Backdated Bastard Chopped Convertible Build

[vaughn bros.]

Some history first, then the build. Its a 1970. Bought the car locally for $400.00. Polaroid's were taken the day after I got it home and got rid of the stock wheels. We cut and welded the front beam. The IRS went down a spline. I happen to have at the time, a set of "wide" 4 lug sprint stars. Chrome on wheels was rough so they got sprayed rattle can flat black.

I drop in a simple 1600DP no frills stocker. You can see in this early photo how good the original paint was in the engine compartment. The highlight of this car was the near rust free heater channels.

Wheels turned out to be fataly too wide for stock fenders after I lowered it. The year was about 1986 and my thoughts were to widen those fenders.
So lets widen the fenders and frankenstich the headlights back in place. Just widened at the body. Used an extra set of front and rear fenders to widen my fenders. Now they clear the tires but its still kinda lame nowdays.

Next, chop the top. Steel top frame no problem. Brass window frames got brazed, no problem. Used lexan for the windows, no problem.

Bought a cheap vinyl top from a local parts store. Top had a DIY cut out back window, I went for the no back window option.

Drove it for about 5-6 years. Went to dozens of out of town and out of state shows.

Hell, in 1993, it even got 15 minutes of Rod&Custom mag fame by appearing in the background of a picture. Article was for a Studebaker truck we built but my convertible shows up in behind if you look real close.

(tiny picture of magazine cover deleted, wasn't me!)

(tiny picture of article deleted, wasn't me!)

(picture of my car in article deleted, wasn't me!)

Then came the I-40 east engine lock up. The oil ran out quick before I could stop. Oil Cooler Seals must have failed. Oil all over the top of engine. It was a roadside mess. I sat on the side of the road long enough to make up my mind of the cars future. I knew then that when or if I ever get it home, its going to get tore down and rebuilt.

So now its parked in the driveway. Time to get a job where they supply you with a company vehicle so I can tear down the convertible.

Now the build. Leave now or else.

[Cody1963]

wow, ive never seen a chop top convertible before, i love it....... how did you do it?
_________________
Cody
57 Oval
63 Bug "Slammed"
68 Bug "Shortened"

[vaughn bros.]

See if you can stomach this video on YouTube. Its my only record of the chopping activity. damn its bad

http://www.youtube.com/watch?v=fs0Hhitj24c

[vaughn bros.]

I kinda started with the rear floor. It was rotten. Found a nice one and stiched it in.

Next starts the bastard backdating. I thought, yeah, lets make it an early car. Common sense doesnt figure into decisions of young man like myself. Ok lets replace front apron, gas door lid, early bumper brackets, early gas tank,,

[vaughn bros.]

Look at that wiring. I never showed my state farm agent this view.

Made the doors appear old by removing late door locks.

[vaughn bros.]

Fixed the rust in all four quarters.

[vaughn bros.]

I come to the conclusion that my dash has to change.Too late now, its already done.

Top hooks.

[vaughn bros.]

Now its startin to look a little earlier than a 70. Yeah its a bastard backdate.

Next is an interior.

[vaughn bros.]

The body gets stripped and blasted and DP-90'd. After that its time for some interior. The idea was to have a smooth interior, no funny lost corners or areas that do not meet up. Keep in mind, these are the 1990's. I may trash everything and start over.

There were a total of 16 seperate pieces that were plaster molded.
First there is the foam shape.

Then bondo and primer on the foam.

Then big wall mirror for table, a pallet of plaster of paris, and all the play dough wal-mart had in stock.

Then THAT made the plaster molds to make the fibreglass pieces in.
The rest is flat panels. Since these photos were taken, there are no funny curved designs in panels.

Last shot of the molds before storage.

The fiberglass pieces are minimum 3/16" thick.

Just flat panels for roll & pleate. Aw yeah, bought a sail right commercial sewing machine for later use.

[my65vert]

Sano, Retro, flashback, 80's pimptaculous.
_________________
OGJHC
Kombisutra;
I'm starting to get little wafts of bus stink coming from the north. Something about the unique scent of drivers seat padding when it's glued together with mouse piss and shit that really gets me going... and I'm smelling it! Oh yeah! Time to start loading up the equipment.

[dubshack1]

I saw this bug at a Farmington show I believe. I associate this bug with a flyer I have from when I bought a set of Z plates to lower the rear of my car. Is this the same bug? looks great.I am a big fan of full custom cars,especialy vw's.

[vaughn bros.]

[vaughn bros.]

Had to come up with a early chassis for the backdate bastardation to continue. Found a decent 1963 chassis. Put new pans and lines and whatnot on it and then it sat for 10 years waiting on me.

Here are my Z-Plates.

Back then, urethane was cool!

[vaughn bros.]

The build skips ahead over some details because I dont have photos to go along with it. I have to skip all the bondo and primer flying everywhere for about 3 months.
At this point the main body has all of its bodywork done and is ready for the chassis.

[vaughn bros.]

Time for some wheels. I start with the original plan which was polished 5-Spoke Empi's.

Then I finally rounded up enough matching CalParts. But they are wide wide wide. Was gonna go extreme and have pre A brakes too but I didnt win the lottery. Only way to afford wheel cylinders and hardware.

That didnt look too bad but I just needed something more.
I then whipped out the retro's.

They didnt look too bad either but why not try it again. My next choice scared my family and friends. But WTF, I liked it.

I finally compromised and settled with this combo.

The cars wiring. I started in the 90's with a Ron Francis universal wiring block. Had everything worked out to a tee.

Then, I stored the car for a few years and WAA-LAA. RATS RATS, they ate my damn wiring. I threw it all out and started over.

Ran a few yards of new wires. Made a schematic and got to it.

Made my own block and added some extra tricks.

Here is a thread with some more details as I was doing it.
http://www.thesamba.com/vw/forum/viewtopic.php?t=3...iring+jobs

[vaughn bros.]

Next, the trans. I had put in a short axle Rancho Pro-Street in 1999. After 9 years in storage, it looked pretty rough. I dolled it up with some chrome and I think it will live. Used one piece boots. Had to use somebodys brake line brackets. I re-did the rear brakes using all new parts including drums.

[c-real]

very good job !!!
_________________
52 split deluxe
http://c-real-product.skynetblogs.be/

[vaughn bros.]

[vaughn bros.]

Lets build an engine. More than anything in the world, I wanted a good running 1600 but wanted the old doll up items that I grew up seeing. In other words, Pimp my 1600.

I started with a Scat 1641 engine kit which included heads! It all seemed fine except the crankcase. It was the type with a rubber cam plug. Everybody loves them but I dont. Its a personal opinion only. I got a CB center section because they look damn killer. I got one of those early fanGuard serpintine kits. No fresh air buddy boy.

I felt the wild hair and took it all apart. Bought new bearings and P&C's and other consumibles to build another one. this time with a new dual relief magnesium case.

Didnt sleep at night again when I learned of those new High Roof shuffled full flow cases. So I took it all apart, bought more consumibles, and built me another one.

Now I think I am satisfied with the way things bolt together. The main thing is I can sqweeze down a metal cam plug, I can full flow with ease, and the head stud inserts are tight. Lots of work done to the case to make it work but its pretty heavy duty. I just want a good 1600.
But wait. I change my mind again.
As time went by and it got closer to "Fire it up" day, I went crazy.

Changed the intake, throttle cable stuff, oil pump, cooling tin, sump, fuel pump, dist, rockers, push rods, ,,,on and on.
Now lets see if it will run.

I built a test stand to fire it up on. Worked great. Here is the thread for more.
http://www.thesamba.com/vw/forum/viewtopic.php?t=380203&highlight=

Had lots of trouble with the aftermarket cooling tin. Being a convertible engine compartment and Tin made in china for Scat, it all sucked. Got the last of the OE style VW Tin from CIPI1. From what I here, this stuff is starting to become hard to find.

Anyway here is a link to the cooling tin swap.
http://www.thesamba.com/vw/forum/viewtopic.php?t=3...ooling+tin

[vaughn bros.]

Bolted all the goodies back on the engine and laid underneath it for a while. Here is what the reinforcement rails turned out like.

Get the engine all plumbed and,,,,,

I dont like it. The oil lines are a fuckin jungle and the pump sucks. So does all my other plumbing.

Got a bad feeling about my fuel pump and lines. Here is what I started with.

Here is what I did to make myself feel better.

My 44EIS/Solex kept flooding after long test runs so I thought, I dont even know what my fuel pressure is.
I did have just a nice rubber line to carb from chassis.

Took it all off and did this.

Got another bad feeling over my oil lines and pump. So it got changed out again,,again.

As you see I started with a way too large A1 merged header. I needed a 1-3/8 for my engine size. So I got confused over the A1 and the Als header and bought a Als header.

It had so many problems it was almost a lost cause.
Heres the repair thread.
http://www.thesamba.com/vw/forum/viewtopic.php?t=434467&highlight=unfinished

Anyway after much work,,,

Now it fits good. Now to take it off again, sand and grind it down for coating.

I will post the "coated" pictures next week.