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The "Gartenkäfer" - '62 resurrection
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bullibene
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PostPosted: Thu Mar 03, 2016 1:59 pm    Post subject: The "Gartenkäfer" - '62 resurrection Reply with quote

Hello all,
I bought this 1962 bug a year ago near Nuernberg(Germany) and had it sitting in a friends garage since then. I will upload pictures of the restoration in this thread.

The car sat in this backyard for over 30 years due to the owner.

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tree in engine compartment Shocked

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Loaded onto trailer
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After 5 minutes of driving the right back wing fell off ... Rolling Eyes
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In this garage of a friend of mine it waited another year for getting brought back to life.
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This won't be a perfect restoration with all the correct panels etc. but all work will be executed technically well.
I will keep the original white paint and it's patina an it will be my daily driver after being finished.

Best regards from Germany

Benedikt


Last edited by bullibene on Fri Mar 04, 2016 12:02 pm; edited 1 time in total
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itskyle
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PostPosted: Thu Mar 03, 2016 6:59 pm    Post subject: Re: The "Gartenkäfer" Reply with quote

Hartzliche Gluckwuschen!

Und, viele gute fahrts!
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bullibene
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PostPosted: Fri Mar 04, 2016 3:05 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

While it still was at my buddys house we seperated the body from the chassis, stiffend the body and put it on self built trestle to bring it to my place.

Pan from underneath
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Yes it smelled as bad as it looks Laughing
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Heater channel...or what was left oft it could be taken out with bare hands Shocked
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Still alltogether....
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...demounted some parts to reduce weight to carry it out of the garage onto the trestle
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I wasn't allowed to weld in this garage so we had to take the body of without any bracing Confused
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...outside I welded in the bracing i built out of square tubes and turn buckles so i can adjust the door gaps
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As I life not far from my buddy we transported it by a pretty unconventional way i would say Laughing Razz
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Arrived I tried how good the original paint would clean up... good enough for a ratty driver Cool
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That's it for now

Bene
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Joe.F
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PostPosted: Fri Mar 04, 2016 10:37 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

Nice progress,

Can I ask, is it still sensible to restore beetles in this condition in Europe? I know in other countries it is, but with the amount in Europe I would have thought there would be much easier projects to be found.

Here in New Zealand I am starting a '58 in similar condition. I look forward to seeing this progress.
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Rome
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PostPosted: Sat Mar 05, 2016 7:59 am    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

Mein Lieber, hast du was vor! You will end up being an expert welder when the car is finally safely repaired and on the road! I certainly wish you perseverence, and hope you take a few minutes each week to provide updates.
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PostPosted: Sat Mar 05, 2016 10:26 am    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

You're a brave man to consider trying to save that extremely rusty bug. Have you done this type of work before? You really are looking at hundreds and hundreds of hours of cutting and welding to bring that bug back. The cost of all the replacement metal you're going to need will make you shutter.

While we all love to save these old VW's, I think there's times where we should really wave the white flag and find a more suitable candidate for restoration. There's hundreds of thousands of rust free bugs in the SW USA looking to be loved again. You'd save yourself thousands and thousands of dollars by starting off with a rust free bug to bring back to life. Even shipping in a rust free bug from the states or Mexico would be cheaper than what you're going to spend in dollars and time trying to save that bug.

I'm not trying to discourage you nor look down at your decision but rather, give you a realistic view of what you're potentially getting into.
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jensenflagg
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PostPosted: Sat Mar 05, 2016 3:47 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

On the other hand...

If you are resourceful and determined enough to use skateboard trucks and a bike to move the shell, have at it!

Good Luck!
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PostPosted: Sun Mar 06, 2016 11:33 am    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

Das ist ein wirtschaftlicher Totalschaden, schlachten. Wir haben ja noch TÜV, und der Rahmenkopf hat fertig.
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bullibene
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PostPosted: Sun Mar 06, 2016 4:28 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

Joe.F wrote:
Nice progress,

Can I ask, is it still sensible to restore beetles in this condition in Europe? I know in other countries it is, but with the amount in Europe I would have thought there would be much easier projects to be found.
.


Sensible? I would say no! But this hobby is not being about sensible Wink
This project is more likely a challenge for myself and about the fact that I hate seeing early bugs getting cut up for parts.


wcfvw69 wrote:
The cost of all the replacement metal you're going to need will make you shutter.



It's not that bad if you use cheap Klokkerholm repro panels and do all the work by yourself Wink This won'T be a concours resto... just a cheap, ratty driver


The work has begun.
Before I can start to work on the body i needed to repair the doors to fit them and adjust the door gaps.

I repaired the inner structure of the doors... the outter original paint door skin will stay how it is... as I said... just a ratty driver Wink

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New repro panel
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door hinge was gone Shocked

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cut out...

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repro panel fitted an welded on

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Door No. 2 was next:
Same procedure again...

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cut...
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the stiffner panel for the door hinge was also gone... so i had to fabricate them...

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Both doors solid again Smile
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Next were the mounting points for the door hinges

I used the old hinge as a template and bent and drilled a panel in appropiate thickness

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trimmed...

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ready to be welded in...

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test fitted with new hinge and welded in.
I also welded in an additional stiffner panel to the downside of the door for extra stiffness
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same procedure for the other door
I used a template of the first... then bent and drilled it

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welded in...

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...and filled the hole

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To be continued
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Joe.F
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PostPosted: Sun Mar 06, 2016 5:17 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

Awesome man, power to you! Smile
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PostPosted: Sun Mar 06, 2016 5:22 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

Awesome man, power to you! Smile
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67rustavenger Premium Member
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PostPosted: Sun Mar 06, 2016 5:28 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

bullibene
Welcome to the samba.
Ok! I'm pretty sure this man has the skills to pull off this restoration. Based on what I have seen so far in his posts. So you all can forget trying to talk him into finding a sound, rust free SW USA car to start with.
I lived in Eastern Europe for more that a year and a half 2008-2009. I was amazed by what folks could do with nothing. There was a neighbor in my village that made a homemade tractor with two steering wheels in his shop.
So my hat is off to the metal working skills of European craftsmen that take on such tremendous challenges. I just wish I had the metal working skills that some of these European guy's have.
Good Luck. And keep us posted on your progress.
BTW I had a huge laugh at your car dolly tow vehicle. That's inventive.
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PostPosted: Sun Mar 06, 2016 5:34 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

Love the tow-by-bike idea.
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bullibene
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PostPosted: Mon Mar 07, 2016 1:51 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

As the whole "frame" (heater channels, cross member & firewall) was rotten as hell. I put a new repro frame together separate on a good floorpan.

When everything was aligned I welded the parts together.
Next step will be to put the body onto the new "frame".

I used the recently available crossmember in better quality.
They are really well made but still not 100% correct for early crossmembers
(This really doesnt matter for this build... just as information for evtl. other potential buyers of them Wink )


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Unnecessary hole...

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...welded....

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...grinded...

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...in primer.
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Next I prepared everything to be welded together: Making holes for spot welding, straigthen everything, applying weld thru primer and aligning everything... took longer than it actually looks in the pictures Laughing

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The coating on the firewall peeled already off by looking at it... so i sanded it down to apply some Epoxy later.

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Everything put together

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closed gap

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Finished Twisted Evil
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63Ragtop NZ
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PostPosted: Mon Mar 07, 2016 3:51 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

Great work Sir! My new favorite samba thread!
I have not seen those rear cross members before, they do look much better than the old square shaped ones.
Applause Applause
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PostPosted: Mon Mar 07, 2016 4:54 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

Well, he certainly answered my question about doing this type of work before. Very Happy

Good luck with your project as you're off to a great start.
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PostPosted: Tue Mar 08, 2016 8:25 am    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

You're much braver than I am. Looking good. I completely went through a very rusty 1985 Toyota 4x4 about 10 years ago. Body parts were nearly impossible to find so I had to improvise. Sad to say after that I just don't have the patients anymore.
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PostPosted: Wed Mar 09, 2016 7:49 am    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

You are on brave brother, to save that one!
"Build your own bug kit-package"... available at the Home Depot and OBI Baumarkt stores near you soon, hahah Wink !
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PostPosted: Wed Mar 09, 2016 7:54 am    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

CRAZY Shocked Shocked Shocked
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PostPosted: Fri Mar 11, 2016 12:42 pm    Post subject: Re: The "Gartenkäfer" - '62 resurrection Reply with quote

Good work, keep it up. They all deserved to be saved.
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