New project - 1954 VW Beetle Deluxe w/ VW Canada prodn plate

[kintail]

40 hp Stale air engine is now out. Thanks again to Don for coming over to help out.

Interesting bolt...... ended up removing with cutting disk.

40 hp stale air motor in good condition. Was running when I bough the car. Good solid compression and end play.

Transaxle will need new mounts and cleaning up.Otherwise in good condition as well.

Original pair of semaphores taken out for reconditioning.

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Scott

August 1954 Beetle Canadian Deluxe

[kintail]

When I bought this car the choke was still located on the dash but not clear were it was otherwise. The 40hp was in place but it uses an electric choke. My immediate thought was maybe it was cut.

But somebody had coiled it up and left it underneath the rear parcel tray above the transaxle. This wasn't good. These old cables just love to rust up and then seize up.....not an easy replacement!

So I uncoiled it and sanded the cable end for rust and ran penetrating oil down the sheath. Also lubed it at the front dash. Closing and opening the choke is smooth as silk. Got lucky here.

Next....just the transaxle exterior at some point was sprayed with a little light grease or something like it. This has left it coated in grass, asphalt, fuzz, mud ,etc. There was a very small transaxle leak that over the years formed an aerodynamic wave an inch long. So not sure how to clean this up yet although options are being considered.

Awaiting a couple of parts from Argentina which will arrive this week.
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Scott

August 1954 Beetle Canadian Deluxe

[kintail]

Thanks to Ricardo a couple of more parts for the project!!

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Scott

August 1954 Beetle Canadian Deluxe

[banana split]

Great project! Let the spending $$$ begin!
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My Beetles :
1951 Crotch Cooler 11G Split Ragtop
1953 Zwitter
1964 Chop Top

[kintail]

The spending train left the station when I bought the car last November. Buying parts when the budget would allow and adding to the list.

My 1959 Kabriolett had a Petri horn ring with dual Bosch horns. Also had Foxcraft fenders skirts which I paid $100 for last century NOS in original gray primer...... had to have these back for this project.

Currently being inspired by another ultra maroon car fresh out of its first base coat. Who is this?

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Scott

August 1954 Beetle Canadian Deluxe

[kintail]

Been working on removing the steering disc connector. Four bolts with tiny cotter pins.... lovely!

The connector looks like the rear transaxle; one big fuzz ball. Used a wire wheel to clean it up for better access. So now fighting over the tiny cotter pin removal. Is there an easy way to get this done? Or one of these fight to the finish??

After talking with Cam over the phone about doing the body work on the car, we finally met last weekend to go over the build. One change will be doing the rear apron with a different approach than previously discussed, for fit and finish.

Buying the rear bumper bracket full panel, left and right, from Wolfparts and removing the OG rear h panel by drilling out the spot welds of the inner brace and leaving it in place. This approach inspired by Jimmy V and Dan22.

The rear parcel shelf, driver and passenger door door hinge repairs plus external door panel repair, rear fender skirt (Ricardo) adjustment for fit, are all doable. Cam commented on this '54 being one that he rates highly for being extremely solid despite the complied list. Specifically he liked the replacement panel quality that was derived from Don (Sunroof) and '53-'57 forum member recommendations provided here. Virtanen, Wolfparts, Klassic, and door hinges from a Michigan provider. Hopefully Cam can start this summer on the '54.

Working on refinishing the steering wheel for the new horn ring. Using stock VW horn button and ring which I just cleaned up.

Also got civilized and bought some reasonable $ clear plastic bins w/tops for the bag/tag effort which you can see into! Much better than boxes.
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Scott

August 1954 Beetle Canadian Deluxe

[sunroof]

[kintail]

Don't do what I did.

Taking the two small Phillips screws out to remove the drivers door handle, one decided to strip the head. So I thought another extractor attempt might be successful this time. This dream was cut short by the carbide extractor snapping off ... so I am zero for two .... again! Bought a Dremel carbide 562 burr($27) and just let it run without too much force on it. Important... make sure to wear safety glasses as carbide can shatter with shrapnel resulting!! Was able to sink two small holes on either side of the screw..... and it was able to be unscrewed with minimal damage all in 15 minutes! Fortunately the screw is relatively soft metal. In hindsight just should have drilled it out directly. No more extractors for me.

The entire lock cylinder fell out and the door handle is broken in poor condition. Will be looking for some replacement handles in the near future.

The steering coupler is coming along. I'm using a 14mm open wrench to severe the cutter pins, as per Don's suggestion. Lots of penetrating oil here...

Also looking at refinishing the steering wheel myself . Started sanding and will be doing a couple of tests on filling cracks with non shrinking epoxy.

Got smart and bought some clear plastic bins with covers to store all my bagged and tagged parts. Much better than boxes of sizes plus you can see inside!
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Scott

August 1954 Beetle Canadian Deluxe

[kintail]

Got the engine I was talking about: Car built August 13, 1954

Engine serial number range for August 1954 - 1-0703 464 to 1-0850 932

Engine serial number: 1-0834 128

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Scott

August 1954 Beetle Canadian Deluxe

[EverettB]

Nice, that is super close!
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[kintail]

This 36 hp motor is a local find that was saved by a handful of good friends in the hobby who have known each other for years/decades. I am beyond extremely grateful that it landed in this build!!

More information on this as we move forward!
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Scott

August 1954 Beetle Canadian Deluxe

[kintail]

I would have had no problem putting the stock 36hp back together. But the 'Net and VW parts sales combo, has once again impacted my "budget".

Since the Wolfsburg West repro of the 'Okrasa' dual port head kit was introduced years ago I have always wanted one, so a decent price showed up....... and what could I do!! Then the additional parts that should be added to the engine build turned into another rabbit hole. Mild cam, domed pistons, balance and blue printing, etc.

So after a discussion with a few people from here, decision made in keeping it simple and putting it together "stock". Now somewhere just slightly over my budget, or way beyond my budget. Maybe it had something to do with the sale of the STI and clearing that out of my garage last week!!

My schedule for bodywork to start remains this summer/fall.

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Scott

August 1954 Beetle Canadian Deluxe

[sunroof]

So 2010, only 15 years ago not the 20 I initially thought.

https://www.thesamba.com/vw/forum/viewtopic.php?t=435229

Don
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Better and better mistakes!

[kintail]

Don asked me if I was going to be around the other day so he could drop by for a visit. Yesterday morning as arranged, he rolls into my driveway in his ’54 Canadian Custom. Checked this all original beauty out once again paying particular attention to the engine compartment and all it’s one-off original parts, waterfall fuel pump, air cleaner etc. He asks me if I would like to drive it…. sure thing!!

My past experience was that of driving my ’59 Beetle Kabriolett over nine years ago. And then a brain cell that pops up… telling me I have driven in a oval but not actually ever driven one. That could be a problem

The next five minutes or so are embarrassing! I pull out of the driveway and drive down the block to the main road. First off, my left foot can’t find the clutch pedal; once that crisis is dealt with…. Shifting into third gear …. With a straight gear shift equals long throw and grabbing air, so in the confusion and slowing down for the stop sign. I down shift into……first gear. #@$$%^!!!

As I get up to speed again, going into third I must really push it forward to engage …. otherwise it pops out of gear. Then the decision when to stay in third or shift into fourth brought past memories.

I have to say the ’54 front windshield is really quite small compared to the ’59 and complimented by a similar view out the back window. I like it but can see why VW enlarged the rear window in ’58. The drivers exterior mirror also small and having bought a passenger side mirror for my build was definitely a good decision.

The semaphores take a bit of getting used too. You hear a solid thud as they deploy, but you can’t see them. You wonder if maybe they have fallen off the car…… they haven’t!

So one more first gear grind …really really sorry…. Driven by location memory and driving another car. The final five minutes of the drive are better than the first as finally I pull it all together. As we come down the road, FedEx is parked in front of the house delivering more VW goodness. Now looking forward to getting my ’54 back on the road.

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Scott

August 1954 Beetle Canadian Deluxe

[sunroof]

That was a bit hair raising but ended well. I thought you should drive a car like the one you are restoring. And yes, You really can't see out of an oval. Makes for interesting lane changes in traffic!

Don
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Better and better mistakes!

[kintail]

Wolfparts rear bumper mount panels arrived.

Rear window glass and passenger side glass removed. Passenger door glass removed and internal door parts Window trim next....

Body bolts being removed with no issues ... so far...

Wheels on with dollies making garage life easier!
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Scott

August 1954 Beetle Canadian Deluxe

[VW_Jimbo]

Looking like you are set to have some fun!

Those wheel dollied are a game changer! Nice shop upgrade!
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[kintail]

Decided to get an air gun after decades of Armstrong tools!! That was a slow uptake of technology on my part as I already had the compressor!!

Steering wheel took less than a second to take off. Needs some attention with the cracks and of course with blue paint on it. Will look great with new horn ring and stock horn button. Thanks again to Ricardo of Split Parts Unlimited!

Next task for the air gun …….. removing eighteen body/pan bolts (nine per side). How did it go? The drivers A pillar must be replaced and rust evident at rear of heater channel; so three snapped at A pillar and one behind jacking point on this side (top four in photo). Passenger side no problem!

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Scott

August 1954 Beetle Canadian Deluxe

[kintail]

Bolt battle conclusion after lots of rust penetration oil and patience from front to back:

Front two body bolts - no problem

Front floor pan to body bolts - one snapped, one tore itself out and remaining two came out in a shower of rust. No surprises.

Eight bolts under rear seat - two of them required gradual movement to free-up. All came out clean

Back passenger side body bolt - no problem. Drivers side sheared right off at head and have to drill out. Related to rust issue in parcel tray area.

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Scott

August 1954 Beetle Canadian Deluxe

[kintail]

My steering wheel needed some attention so I thought I would give it a try.

After an initial sanding, I tried JB Weld 6 minute epoxy (pic 2).With the quick cure time it was hard to work the material into the cracks. Fumes and sanding dust are a problem. And it a coarser sand paper, which removes too much steering wheel material as well, imo.

So being a modeller, I am also trying an acrylic resin, Vallejo (pics 1 and 3). Full dry time is one to three days. During which time you can remove excess material and further sculpt the repair. Fills cracks easily and less material used to sand. Fumes also minimal. Still figuring out timing of application and when to sand.

No clear winner yet but liking the acrylic. Stay tuned!

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Scott

August 1954 Beetle Canadian Deluxe