My 69 Bug Build

[VengeanceASX]

So I picked up my first ever Air cooled car last month, a 1969 VW Beetle. I've had a few posts, so I figured I would just start a build thread. This is a daily driver that I picked up to use to commute to work 3 times a week. So I am trying to fix it up while maintaining drivability until the summer, when I can strip and paint it.

This is not my first car restoration. I've done a dozen or so restorations and a few motorcycles. I know my way around a wrench, but this is my first Air Cooled VW. Hopefully not my last.

Here's what I started with.

Had to fix the only rust I could find in the car.

Cleaned up some wiring and a radio that wouldn't turn off.

Pulled the interior, POR 15 and some sound deadener.

Don't know what they kept back there, but it left its marks.

Sound deadener. I hope it's as good as the 3 headliners I removed.

This next weekend, I hope to finish the sound deadener so I can put the seats back in. I am planning on wiring in a fuel pump relay and getting my new seatbelts (back ordered for over a month now) and bumpers on.
I have another set of seats, doors, fenders, hood, and deck that I will be working with where needed. I think I am putting a new rear deck on with better venting and the original fenders on for the tail lights.
I also have a set of doors with OG paint and original wind wings that I am going to install. I'll keep you updated as it progresses. I

Feel free to comment and leave suggestions. It is my first time...

[Tom K.]

Nice project! You started with a car in pretty good shape, and you certainly know how to weld - nice patchwork! In the engine, you will probably want to find a real VW air filter (oil based). Also the vacuum line between the distributor and the carb look wrong to me, but it could be a set-up I'm not familiar with.

Regarding sound deadening, there is no need to cover every square inch with the stick-on vibration stuff. VW did with the old tar board because that is all they had to work with. The best products suggest that covering 30% of the metal surface is all you need - enough to kill the vibrations. Even 100% won't reduce air noise by much. But everyone in the VW world seems determined to cover every inch with the stick-on stuff and do nothing more. But after 30% coverage with the stick-on stuff (butyl-based preferred), you can reduce air noise significantly by covering 100% of the surface with a 1/8 inch layer of cell foam (neoprene) and then cover 100% with an 1/8 inch layer of mass-loaded vinyl. These last two products are inexpensive.
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'91 Vanagon Westfalia
'70 Beetle Convertible
'71 Super Beetle Semi-Automatic: https://www.thesamba.com/vw/forum/viewtopic.php?t=714131&highlight=
'65 Ghia: https://www.thesamba.com/vw/forum/viewtopic.php?t=762478&highlight=

[VengeanceASX]

Ha, Yeah I went a little over kill in the sound deadening compartment. I bought 100 sq ft of the stuff on Amazon. I got most of the roof done and realized when I tapped on it that it was probably good right there. I already picked up an oil bath air breather and am in the process of restoring that. I also got the pre heat stove pipe and ducting to hook all of that up along with the bent vacuum tube for the distributor to the carb. I am also going to add all the vent setup and even a charcoal canister like the 70 and up Beetle. The PO had a venting gas cap on and I am changing all of that.

[Buggeee]

Rockin' and Rollin'

Your wiring looks great now.

Tom's practical approach to the sound material is a day late for me I've got rolls and rolls of quickroof in the basement now, and I'm a-gonna-use-it, just like these pics here! lol

Nice yellow bug. The two tone looks cool. Enjoy the driving - we're salted in for the winter over here.
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1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[VengeanceASX]

Yeah, I'm working on the asphalt stuff in the pan. Luckily it's only on the driver side and tunnel. I'll get on it with the heat gun this weekend probably. I have a set of green fenders correct for the year and some green doors that have vent wings in them. I think the one piece window kit lets water in or doesn't drain as well or something because the bottoms of the doors are pretty rusty on the inside and the panels were ruined from water damage. I also have a green deck lid for the rear. I think once I add all of those things, I'll throw some white primer on it until summer. I'm having a blast on this thing!

[VengeanceASX]

So I got my new heat gun in to tackle the floor pans and that thing worked great! I read a post here not too long ago about whether or not to remove the original tar paper sound deadener and let me tell you I am sure glad I did. Not rust from the bottom, but oh man was there some water trapped at some point. I think there was even some white mildew between the layers.

I fully recommend removing this stuff! I poled around and welded a couple pin holes where the pan was thin, neutralized and POR15.

[VengeanceASX]

I also removed some old sound deadener that had been stuck on the right rear quarter panel and noticed there were tons of dents and holes where someone had attached a slide hammer to pull it out. Tons of Bondo was used to make it straight on the outside. It happened with the original paint and had 4 paint jobs after that with primer in between all but the last one. I got distracted and hammered everything back out and welded the holes. I will post some pictures this weekend, but I forgot to take before pictures. I'm guessing this thing was hit back there, maybe the engine hit the firewall and that's how those dents and a newer engine got there??? Also new stick on side chrome??? pulled the paint off when I removed it.

[Buggeee]

[VengeanceASX]

[zmichael84]

Now that I'm on the home stretch for my 69 build, I appreciate the current state of yours and the work you're doing. Keep chipping away at it and keep the updates coming; I'll be following!

[VengeanceASX]

I've been debating if I should take the sound deadener off of the tunnel? It is in really good shape and I don't see how water could get trapped under neath. Suggestions, please...

[zmichael84]

It doesn't come off as easy as it does on the floorboards. I left it. You can get a good idea of condition with an inspection mirror through the shifter hole, or looking in the front cover.

[VengeanceASX]

So I left the original sound deadener on the tunnel. Everything that I could tell was rust free so I just cleaned up the floor panels and coated with a Rust converter/barrier and finished the floor.

I finished knocking off and cleaning up the back right quarter panel where it was wrecked at some point and welded all the old holes up that were left from a slide hammer or puller. I welded some nuts in for the fenders and had one little spot of rust in the bottom corner to fix. Put some new fenders on it with properish tail lights(from a 1970) and a 1970 rear deck lid. I figure this newer 1600 dual port might need a little more air when it gets in the 100s this summer.

I also finished wiring up my new fuel pump relay and it starts and runs like a champ. Just need to vent the gas tank and add original air cleaner, engine stovepipe, and relocated the plastic fuel filter to somewhere safe. I still have a few heater ducts to run behind the dash, but I have all the parts. I will post more pics when I get a chance.

Any recommendations on where to put the fuel filter?

[tasb]

The vacuum line from your distributor is going to the wrong port on your carburetor. It needs to be re-routed to the drivers side in front of the throttle spring.
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Roads Scholar &
1957 Kombi low mileage 36 hp governor equipped M 178 Slow Drag Winner 2014, 2015, 2018

1965 hardtop Deluxe Microbus owned since 1990 M 620 factory 12 v 1500cc

1961 (October)Single Cab- Road Trip Workhorse

[Buggeee]

A preferred spot for the fuel filter is above the driver's rear axle where the metal fuel line exits the body. That way if it leaks or cracks the gas just ends up on the ground.

This is moving quickly!
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1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[VengeanceASX]

[VengeanceASX]

[Buggeee]

[joey1320]

[sjbartnik]

I did that as well, and zip-tied the filter and part of the fuel hose to the clutch cable Bowden tube so it doesn't flop around.
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1965 Volkswagen 1500 Variant S
2000 Kawasaki W650