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1959 RHD complete original restoration project
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vwbug47
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PostPosted: Sun Nov 17, 2013 12:12 pm    Post subject: 1959 RHD complete original restoration project Reply with quote

I have created this thread to log the progress of my 1959 original Beetle restoration.

My aim is to restore this car as closely to the day it came out the factory as I'm able down to original period nuts, bolts and washers.

The car was (and will be) painted Indigo Blue.

I am 25, this is my 3rd Beetle but I have never taken on a project anywhere near the size of this.
Any help, hints and tips will be warmly received.

I look forward to hearing peoples thoughts.

Below shows the chassis with floor pan. Freshly painted and in amazing condition. Sound deadening material has also been added to floor pan
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The original shell stripped to bare metal. not a spot of rust anywhere
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Front axle and gear box with drive shafts added to chassis

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The first 30horse engine stripped. Awful condition inside with serious amounts of damage and a hole corroded in the underside of the engine casing

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Another 30horse engine sourced from Belgium stripped and in fantastic condition considering it's age

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Fuel tank painted, original engine tinware painted and lovely shiny hubcaps. Have to say I'm over the moon with my shiny fuel tank.

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Matching year correct seats sourced from Belgium. Needing re-covering...

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Original steering box, king pins, peddle assembly and starter motor all cleaned up and freshly painted.

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Original shiny bumpers

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Stunning condition period heat exchangers

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Engine progress...

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Few chips removed from the original steering wheel, getting ready to paint.

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A blasted ash tray and front plate with original knob. I think its a great example of the engineering that went into each part of these early bugs.

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The only part I have showing the original blue it came out the factory in that it will be painted.

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The second engine (sourced from Belgium) as I received it.

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Original with VW stamp and label.

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Dismantling of the carb to clean the jets, casing and check the diaphragm.

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The engine casing from the second engine all cleaned up and bolts checked and double nutted tight. Over the moon with its condition.

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Today's job was stripping down the fuel pump, cleaning it up and reassembling.
Ready for install..
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Next job.. completely clean the carb and ensure no blockages in the jets..

Carb now fully cleaned, jets checked and re-assembled. Looking much better.

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Carb and fuel pump ready Smile.

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Cannot wait to get the steering wheel painted and this added to the centre.. I'm told these are hard to find in perfect condition Smile.

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Essential organisation.. new shelves Smile.

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Original instruction manual and service booklet.
Forgot I had them!

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Original VIN plate

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Found some photos the previous owner had given me..

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Engine is now very nearly ready for re-assembly. Just a final petrol clean and then can get it together. Will mount it to the gearbox and mount the tinware from there. An exciting moment in the project. Photos to follow...

Small job but forgotten I hadn't cleaned and painted the tinware plate that slots under the barrels before the heads go on.. all done now and ready to assemble the engine.. I think!

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Progress today. Engine being put back together. Had to pause progress to solve a query about one of my bearing dowels. Feels too thin.

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Heads shot blasted and looking as good as new. What a difference!

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Removing the valves for cleaning and to clean the passages..

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The valves cleaned up..

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Before and after..
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Bedding in the valves...

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Original clutch shotblasted and cleaned up very nicely..

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Original flywheel shotblasted and shined up..

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New pushrods with seals added...

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The promised progress fell short. Wanted to change the exhaust manifold studs on the heads as several were worn and 2 were not even the correct ones but a few snapped so had to be drilled out and re-bored. All sorted now....

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Rear lights surrounds in primer.

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PLEASE EXCUSE THE MUCKY FINGER PRINTS ON THE ENGINE BLOCK/ CYLINDER HEADS... THEY WILL BE REMOVED... I WAS IN A RUSH!
Pistons fitted, barrels pushed in with gaskets and copper seals. Tinware plates under the barrels fitted, push rod tubes positioned and cylinder heads fitted.

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Rocker gear fitted, tappets adjusted and Bosch super plus spark plugs fitted.

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Engine so far... before and now.
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Oil cooler blasted and painted. Before and after.
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Pulley and more engine tinware in etch primer.

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5 original wheels in etch primer.
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Tiny job but oil cooler fitted

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volkspower5150
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PostPosted: Sat Nov 23, 2013 10:56 am    Post subject: Reply with quote

Subscribed! looking great!
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vwbug47
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PostPosted: Mon Nov 25, 2013 4:38 am    Post subject: Reply with quote

Thankyou! Means a lot.

Currently sorting out the colours so I can have the wheels painted.

Have also just shortened the brake lines so they look a better fit.. pics to follow...
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anthracitedub
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PostPosted: Mon Nov 25, 2013 4:59 am    Post subject: Reply with quote

Very proper, all your work will be well rewarded.
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bowserb61
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PostPosted: Mon Nov 25, 2013 10:58 pm    Post subject: Reply with quote

You're doing a really nice job with all this, and you won't regret having done each step the right way.

If you're as meticulous with the interior as you are with the rest of the car and you really want a factory day restoration, I've got some disappointing news if you don't already know. Nobody, and I mean nobody makes a really accurate 59 interior. I had the exact same blue interior with the cloth seat faces, and that has been the most consistently frustrating part of parts searching. That fabric pattern was 58/59 only and it isn't reproduced anywhere, but some people have had luck with having it custom woven.

So my advice from all this complaining is: don't throw away any original interior you may have. Restore old vinyl when you can and go the extra distance matching fabrics. If that stuff matters to you, there's nothing quite like the real thing.
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AlteWagen
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PostPosted: Tue Nov 26, 2013 10:39 am    Post subject: Reply with quote

Looks great!!!

Just wondering why you are using a 60-63 steering wheel instead of a stock 56-59 unit.
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sunroof
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PostPosted: Thu Jan 09, 2014 10:21 am    Post subject: Reply with quote

I have correct cloth for your interior if you are interested.

Don
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59RAIDER
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PostPosted: Thu Jan 09, 2014 11:35 am    Post subject: Reply with quote

AlteWagen wrote:
Looks great!!!

Just wondering why you are using a 60-63 steering wheel instead of a stock 56-59 unit.


I had the same question Very Happy
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AlteWagen
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PostPosted: Thu Jan 09, 2014 12:49 pm    Post subject: Reply with quote

I reviewed the post and noticed that the vin tag is a 60 model year plate. Probably an early 60 (8/59-12/59) which the owner is calling a 59.
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Fifty-Eight Rag
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PostPosted: Thu Jan 09, 2014 7:14 pm    Post subject: Reply with quote

59RAIDER wrote:
AlteWagen wrote:
Looks great!!!

Just wondering why you are using a 60-63 steering wheel instead of a stock 56-59 unit.


I had the same question Very Happy


Ditto
Here is the correct wheel
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lawn ninja
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PostPosted: Thu Jan 09, 2014 8:00 pm    Post subject: Reply with quote

Also if you are deadset on super original the engine case should have a gold-ish creosote coating on it. Also as far as I am aware the gas tanks were grey and the replacements were black. The rear shock towers also look like they have a bit of rust. Looks like you cans see some daylight there. Not nitpicking but I wouldn't want you to miss that rust.
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56Cabrio
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PostPosted: Thu Jan 09, 2014 10:19 pm    Post subject: Reply with quote

AlteWagen wrote:
I reviewed the post and noticed that the vin tag is a 60 model year plate. Probably an early 60 (8/59-12/59) which the owner is calling a 59.


Explains the 60-63 steering wheel.
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Blauchen L331
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PostPosted: Mon Jul 14, 2014 3:30 am    Post subject: Reply with quote

Your car SHOULD have the "new" style 1960 steering wheel, if it was built after August 31st 1959.

Steering wheels changed in late August 1959 and YES, there's 1959 titled registered cars in Europe that are sold 1959 but have ALL the 1960 "new" parts........

Does your data plate have a year stamped onto the right side I can't see the plate well, it should.....

The correct proper interior for your car might be leatherette? ~ While it was EXPORTED outside the continent, to a RHD destination, which would have been
code 70 Steel Grey with Blue sides.

If the car had Cloth then it would be the German code 50 50 Water Blue, or known in European VW circles as "Pajama Stripe" interior.
(I know where to GET this fabric, it's STILL being made, no matter what some people say.....!)

I'm PROUD to see someone restoring a 1960 Euro correctly and to Original specs, so many of these cars now are cut up, messed up, lawn mowers with 20% original parts just the Semaphores left working, BRAVO to someone wanted to save a car and keep it original.

If you need any advice and help about the originally of the car, please write me off the thread.

Best of Luck With Your Restoration,

Tom
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OG PAINT L331 JUNE 1957 TYPE 1 OVAL WINDOW
(US Army In Germany POV/Grey Market Special Ordered Car from MAHAG Munich)
Delivered with Semaphores - German "Puntchen" Cloth Polkadotted Interior -
USA RAM Protection/Export Overrider Bumpers - MPH Speedometer -
Sealed Beam Headlights and Bullet Front Turn Signals!
99.9% ORIGINAL PARTS WITH ONLY 33,000 ORIGINAL MILES/ GARAGE FIND/ UNRESTORED CAR
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Blauchen L331
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PostPosted: Mon Jul 14, 2014 3:42 am    Post subject: Reply with quote

BTW.

I just watched a episode of the 1960's adventure show "The Saint" with Roger Moore and there was a European L 363 Arctic Blue car (same kind of Beetle I once owned except mine was LHD), the one in the TV programe was a Irish Registered RHD car and it has the same style of interior that might have been in your car as well, the code 70 leatherette......

Super very kool episode and the car had some strange single fog light and hooded headlight set up, I'll try to get some screen captures and make a thread about it.....stay tuned!

Tom
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OG PAINT L331 JUNE 1957 TYPE 1 OVAL WINDOW
(US Army In Germany POV/Grey Market Special Ordered Car from MAHAG Munich)
Delivered with Semaphores - German "Puntchen" Cloth Polkadotted Interior -
USA RAM Protection/Export Overrider Bumpers - MPH Speedometer -
Sealed Beam Headlights and Bullet Front Turn Signals!
99.9% ORIGINAL PARTS WITH ONLY 33,000 ORIGINAL MILES/ GARAGE FIND/ UNRESTORED CAR
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