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My '67 Bug Project Custom Build
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Goshen
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PostPosted: Sun Jan 20, 2013 10:44 pm    Post subject: My '67 Bug Project Custom Build Reply with quote

I've been involved with vintage VWs since 1979 where a couple of friends and I built our first Dune buggy for Auto Shop class in High School in NYC.

Sometime in the near future into my college days I owned a Super Beetle as well as some regular Beetles, Notchbacks and Karmann Ghias.

Fast forward, 31 years later I had been looking for a regular beetle but living on the East Coast of Florida the ones to be found here are usually rust buckets. I searched as far as New York and they were all pretty much the same .. rusted out through and through. After much money spent and driving across the state of Florida I decided to cut my losses and just get one from California or Arizona where the ambient weather is a bit more forgiving than the East Coast.

I purchased a 1967 One year only beetle with '66 front fenders for $1,750. from Roseville, CA and had it shipped for about $850.00 to my home in Miami, FL.

This car is a running car and I was able to drive it off the trailer and it felt great to be back in a beetle again.

I went through her thoroughly and came to find out that the previous owner was not lying when he told me there was mild rust behind the rear seat in the luggage area.

First things first is to get all the mechanicals out of the way.

First mechanic to work on it was Jonas aka "Static" and on the samba he goes by "Volks Medic" who I had the chance to meet driving his '61 Right hand drive European born Beetle named "Trixie"

He did the usual such as oil change, readjusting the valves and brakes. I was off and running and driving her.

The time was April 22, 2012

Here the story and pictorial begins.

The restoration of my '67 beetle converted to '65 and I know some purists were not pleased but I have always been someone who thinks out of the box and not a mainstream man.

I have decided to document this build now almost 9 months after beginning on this frustrating and overwhelmingly trials and tribulations.

There have been 3 Auto Body shops in the past 7 months that have tried doing work on my beetle and the reasons why so many body shops I will make clear in future posts.

3 Mechanics or should i say motor builders and the stories will even frustrate you but i felt it was necessary to document this so some of you are thinking of restoring a VW bug may have an idea as to the ups and downs, pros and cons, the frustrations one may have to endure with accountability or lack thereof from some scrupulous individuals and the ones that are worth working with.

Here the Story begins on April 13th, 2012


Last edited by Goshen on Sat Jan 26, 2013 8:18 am; edited 2 times in total
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Goshen
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PostPosted: Sun Jan 20, 2013 11:04 pm    Post subject: Reply with quote

Here are the first preliminary photos from when i got to buy the '67 Beetle:

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b]The interior was pretty much shot and cheap carpeting installed.[/b]

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b]The motor is just a 1500 single port[/b]

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b]A Walking Tall stick to hold up the Hood spring less front hood.[/b]

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All the numbers matched so the deal is done

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Last edited by Goshen on Mon Jan 21, 2013 10:08 pm; edited 2 times in total
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Goshen
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PostPosted: Sun Jan 20, 2013 11:12 pm    Post subject: On the Trailer having made the long trip from Cali to Miami Reply with quote

b]All loaded onto a trailer in Roseville, CA[/b]

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b]She arrives in Miami on April 27th 2012[/b]

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In the driver's seat getting ready to drive her off the trailer.

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Now sitting in front of my house[/b]

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b]Now this is the only rust on this beetle:[/b]

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b]I bought a luggage panel from JOHNEX in California
and welded it in with Harbor Freght Tools 110 Flux wire welder[/b]

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Last edited by Goshen on Mon Jan 21, 2013 4:07 pm; edited 1 time in total
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Goshen
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PostPosted: Sun Jan 20, 2013 11:20 pm    Post subject: Reply with quote

b]Another pic of the area that I welded for the fist time in my life. I burnt a couple of holes from the lack of experience but soon got the hang of it. Prior to the welding I used Ospho and then primered it and finishing up the job with a seam sealer from Home Depot $3.50[/b]


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I didnt like the color on the beetle so i changed it with some rattle cans from the Home Depot.

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b]Gutting her out and Ospho:[/b]

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Lots of surface rust was removed as water seeped into

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b]POR-15 to seal... careful with this stuff.. gotta use some heavy duty gloves because if you don't and you get this stuff on your skin it will take a good 30 days before you can get it off your skin. [/b]

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Last edited by Goshen on Mon Jan 21, 2013 4:31 pm; edited 1 time in total
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Goshen
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PostPosted: Sun Jan 20, 2013 11:29 pm    Post subject: Reply with quote

OSPHO all over the floor

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b]POR-15 to seal... careful with this stuff.. gotta use some heavy duty gloves because if you don't and you get this stuff on your skin it will take a good 30 days before you can get it off your skin.[/b]

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PostPosted: Mon Jan 21, 2013 1:24 am    Post subject: Reply with quote

I like it Smile
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PostPosted: Mon Jan 21, 2013 9:04 am    Post subject: Reply with quote

Nice project.

But why do you call it a '65? Just because of the sloped glass headlight covers? Euro '67s came that way. It's a long way from a '65 (center defroster, 4-way flasher, rear hood, slotted wheels with flat hubcaps, etc etc etc, and that is just on the outside-- ball joints, etc mechanically).

Rear luggage shelf rust? I call it "easy clutch cablke adjustment access"!
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PostPosted: Mon Jan 21, 2013 4:42 pm    Post subject: Reply with quote

KTPhil wrote:
Nice project.

But why do you call it a '65?


The transformation is not just external body panels. I also drilled up the bodyside moulding holes to 8mm. I modified 65 exterior door handles to work on the '67 door. I also made a kit that would allow the use of '65 interior handles to work with the stock '67 hardware. You won't find the door locks up and down thiggamajig. The rear hood has already been replaced as well as the rear apron.. you will see in photos that i have yet to upload. I will be using Empi 2nd gen wheels... patience please...

Before the mod:

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After the mod:

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Last edited by Goshen on Mon Jan 21, 2013 5:01 pm; edited 1 time in total
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PostPosted: Mon Jan 21, 2013 4:55 pm    Post subject: Reply with quote

Chris Vallone from Classic Bugs suggested I use Quick-Roof that i could buy at Home Depot.. it is like Dynamat but cost a lot less for only $16.00 for a 25 foot x 6" wide roll. I used a total of 4 rolls

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PostPosted: Mon Jan 21, 2013 6:17 pm    Post subject: Reply with quote

b]The previous owner had told me that he bought this beetle without hood springs and the mounting area underneath were removed... for what reason.. I don't know.. I couldn't weld a new piece so i bought this from Home Depot for about $1.50[/b]

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b]I searched far and wide some 2 months before I bought the beetle I bought these wheels about 240 miles up north near Orlando and picked up these Empi wheels. Jason who sold them to me told me these were original Empi... 4 are identical and the 5th wheel the spare is an American Eagle. $400.00 [/b]

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b]Jonas "Static" or VolksMedic on this forum lowered both front and rear... I guess the '67 is not too accommodating in the rear but the front was lowered by way of Dropped spindles and thin leaves removed up front.[/b]

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Last edited by Goshen on Mon Jan 21, 2013 10:20 pm; edited 3 times in total
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PostPosted: Mon Jan 21, 2013 7:10 pm    Post subject: Reply with quote

b]I decided to do some of the work myself to save some money,,, so i looked up a thread that detailed a couple of ways to remove the rear apron... my idea is to make it removable with aircraft nut plates I have had in my toolbox since I left Pan American World Airways in 1990[/b]

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b]
Here is the replacement panel ... Aftermarket that didnt quite fit but I will make it fit somehow[/b]

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I also bought this nice Dual muffler from a vendor on the samba.

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Last edited by Goshen on Mon Jan 21, 2013 9:20 pm; edited 1 time in total
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PostPosted: Mon Jan 21, 2013 7:18 pm    Post subject: Reply with quote

I can't wait to see the replacement of the frame head.
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PostPosted: Mon Jan 21, 2013 9:34 pm    Post subject: Reply with quote

Rabbi_Zachariah wrote:
b]The motor is just a 1500 Bone stock single port[/b]
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Sure, bone stock... except for the gas filter, aftermarket air cleaner, 009 distributor, Blue coil, lack of heater/hoses, ...
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PostPosted: Mon Jan 21, 2013 11:31 pm    Post subject: Reply with quote

Is there any smell from the quick roof? I read about using some home depot stuff instead of Dynamat on a Dodge Diesel forum I frequent and the major complaint on that one was the fumes on a hot day. I believe it eventually subsided or the owner got used to it. I don't recall if it was the same stuff that you have used but I need to do the Por 15 and some sort of Dynamat on my '67.
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PostPosted: Mon Jan 21, 2013 11:45 pm    Post subject: Getting the 1641 Motor built Reply with quote

b]A Jamaican guy named John who I have known since 1989 while working at Pan Am Airways has always tinkered with aircooled VW's offered to donate a motor that he would build because he said he sells rebuilt motors from time to time to make some extra money. He told me he would build me a 1641cc motor for $500.00 Guaranteed to be ready in 3 Weeks time but that I would have to pay him up front or the deal is off. I thought I knew him and this was August 24th so the completion date was set for 09/14/2012[/b]

b]The following pic was taken on the 3rd week... John hadn't even begun to build the motor.
[/b]
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b]Here is part of the case still on the ground of his Shop:[/b]

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b]There is the crank on the ground and part of the case on the engine stand[/b]

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Almost 9 weeks go by John said to come by in 2 hours on a friday afternoon so i can pick up the motor. My wife accompanied me and she sat in the car with me for about 5 hours til John finished building the Long block motor... It was friday night about 11 PM and we had missed Shabbat waiting for this motor.

I took the motor to Jonas for him to look it over and it turns out that there was a huge 1/8" gap on the front of the case above the crank. John had told me that it wasnt a big deal just to get some nuts and tighten it and it will be fine. Static said the crank was locked and that the motor was a bad build. So i took it back that same weekend.

John the Jamaican guy said that he had another block available and he would build me another motor in no time at all. He said the block was from a '74 beetle. ( I know now how to tell the difference but back then I just took his word)
Another week goes by and now we are on the 11th week and John gives me another Longblock of which i had to camp outside of his shop for about 3 hours.

This is what i got:

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Can you see what is wrong with this pic?

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There are two stress bolts missing in the image above. John tried to convince me that it was no big deal that all i had to do is install a helicoil and two 8mm studs.

Jonas looked it over again and said that the case has to be split in order to install the studs.
He was busy so he couldn't take it apart so I took it over to Michael Hare from Karls German Auto and from the case number he was able to determine that this was not a 1600 block but rather a 1500 block.

At this point I wanted to make sure that it was a 1641 and Michael removed one of the heads to find out that the pistos were 85mm and not 87mm... it would also be futile to work with this 1500 block.
The oil pump that the Jamaican guy John provided was for a 6mm studs and not 4mm.

I was angry at this point..... I contacted John and he was pissed off that I took it over to another mechanic... in fact Marshall Painter had also looked at it and advised that i should take it back to the Jamaican guy and get my money back...

At this time in this mess I was at 12 weeks and no motor so I took it back and I had to get the police involved to get what i paid for. His lawyer was there present as was mine to get the parts that i needed to build the motor.

Michael suggested i build it myself and he was a good motivator for me to just that. I had to literally give the longblock back to John the Jamaican guy and buy the 1600 block from him and all the components needed for me to build this motor. This process to another 2 weeks because this Jamaican guy the quintessential Cool Running Man took his sweet time and milked it.... milked the process.. Now I am into my 15th week and just got all the parts needed to build the motor.

Here are some pics of the damages to bearings on the crank and other mess.

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PostPosted: Tue Jan 22, 2013 12:16 am    Post subject: Now it is time for the body work to begin Reply with quote

While the engine fiasco is going on back and forth feeling like a ping pong ball I tear down the bug to take it to the body shop where it will get all the body work done and I should have the car back in about 2 months....

This is another Soap Opera Saga about to unfold.

Now to continue tearing down the bug...

Trying to figure out this mess of wires and you have to be careful who installs your alarm system because they will just stuff all the wires behind the wire cover....

Now Jonas " Static " or VolksMedic is good at rewiring so I know he will do a good job once the car is back from the body shop.

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I butchered the radio cutout... it looks ugly but the body guy will be welding it shut so Jonas can start fresh and do it right.

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Now the tearing down process continues so I can take it to the body shop... Now this is the first week in September of 2012

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Removing this headliner stuff is a mess and time consuming

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The first Body Shop guy Angel of Angel Auto Body working out of Body Beautiful . I have known for about 7 years and has worked on my RX7's and BMW's in the past so naturally I thought I would take it to him. I got some quotes in the area from others but most of them didn't want to have to gut out the bug and others didn't want to tackle the curves. So Angel said he would just as long as I can remove everything... .. 3 months later and only some work was done.
If I knew what I know now concerning Florida Law... well I wont divulge now but I won't be caught in a mess like this again !

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This next pic is at 45 days sitting at Angels Auto Body at Body Beautiful:

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This next photo was taken in December at almost 3 months sitting at the body shop ( 82 days ) at this point I was already fed up and frustrated because i wanted my car back.. Bug Jam was around the corner and i wanted to show off my ride. this was too much after having dealt with John the Jamaican guy and now this... so I began to look for someone else that can take the job on and get it done in less than 3 months time. I had known David Hernandez of Oldie Goldie Restoration and he said he would complete it in less than 3 months. So I thought that i would have it for the Show and Shine coming up in March.

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Last edited by Goshen on Sun Jan 27, 2013 4:04 pm; edited 1 time in total
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Goshen
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PostPosted: Tue Jan 22, 2013 12:54 am    Post subject: Reply with quote

surfbeetle wrote:
Is there any smell from the quick roof? I read about using some home depot stuff instead of Dynamat on a Dodge Diesel forum I frequent and the major complaint on that one was the fumes on a hot day. I believe it eventually subsided or the owner got used to it. I don't recall if it was the same stuff that you have used but I need to do the Por 15 and some sort of Dynamat on my '67.


I was advised by Chris Vallone not to put it on the roof of the car... well at least not in Miami where it gets hot and humid.
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PostPosted: Fri Jan 25, 2013 7:47 am    Post subject: Reply with quote

I had the same problem with a body shop here where I live. The guy had my bug from May-October! He stripped the fenders and that was it! I finally got fed up and took my car elsewhere. I was so ticked at him for all the unkept promises. "i'll get started on it real soon', "it's going to look great" blah blah blah....Take it elsewhere
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PostPosted: Sat Jan 26, 2013 10:25 am    Post subject: Motor build in the mean time Reply with quote

While the car is at the body shop hopefully getting worked on by David I decided to get the motor built by a guy local here in Miami that promised to get it done in two weeks time. He is known in the VW community here in Miami but I won't mention his name just yet.

The truth of the matter is that He has had the parts for my motor for 3 weeks and I decided drop in on him .. come to find out that he didn't do jack s**t with it ... It is a good thing that i didn't leave a deposit this time and saved me the trouble of getting it back like some other scam artists in Miami have done.

I was contacted this past week by some forum members and others via text that I should watch out with the place that I have my car right now because other people have been scammed by this guy. I hope that is not the case. I am hoping that he will keep his word and finish my car before March just as he said he would.

I contacted Michael Hare of Karls German Auto and he suggested that I go see Marshall Painter and this was a good suggestion. I bought some parts from Marshall Painter and he was great to deal with.. fair and honest and the prices were good unlike some others out here in Miami that charge a lot for their used parts. PM and I will tell you who charges a lot out here for used parts as if they were the last coca cola in the desert.

I worked on some marketing projects with Marshall Painter where I did some videos to help him get out there . like a website and Youtube.

Here is one of the videos that i taped:


Link


Marhsall Painter offered to sponsor the build of my motor... a 1641cc motor so here is the build process:

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I HAD TO SHAVE THE TWO INBOARD BOLTS SO THE PULLEY TIN WOULD HAVE CLEARANCE AND FIT WITHOUT RUBBING WITH THE HEAVY DUTY FULL FLOW OIL PUMP COVER:

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PostPosted: Sat Jan 26, 2013 10:44 am    Post subject: So here is the finished product : 1641cc motor Reply with quote

So here is the finished product : 1641cc motor .. Thanks to some good people who gave me good advice and Marshall Painter for building this motor


Marshall used a Gene Berg pulley which he recommends using or a Scat pulley but the EMPI fuggegaboutit !!!

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EMPI pulleys suck... they just don't fit right...

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I bought a used stock Chrome pulley at Volksblast for $10.00 and it works fine. Don't mind the clear blue EMPI Distributor cap... its only on there for looks but i will go back with an original Bosch 009 cap soon. Exclamation

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The Dual Solex Carbs I got from Lloyd Fuller a couple of weeks ago from a complete good motor that he sold me that I sold to Louis the cop and is currently on Louis the cop's '67 bug... sorry I only know of him by his first name and that he is a cop ... BTW his '67 is running strong because a good mechanic Jonas 'Static"or VolksMedic on this forum worked on it. You need a good VW mechanic then don't hesitate to call Jonas .. give him a call you won't be dissapointed with the work he does at 305-417-3317

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Here is a close up of the stock chrome pulley... and the front pulley cover was Marshall Painter's idea... i love the way it looks.. most engines i have seen don't have this piece on here but it looks great i think.

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Oil sending unit was provided by Lloyd Fuller and VDO oil pressure gauge from a vendor at Volksblast.

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Another look at the pulley and the cover:

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Here it is in its preglory... Just waiting on David Hernandez of Oldie Goldie Restorations to get done with the Body Work and Paint on my car... God I hope I get it back soon

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