finally a roller but at the moment I'm fighting too many projects to do more than putter on mine. The pre-tag has gone off to my younger brother the 'glass guru to turn it into a Manx II and flatten the rear seat to fit my IRS. He wanted my '82 Harley and I wanted to speed up the build so win-win!

I sent the rear of the Deserter down with the body and it's for sure he won't be using the engine cover, just the left rear inner. If you still want it when you get to that point, it's still yours. I haven't forgotten about it.

[BIGMIKEY]

Thanks Murphy's Law. I appreciate it.

Mike T
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BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[BIGMIKEY]

Except for the Western Bullet wheels, which I decided I didn't like, this is the current state of the Buggy. I am doing a mock assembly with all the parts that came with it. I can set the ride height and steering wheel position then.

The dash is bonded to the hood and is very rigid. I may not need a dash subframe.
Note the tall windshield. Works out well because otherwise my eyes would be looking over the top of it frame even with the Porsche 914 seats mounted as low as they will go. The extra 4" of wheelbase really helps with legroom too.

Mike T
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BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[BIGMIKEY]

Back working on this. Cold weather kept me out of the shop for a while as it isn't heated. Can't take the cold as well as when I was a young man. I also had to work on my daily driver Silverado so that killed a few weeks. Lately I did manage to work a few hours here and there and got some things done. Since it's still too cold to do fiberglass repair I will turn to the parts to be assembled. I am assembling the buggy completely to make sure everything fits before blowing it all back apart for bodywork and paint. Fitting seats, steering, brakes, windshield, roll bar etc, and the engine.

The engine is a 1968 1500 that I had apart to re seal the top end 10 years ago. It's actually a 83mm bore so still a 1500. I have that on an engine stand to clean up for installation.

The buggy came with Dietz 820 headlights and Chrome 62-67 style tail lights that were original to the Buggy. Nice Chrome. Also a Lucas License plate light. An interesting thing is the small light lens in the back of the headlight on the drivers side. It is wired to the high beam side of the light plug evidently an outside high beam indicator.

The light just hangs on the back of the plug, I guess with the bulb installed it's fairly close to the lens. Need to test it to see how effective that is.

I like that unique feature. I will keep that.

The stickers show 1978 as last year it was registered. Inspection is overdue.

The buggy is filthy too from sitting in the corner of my shop since 2012. Needs a bath.

Mike T
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BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[BIGMIKEY]

Haven't done a lot on this build lately due to other Summer projects both VW and non VW oriented. But I did address the rear tire tread coverage with some fender extensions. PA SPCN requires it. These were an option on the Series 1 cars and nearly all of the GS cars had them. These of course are mere cardboard (paper Dolls) for fitment. I plan on using 2'x2' ABS ceiling tiles for construction. It seems like it will be sturdy enough but flexible enough to do the job. The actual Autodynamics items were fiberglass it seems. Which is an option if the ABS doesn't serve the task.

Also working on a custom exhaust idea for the 1500cc engine I plan to use.

Mike T

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BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[BIGMIKEY]

It has been a while but work is moving along on this project. A few things I have done are rear fender extensions. Required for PA Special Construction is tire coverage to the rear as well as engine covered by a "Hood".

Here are the fender extensions before paint. These are copies of the ones offered by Autodynamics as optional. These are made from ABS ceiling panels. about 3/16" thick, easy to form and cut and seem strudy enough to do the intended job.

Also I have been working on the engine. Creating Industrial Shrouds for cooling air control. I made a template and bent some up using a Harbor Fright 18" metal Brake.

I couldn't find any examples in this forum of people using these. Does anyone else use them?

Mike T
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BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[galencurrington]

you know gene berg sells these for like 17$. these came on industrial motors back in the day just an fyi it could save you time down the road.
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"asking and getting are two different things"

[Rome]

I just came across this thread for the first time. Very nice work with sectioning your rear pan sections. What tool did you use to make those cuts so straight?

I remember from early 1970's HotVWs magazines which my dad brought home from work, that PA had strict laws for engine coverage/protection. After you take your buggy to state inspection, can you remove those rear fender extensions for a cleaner look; or would you risk getting a "fix it ticket" by police if they stop you?

[BIGMIKEY]

Thank you. I did that pan 8 or 10 years ago but pretty sure I used a jig saw and an air powered body saw. I did grind and fit to scribe lines. Pretty happy with how it turned out. I was a Quality Assurance Tech my whole working career so measuring is sort of my thing.

Concerning the fender extensions I will leave them on most likely. I like how they look. Hoping to find and modify a set of side pods to match. Deserters are 4" longer than typical buggies.

Mike T
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BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[oprn]

I'm curious to see the "custom" exhaust.
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Our cars get old, we get old but driving an old VW never gets old!

[clonebug]

[BIGMIKEY]

Continuing work on my deserter I noticed this. The urethane trans mounts installed by the PO prior to when I bought the project in 2011 have crumbled to dust. I never intended to use them anyway but I didn't expect to see this condition just sitting in my workshop. I will be using Rhino Mounts for this buggy.

Mike T
_________________
BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[BIGMIKEY]

I have been doing numerous little things that don't even show but did get the engine I am using nearly complete . it's a 1500 (still 83mm pistons). I put new pushrod seals, flywheel seal and gaskets in it.
It runs well and has good end play. I pieced together an exhaust system using a Thunderbird muffler. Still moving along on the build.

Mike T
_________________
BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[BIGMIKEY]

I have not been working on this project at all lately. Not from lack of interest though. Unfortunately a family illness has taken all of my spare time. All my time really. I hope to be back working on this as soon as I can.

Thanks to those that have been following.

Mike T
_________________
BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[oprn]

Sometimes life goes that way. Good luck with it all!
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Our cars get old, we get old but driving an old VW never gets old!

[GS guy]