Steve's 1968 Fastback Restoration - Before / During / After

[68vwfasty]

I bought a 1968 VW Fastback a little over a year ago with the idea that it would be a fun family project. My son is 13 and daughter 10 and I wanted them to get a better understanding of cars and how to fix things. Most kids don't grow up with this type of exposure unless dad is a mechanic.
When I was young I had a 1970 Chevy Nova that I fixed up. And my dad and I restored his 1958 Chevy pickup. My brother was into turning cars for money so I did a lot of that type of work. So I know how to work on cars but had not done anything for many a years.
When I bought the car I was not thinking about doing a full restoration. I just thought it would be fun to have something to work on and get running.
But things did not go as planned and here is my story (and learnings).

Here is the car. Not bad looking. Overall in descent shape. Some body damage to the front and rear. No engine. Mostly original.

[68vwfasty]

A little more history on the car. The PO was the 2nd owner. The car was owned by a friends parents. He actually rode around in the car when he was a kid. He bought the car from them in 2007 I believe. The car had sat for many years. He fixed it up and got it running and slapped a Maaco paint job on it. It was driven until 2013 when the motor went. He took it in to see if the motor could be fixed but the cost was more than they wanted to spend. It sat until they decided to sell it at the end of the year.

I got the car home I started looking at it a bit closer and realized that at least the interior was going to have to be replaced. Most of the window seals were shot and it was leaking water in several places. The interior was pretty moist and mildewy and no way the kids or wife were going to ride in that.

So I removed the seats and carpet. That's when I got a better understanding of the condition of the car. I knew the passenger side pan was pretty bad. I could see that from underneath the car. But I didn't realize it had a fiberglass patch covering some pretty big holes.

Somewhere around this time I am thinking I am going to need to remove the glass and put new seals in. Might as well take care of the rust and paint. Here comes the project scope creep!!!

Now the OCD is starting to kick in. So I strip the car completely for body work and paint. But have not decided to what extent I am going yet.

Here is what I uncovered.

Passenger rear half in bad shape and will need replacing.

The rear trunk deck is in bad shape. This was all covered by fiberglass patches and black paint.

The rear pillar was pretty bad and so was the package tray (which also had fiberglass patches).

And finally I found a pretty bad patch of rust in the frunk when I removed the vinyl covering. I tested it by pushing on it with my finger which promptly went right through.

[68vwfasty]

I begin to look for someone to paint the car. Didn't want a Maaco job. I quickly learn that if you want it done right it's not going to be cheap. I talked to several options and one happens to be a guy I had worked with (at Nike) who had started an auto restoration business with another guy. They are a custom shop who do very nice work. But my goal was to have a nice driver not a show car. But I also wanted a paint job that would last. So I ended up deciding to go with them after much deliberation.
First step is media blast and then see what we got.

So now the good news and the bad news. There is more issues found (not really that surprising). Some rust in the passenger fender. Some not so great body work and Bondo. But overall the car is not very rusty. Most of the rust was inside the car and pretty minor. Now that I have seen some of the cars on the Samba I am considering myself pretty darn lucky since I had no clue what I was getting myself into.

Next big decision is body off pan or not? After some sleepless nights I decide to take the body off. One the main drivers is I want to work on the chassis. And I know the pan work will be much easier to do off. So it is done.

In this picture the master of metal has already fixed the front damage. He is really good.

[68vwfasty]

Time to decide on how to fix the pan. I want to buy the ISP replacement section and limit how much is replaced. But after media blast quite a few small holes emerge on both sides. The shop convinces me to use the Ghia pans. I am doubtful but I know these guys are at the level of metal mastery that they can make it work. They do but they do take my advice and leave the front sections and the outside rail alone since they were in good shape. Basically ends up being a slightly bigger patch then the ISP panels. It turns out really nice.

And the chassis comes home for me to finish.

[68vwfasty]

Now the Body Shop works on the body and I work on the chassis with the idea we will marry them back up in a few months.

I am also trying to figure out the motor during this time. I had the original motor (torn apart by the PO's mechanic). I could see what had happened (spun a bearing). So I took the block to a local builder to have him look it over. It had a crack in it and was no good. Time to ponder what to do.

Meanwhile I begin working on the chassis. I decide I am all in at this point and take the Transaxle to German Transaxle in Bend. The prep work went pretty easy until one of the drums decided it did not want to come off. In the end PB Blaster did the job. But it took some soaking and some time.

They rebuild it and I keep it stock except for a Super Diff. This is a straight axle so I have them do the axle bearings too.

I insert into chassis.

[68vwfasty]

Work continues on the chassis.

I clean up and install the front beam. I have never driven the car I am not sure of the condition but I do all the checks I can do and end up replacing the steering damper. Tie rods and ball joints seem OK.

I work on the brakes. Replace the master. Replace the front rotors. Go through the rest of the braking system.

I fix up the pedal cluster and use Unique Parts components for the clutch and accelerator.

I clean up the wheels, paint the barrels, and polish the aluminum.

And the result is a chassis ready to join up with the body.

To be continued .....

[Bobnotch]

WOW, that looks great so far. Mike would have just stuffed another engine in it, and drove it, rather than fix it.
So, who'd you get to build you a new engine? Tram? Just asking, as he's in your area.
Was your friend from Nike Martin Marlinga? Just asking, as I knew he used to work there. He's also got a little type 3 experience.

The body shop guys did some really nice work on the floor. Grafting in the Ghia pan sections fixed a lot of rust. The ARE 8 spokes cleaned up real nice too. Definitely a nice job on the pan. Keep up the great work, as it's nice seeing another "unloved" Fastback get done.
I personally like seeing them get some love.
_________________
Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120

[68vwfasty]

Thanks Bob!

No, Tram did not build my engine. There is a guy named Mike up here that is a very good engine builder.

And no it was not Martin. His name is Brian and he is more the money guy in the business. His partner Shane is the metal guy. They also employ a guy who is a VW guy. He is actually the one who did the pan work.

Since I am a newbie to the VW world I have only met a few folks that I know are on the Samba. I have met Joel (Boo-Koo-Z) at last years Bug Run (he has sold me lots of bits and pieces). I have met Peter (Catbox) and other members of the Rose City Volksters.

Not sure who I might have crossed paths at last years Bug Run. I was busy trying to collect needed parts. This year I plan to show the car there so hopefully I will get to meet some of the Northwest active Samba folks.

[vwfye]

Looks really good!
_________________
64 No'back Speedster "Pearl"
LME "Little Giant Killer 3"
1974 Ghia "PUK"

[68vwfasty]

I would like to clarify what my intention of this thread is.

It is a retrospective on my restoration. The restoration is complete with the exception of some small items.

I wanted to show some before, during, and after photos that capture the majority of what was done (everyone likes pictures!). And I wanted to provide a condensed story of the build. And finally some learning's that might help other folks. And answer any questions that might help someone.

There are a couple of really good build threads out there for 68-69 Fastbacks (BerT3's and Brent's) so I didn't want to add one that didn't show anything new. Instead I have chimed in on other threads where I could share something specific.

Hopefully this thread will help a few folks!

[68vwfasty]

The story continues …

The body shop continues to plug away at the body. They get the rusty areas repaired. Including cutting out and replacing a large section to the trunk deck.

And dealing with the rust on the front passenger fender under the headlight bucket.

They complete all the other metal repairs and get the car in primer. They do lots of block sanding and get the body super straight. It looks way better than I was shooting for and much more costly.

Time to pick the paint color. The car was originally Granada Red. I thought about keeping it correct but I really don't like that color. So I look at other period correct VW reds but instead go with the current VW Tornado Red. I really like it. And in the end that’s what really matters.

They get the car painted. Pick up the chassis. And the two meet. Don't they make a cute couple?

They get married and come home. And I am delighted with the results.

The project has evolved from where I started. The kids have helped out a little so that’s good. But what started as just something to work on has now become a full fledge restoration. The good news is that I am at the fun part now, putting the car back together.

I am just missing one important part, the engine….

[Brent]

Wow. You've really come a long way. It looks great.

That picture of the rear shelf removed is a good one. Kind of makes me wonder how much sand is trapped in mine back there.

When I first saw your MC picture I thought you had the switches in the wrong places. So thought I'd find those pictures of the large/small orifices that KTPhil put up. Seems his is set up just like yours on an original 71 though from this thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=596920

Anyway, probably just want to check if you haven't already.

Keep up the good work!
_________________
69 Fastback Build
Berg5 Build

[68vwfasty]

Brent, thanks again for your build thread. It was a lot of help.

My car is already done. I am just telling the story. I will get to the end soon.

Thanks for pointing out the MC. I hooked it up how the old one was. I can't remember if I checked the outlets for size. Might be on wrong. I have not noticed any braking issues. I wonder what the implication would be if it is wrong. I will check it out.

[MonT3]

68, your fasty looks awesome!!! post up some currents when you get the chance.
_________________
MonT3
67 Squareback
64 Squareback
63 Squareback
Engine rebuild
Trailer rebuild

[Nate M.]

Project creep is all in your,. . . Umm,. . . wallet!!

Looking good!! That's a lot of work in a short time. Glad to hear you're getting your kids involved with it. These are memories that will stick with them working along side Dad. Very important IMHO and I applaud you for it. As I always say; "Families who build cars together, stay together!"

I look forward to future installs to the story. . .
_________________
Regards,

Nate M.

Squarsche build
Heavy Metal Affliction feature

For heaven's sake, put a type4 and a Porsche 5-speed in there. . . It's the right thing to do!!

[68vwfasty]

Time to finish this story …

Over the past few months I have been in discussion with a local engine builder. Remember my engine is trashed. It was already converted to dual carbs so I don’t have any of the FI system. I want an engine with enough power that I can make it over the mountains to get to the coast and not be holding up traffic. We’re talking in the 90hp range. I am also looking for an engine that will last. So we are looking at a 1904. But somewhere along the lines during the picking and choosing of components I find myself at 2110. I still don't remember how we got there. So it gets built.

[68vwfasty]

Meanwhile I am getting the car back together ...

I get the headliner in. Not perfect but a good learning experience. Samba threads helped here.

I replace the complete wiring harness (from ISP). I’m good with electrical but it is still a pain when you’re using old relays, switches, and such. Wiring diagrams on the Samba help and ISP provides good information. I buy a new fuse box from EIS Parts. It is not correct and needs modification to work. I also clean up and repair the instruments. And get all the electrical functional.

In the process of getting all the wiring harness in I am doing the final install of the fenders. I really struggled with the driver side rear. The seals from ISP are excellent reproductions. But what I learned was you really need the one that goes around the wheel well to be really soft when you put the fender on. Or it won’t bend like it needs too and you will be fighting to get the fender on.

I get the dash from Retrovan (Herman) and get that installed. Originally I installed it without the black rings that are embedded in the original dash. Don’t do that or you can’t get the gauges back out once installed.

Next I install the glass. I get all the seals from ISP. Pop-outs first. Thanks Brent for the awesome pics and tips. Only thing I learned was don’t use silicone to put the glass in the rubber seal. It is better for the seal to be grabbing the glass and keeping it in the correct shape.

Front window goes in easy. Back was a PITA. I think I needed some sort of lubricant between the seal and the body. Got it in but it is not really in completely. I was hoping it would settle over time but I might have to redo it.

Door glass is definitely not a lot of fun. Brent has some great information in his build thread.

[68vwfasty]

Finally the engine is ready!!!

I had the builder break it in so it is ready to go in. I have never taken an engine out or put one in a VW so it is a new experience. Actually was pretty easy. Only hard part was getting the car high enough the get the engine under. Type 3 is a pretty tight fit but I managed to get it squeezed in and hooked up. I start it up and she runs!!!

But I have not got the gas tank ready. It needs cleaning. I use Muriatic Acid and Phosphoric Acid. It cleans up nicely. And I get it installed. All new fuel lines and filter. And a new fuel gauge sender. It had a Type 1 sender in it. Which I found reads backwards to a Type 3. A bit confusing.

I reupholster the driver’s seat using TMI seat covers and get it in the car. I fire the engine up and take it for my first drive. It is just a dead end gravel road so I only get it up to 2nd gear but everything is working. Very exciting. Finally some payback for all the hours and dollars invested. And remember, I have never driven this car, nor any Type 3 before.

[68vwfasty]

But there is still a lot of work left …

I decide to buy the SS bumpers from PTT. Main reason was the local plating shop wanted $2G’s to fix mine. I get them installed and they look great. More details available on that thread.

I finish the interior. All TMI stuff. I stayed original to what the car came with (Black Leatherette). I install a reproduction steering wheel (Airhead), modern seatbelts (EMPI), and add some Coco mats (Cocomats.com).

I redo the frunk and trunk using the material from SMS. More on that in those threads.

I install all the trim and the car is completed.

[68vwfasty]

And here is the final product ...