My 1961 VW Beetle Build Thread

[wachuko]

I got a VW bug!!!! So exited! First bug I have owned. Really looking forward to the journey.

1960 err, I mean 1961 VW Beetle

Photos when I bought it:

First thing that I did last night was to fix the headlights... one wire was installed incorrectly and it was blowing a fuse... all lights working fine now.

First changes that I want to tackle this weekend:
1. Replace one rear wheel bearing
2. Raise the car
3. Replace muffler

More later, just could not wait to share.

Edit: Adding the list of things done and those pending... will continue to update the list as I tackle these tasks...

Photo as of Feb 2, 2019

This car will never be a concourse car… I just want to make it a reliable driver.

Just making a list of pending items. Except for the first one, the rest are not in order of priority:

Pending:

1. Fix fuel line and ignition wire routing
   
2. Need to get under the car to validate what type of transmission I have. To determine if it has a reverse switch. If not, I will need to buy speedometer reverse switch and run wires for reverse/backup lights
   
3. Paint rims Silver Beige. Will paint them for now...got the paint from WW. Eventually, would like to get them powder coated.
   
4. Install inside door window squeegees
   
5. Install seat covers. Want to strip the seats and powder coat (or at least paint for now) the frames.
   
6. Install headliner. Once this is in place, I can then install the rear side panels
   
7. Install new rear window seal and trim. After headliner is in place…
   
8. Unclog heat riser (purchased in the classifieds) for stock setup
   
9. Install stock carburetor with oil bath air cleaner
   
10. Install stock distributor
    
11. Correct title in the DMV from 1960 to 1961
    
12. Fix/connect windshield wiper motor (also install the voltage drop resistor/heatsink)
    
13. Fix windshield washer water system… this one will be fun…
    
14. Fix rear lock. For some reason, I cannot turn the key to lock it. I got this new one as a set. If I take it out, I can turn the key without issues... installed, I can only turn the key if in the open position.
    
15. Replace wire harness sections as I tackle the different issues.
    
16. Remove radio to inspect operation and reinstall.
    
17. Have local shop replace/repair any metal needing attention. Replace rear apron for correct one. Repair area in front of rear fenders due to bad patch job..and anything else critical that requires attention.
    
18. Buy and install REAL running boards…

Done:

1. Raised
   
2. Removed exhaust and replaced both muffler and J-tubes with stainless steel units...
   
3. Cheap #@%#@$ running boards installed
   
4. Odometer cable
   
5. Fuel gauge light socket
   
6. Stainless steel moldings
   
7. Door window trim replaced
   
8. Tag light lens and bulb
   
9. Front door panels replaced
   
10. Sun visors replaced
    
11. Rear-view mirror replaced
    
12. New Pop-out windows installed
    
13. New steering wheel installed
    
14. Front windshield, seal, trim installed
    
15. Missing radio. Only put in place for looks (for now)
    
16. Headlights and turn signals operational
    
17. Stainless steel roof rack installed
    
18. New dash grab handle installed
    
19. New knobs for switches and ashtray installed
    
20. Emergency brake handle fixed
    
21. Installed missing bumper brackets/spacers. This fixed the clearance issue between the rear engine lid and the bumper
    
22. Broken wheel stud replaced
    
23. OG Gas tank cap
    
24. Missing gas tank hold-down brackets and bolts installed
    
25. Matching keyed ignition switch, door handle, rear engine T-handle installed
    
26. Oil change
    
27. Billet crankcase cover
    
28. Air filter on existing weber replaced
    
29. Door rubber seals
    
30. Engine lid rubber seal
    
31. Replacement driver-side fender replaced and missing horn grill installed
    
32. Replaced front turn signals
    
33. Replaced rear turn signal lens
    
34. Installed glove box basket (was missing the bolt and I had it upside down…)
    
35. Replaced glove box door hinge spring
    
36. Installed trunk liner
    
37. Installed dash back (trunk side) cover
    
38. Installed 3-point seat belts for driver and passenger. Went with gray.
    
39. Installed assist straps – missing from my car. Got them from WW
    
40. Replaced alternator pulley, shims, woodruff key and belt
    
41. Installed and connected horn
    
42. Replace rear passenger-side wheel bearing. This was something that the PO told me that it needed to be done. When I went in to replace it, it was in good condition, so only replaced seals
    
43. Removed bumpers to install rubber grommets. Paint inside of blade in the front bumper. Installed rear-missing support. Install the bumpers back and tightened everything properly.
    
44. Replaced rear brake shoes and hardware
    
45. Installed support brace for driver side arm rest and installed missing handle springs
    
46. Replaced valve cover gaskets
    
47. Drivetrain hopping fixed!! Replaced bowden tube and bracket. Replaced the clutch cable and clutch pedal shaft while I was there... oh, and new pedal pads installed as well
    
48. Ran wires and installed switch for fog lights

_________________
Drive safe,
Wachuko

1961 VW Beetle - Ownership Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=711372

[vwuberalles]

Looks like a great start, congratulations and welcome! It'll look even better once you fix the suspension.
_________________
1973 Superbeetle: 1st car, owned since age 12. Update thread --> https://www.thesamba.com/vw/forum/viewtopic.php?p=9919140#9919140
1967 Kombi: Owned since age 17, Dad's retirement project.
1966 Beetle: My new project. (SOLD) Build thread--> https://www.thesamba.com/vw/forum/viewtopic.php?t=678040

[panicman]

Welcome Wachuko!

1960 is near and dear to me. I’ll be looking forward to your updates and seeing your plans unfold.
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Plate of shrimp

[Sharp64]

I saw that listed on FB. Looked decent. There’s a growing VW scene in the area so welcome. What area of Orlando? I run with a couple of guys in the Oviedo area. Hit me up sometime. What are your long term plans?

I guess my buddies and I have broken suspension too. 😂

Mines the 60 on the right.

_________________
1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine

[wachuko]

Thank you for the warm welcome!!

Photos of the interior:

Steering wheel is all cracked... I have seen the videos on how to repair them... but I am just going to order a new one...

Ok, back from the tag agency... it is all legal and registered. Seeing the photos I realized the previous owner forgot to take his tag... I see him this weekend to get a spare driver side fender he has... will give it back then.

So... car metal is solid. That was the main thing that I was looking for since my bodywork skills suck... I can work the rest. I just want a driver for now. Promised myself I would not go crazy trying to restore it... just want to fix the interior and make sure anything mechanical on the outside is working as expected.

Last night, as I was fixing the lights, I was making a list of stuff needing attention. I was also going over a lot of the stuff that is just loose... For example, front trunk lid was not locking and it was just because the catch's bolts were loose... bumpers are all loose, need to adjust all the bolts on the mounts to body and bumper to mount bolts. I need to get more blue and red loctite!!

So this morning, left early, and on my way to work stopped by the local VW auto parts (Triangle Auto Parts here in Orlando)... Got the following:

I really want to get rid of this:

Debated between a stock setup...or the same one I got but in steel (a lot less expensive)... at the end, since I do not plan to get rid of this car, I went with a stainless steel exhaust in the hopes that it last longer while still looking decent...

Stainless steel exhaust

I also got:

• New rubber seals for trunk lid, engine lid, doors
  
• Fender to body seal for that fender that is there right now... no rubber trim on it right now
• Emergency brake handle (my is missing the mechanism that allows it to lock in position. I will try to fix mine with the internals of the one I bought... if not, the new one goes in completely... wanted to keep the gray painted one that is there right now. Will see how that goes.
• Rear wheel bearings with the seal/gasket kits
• Odometer cable (humm, I hope they remember to add the circlip in the bag...
• Side Molding Kit, Stainless Steel, 7 piece, For Use w/ Wolfsburg Crest - In the photos you can see that the trim on the trunk is longer than it needs to be...I just wanted that strip but ended buying the complete set in stainless steel. Got new clips and seals to replace all of mine
• Glove box. Plastic box was missing in mine.
• New bolts for the bumpers. The ones on the bumpers, some were missing, some where fully rusted...
• Engine lid handle with key
• Door window trim - I thought I could just buy the rubber squeegee but learned that it is all a complete trim with the aluminum piece
• Tail/Tag light clear plastic housing with rubber seal.
• Some spare fuses and light bulbs

.

Pending things to get:

• Steering wheel... after seeing a new one at the store, I am not going to try to restore mine...I will just place it on the wall and install the new one in the car. Need to take a look at the car again on the sun light to confirm if it is gray or ivory... I kid you not, I was so tempted to buy it this morning but was not sure of the color... that new wheel looked sooooo nice...
• Headliner. I was surprised it was not perforated vinyl...also need to decide what color this should be... but I would like to switch it to perforated vinyl... that is what I remember seeing in my dad's car (this is the main reason for getting the VW Bug...the older I get the more I am turning into my father...must be nostalgia for not having here anymore)
• Seat covers and door panels - would like those to look sharp... will repair the existing panels for now and install some moisture barrier to make them last longer
• Pop-out side windows - I don't need these... but I sooo want them, lol
• Driving lights - another thing that I do not need but looks so cool...
• Period correct looking radio... not high on my priority but to fill that hole in the dash

That is it for now... can't wait to start working on the stuff I got today.
_________________
Drive safe,
Wachuko

1961 VW Beetle - Ownership Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=711372

[thechief86]

Nice score! Looks like a nice 80's 911 in the garage as well?
Raising the suspension back up a bit isn't a bad idea. I've had some pretty rough experiences daily driving a slammed car, and am hesitant to go that low again.
I've had many cars that are much "better" than the best bug could ever be, but nothing scratches the same itch. It gets in your blood if you let it.
Even friends I've had that said they'd never have another one end up getting one or wishing for one anyway.
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"A poor workman always blames his parts... Ya gotta have skillz to hang junk." -johnnypan

[Sharp64]

One thing I’ll suggest and then shut up. Slow your roll on buying a bunch of parts. There are definitely different levels of parts quality. EMPI tends to be lower quality on a lot of parts which is what most places carry. Especially chrome parts. Look at places such as Wolfsburg West or West Coast Metric for new parts, especially the latter for rubber seals. You make also want to look for N.O.S. vs reproduction.

You may also find that you’ll need to modify the trim for the hood to fit over the badge correctly. I did and had to do my buddies as well.

The headliner in 1960 weren’t vinyl but the mouse fur like you have. That looks potentially like the OG headliner. I would also think twice before using loctite. Get the correct size wavy washers to lock the nuts in place.
_________________
1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine

[wachuko]

[wachuko]

[wachuko]

A question I had was on the gap the engine lid has... what should be the correct gap?

This is one I did not touch last night (well, because it was 1:30 am already! ) because I had no clue on what was the correct spec for it.
_________________
Drive safe,
Wachuko

1961 VW Beetle - Ownership Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=711372

[wachuko]

Well, thank you again Sharp64!! I was going to have three keys for the car... Guess what? Wolfsburgwest has a matching set... adding to the wish list. For now will use what I have... but soon... very soon...

_________________
Drive safe,
Wachuko

1961 VW Beetle - Ownership Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=711372

[Bigjacksauto]

NICE bug.looks like you may have a 61 or newer speedometer and someone added a fuel gauge?
Great advice above of not buying to many parts to quickly. Although I will admit I am guilty of that lol.[/list]
_________________
https://www.facebook.com/groups/2778888602388847/?ref=share
1968 Beetle "Herbie" replica Father Son Project
1960 Beetle deluxe / Flint/Pebble Grey og 1200cc 36hp
1975 Westfalia bus sold
1967 SO 42 Westfalia Bus

(o\_!_/o)

[Sharp64]

[wachuko]

[wachuko]

[wachuko]

I should search first before posting questions... so much information already available.

Couple of links on the gap question I had:

https://www.thesamba.com/vw/forum/viewtopic.php?t=484078

https://www.thesamba.com/vw/forum/viewtopic.php?t=654300

https://www.thesamba.com/vw/forum/viewtopic.php?t=674793
_________________
Drive safe,
Wachuko

1961 VW Beetle - Ownership Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=711372

[zabo]

looks good – Ill echo Bigjacksauto

- you sure its a 60? fuel gauge and grab handle point to a later model
Rear apron is not correct either -tailights look misplaced in the one photo but that could just be the weird angle.
_________________
1960 6 volt sedan- 1978 adventurewagen
–wanted bill spreen atlanta dealer tag frame

[wachuko]

[wachuko]

Engine photos... car is running fine, but that carburetor... missing choke parts??

I got a different cable setup just in case... but I rather continue to use it as is until it gives me an indication of needed attention... that will give me time to figure out what would be a proper setup or what this one is missing to have it all working as it should. Much to learn on my side... much to learn...

_________________
Drive safe,
Wachuko

1961 VW Beetle - Ownership Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=711372

[Sharp64]

Post a pic up of under the front trunk lid.

The knob on the lower right dash would have been a choke on a 60, but that motor is a much later dual port motor. Wonder if it has the doghouse oil cooler or not?

Regarding the year. The VIN on the should match in two spots. There is a VIN on the pan under the rear seat. There is a body tag in the inset behind the spare tire. These should match. Florida only cares about the VIN on the pan for title purposes, but good to know what you have. It’s not uncommon to see a body and pan being swapped.
_________________
1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine