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69 Squareback Restomod
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iamnotatwork
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Joined: August 21, 2018
Posts: 162
Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 10:33 am    Post subject: Re: 69 Squareback Restomod Reply with quote

It's been a few months since posting but work has been progressing...

Putting the doors together:



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1967 Bug "Giblet"
1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Joined: August 21, 2018
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Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 10:37 am    Post subject: Re: 69 Squareback Restomod Reply with quote

The wiring has been kicking our asses. I have three schematics and they are all different but all labeled for a 69. Anyway, we have some stuff installed and working:


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This is the controller for the LED's inside the rear fenders:

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1967 Bug "Giblet"
1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 10:41 am    Post subject: Re: 69 Squareback Restomod Reply with quote

Found an old hide-a-key under a fender:


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Installed the front bumper and new horns. The bumper is temporary until I can get a better one:


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1967 Bug "Giblet"
1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 10:45 am    Post subject: Re: 69 Squareback Restomod Reply with quote

Time for some work on the frunk. Gas tank installed:

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Next, deciding where to put the fuel tank for the diesel heater. Originally was going to do this:


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Then flipped it around and added some sound deadening panels to the frunk:


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1967 Bug "Giblet"
1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 10:49 am    Post subject: Re: 69 Squareback Restomod Reply with quote

Here is where I ended up but still didn't like it. You'll see shortly in upcoming photos that I ended up getting rid of this tank and going a little different direction with it.

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For the carpeting in the frunk, I made backing panels out of 1/4" plywood and glued it down.


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_________________
1967 Bug "Giblet"
1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Joined: August 21, 2018
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Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 10:52 am    Post subject: Re: 69 Squareback Restomod Reply with quote

More NVH panels! This has really helped lower the resonant frequency of the sheet metal. Nice!


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_________________
1967 Bug "Giblet"
1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Joined: August 21, 2018
Posts: 162
Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 10:54 am    Post subject: Re: 69 Squareback Restomod Reply with quote

Thanks to Dave, I have a set of pedals again...


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Dave also made a custom plate for the diesel heater exhaust:


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...and I covered the other side with a beer can bottom:


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1967 Bug "Giblet"
1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Joined: August 21, 2018
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Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 11:00 am    Post subject: Re: 69 Squareback Restomod Reply with quote

We installed the brand new 2276 in August...

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After installing the seal around the decklid, it sat proud so Brian made some panels...


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...and now the carpet and rubber mat sit nicely:


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Installed a seat for the first time in 2 years. Woohoo!

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Finally, on this day we installed the frunk seal.

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1967 Bug "Giblet"
1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Joined: August 21, 2018
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Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 11:06 am    Post subject: Re: 69 Squareback Restomod Reply with quote

I am installing a basic sound system with an eight-inch sub under the driver's seat, a 4-channel amp under the passenger seat, and a Bluetooth head unit in the glovebox. Not sure on speaker placement yet as I have yet to decide if I want to use the bamboo tray.

I am concerned that the power system won't be able to handle the extra load...

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Instead of the garbage crossover networks that came with the speakers, I made my own point-to-point out of much better components

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I am wondering where other Type 3 owners are installing speakers... ?
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1967 Bug "Giblet"
1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 11:08 am    Post subject: Re: 69 Squareback Restomod Reply with quote

Update on the diesel heater's fuel tank... Brian found a better size for the tank and we installed it like this:


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_________________
1967 Bug "Giblet"
1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Location: Oak Harbor, WA
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PostPosted: Tue Sep 21, 2021 11:10 am    Post subject: Re: 69 Squareback Restomod Reply with quote

It's time for the dreaded headliner. I've never installed one. Everyone groans at the prospect of installing it. Oof.

Brian got us started:


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We have a lot more relief-cutting to do to smooth out the bunches. Still working it...
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1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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PostPosted: Tue Sep 21, 2021 11:21 am    Post subject: Re: 69 Squareback Restomod Reply with quote

Dash:

I'm attempting to do an all-metal dash. The headliner is gray mohair that I got from Dave and I have a roll of gray vinyl so I'm trying to mock up different bits to add to the dash to make it look more finished.

Cardboard template:

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Wood insert - ignore the arrows:

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Next wrapped in poly-fill and the gray vinyl over the top. It's just taped on for this fit-check:


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For the gauges, that is going to be a challenge. I have an old dash here:


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The problem is the dash secures the gauges so I have to come up with an alternative. I was thinking of using the shape of the dash to mold a new part and that's coming out ok (no pics of that yet) but I'm really not liking it.

I have access to a 3D printer as well as a structural foam CNC. I just need to design a ring that holds these...

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Finally, the oh-shit handle. I can bolt it on easy but it will stick out and look ugly. I need to fashion some little boots or something to cover the mounting.


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1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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PostPosted: Tue Sep 21, 2021 11:30 am    Post subject: Re: 69 Squareback Restomod Reply with quote

After installing the engine, we found a leak. Turned out the new sump had a manufacturing defect so we pulled the motor and replaced it.


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In other news, the brand new seals I bought for this resto are already cracked. Does anyone know why this would happen?


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1969 Squareback (undergoing restoration) "The Pickleback"
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Clatter
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PostPosted: Tue Sep 21, 2021 12:06 pm    Post subject: Re: 69 Squareback Restomod Reply with quote

iamnotatwork wrote:

In other news, the brand new seals I bought for this resto are already cracked. Does anyone know why this would happen?

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It happens cause they suck. Mad



Unfortunately, they're the only option.

Just gotta live with it.
At least all of our cars will have the same issue.
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W1K1
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PostPosted: Tue Sep 21, 2021 12:24 pm    Post subject: Re: 69 Squareback Restomod Reply with quote

Quote:
It's time for the dreaded headliner. I've never installed one. Everyone groans at the prospect of installing it. Oof.


headliners are not hard, page 3 of my build. start with an 8"wide section front and back and the same in the middle of each side. work evenly towards the corners gluing 6-8 inches at a time. pull it tight towards the corners, there should be no wrinkles. It helps to have someone working on the opposite side to pull tight at the same time, but it's not essential, I've done a few by myself.

https://www.thesamba.com/vw/forum/viewtopic.php?t=...p;start=40
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1965 squareback 1500E
1971 bay window westy- subi swap
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Clatter
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PostPosted: Tue Sep 21, 2021 12:56 pm    Post subject: Re: 69 Squareback Restomod Reply with quote

https://www.thesamba.com/vw/forum/viewtopic.php?p=9393396&highlight=headliner#9393396
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ataraxia
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PostPosted: Tue Sep 21, 2021 1:28 pm    Post subject: Re: 69 Squareback Restomod Reply with quote

iamnotatwork wrote:

In other news, the brand new seals I bought for this resto are already cracked. Does anyone know why this would happen?


It'll be echoed many times but the aftermarket seals are garbage. I bought a set and put them on my car. It never left the garage. Six months later, they looked like yours.

If you're patient, you will find NOS seals. They are expensive and may have shrunk.
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Bobnotch
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PostPosted: Wed Sep 22, 2021 3:24 pm    Post subject: Re: 69 Squareback Restomod Reply with quote

ataraxia wrote:
iamnotatwork wrote:

In other news, the brand new seals I bought for this resto are already cracked. Does anyone know why this would happen?


It'll be echoed many times but the aftermarket seals are garbage. I bought a set and put them on my car. It never left the garage. Six months later, they looked like yours.

If you're patient, you will find NOS seals. They are expensive and may have shrunk.


I'll 3rd this, they suck. It doesn't matter who you get them from either, as they'll look like yours do in 6 months. I've complained about this for years, and they still do that. In my case, the car sits outside, and gets covered in snow in the winter months (just like in Germany), so I can't understand why they do this. According to Ray, the rubber should be better, but it's not.

As for the gauge rings, you might want to find a dash pad that's basically junk, and get the rings out of it. That's what we did for Rob's Roadster when we went steel with the dash.
I hope this helps.
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http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
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iamnotatwork
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PostPosted: Thu Sep 23, 2021 8:24 am    Post subject: Re: 69 Squareback Restomod Reply with quote

Thank you all for the notes about the seals. What a bummer!
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1969 Squareback (undergoing restoration) "The Pickleback"
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iamnotatwork
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Joined: August 21, 2018
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Location: Oak Harbor, WA
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PostPosted: Thu Sep 23, 2021 8:26 am    Post subject: Re: 69 Squareback Restomod Reply with quote

Thank you to W1K1 and Clatter for the headliner help and links. That doesn't sound that bad really.
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