Roman’s Rust Bucket ('67 Beetle)

[67CarGuy]

Nice work! You're giving me some inspiration to finally get back to my own '67...
_________________
1967 Beetle (Family car - 2nd owner) ...What have I gotten myself into?!
1967 Plymouth Barracuda (Family car - 2nd owner) ...See a pattern yet?

[rstrobel]

[rstrobel]

For those who are curious...this most of what I've done so far...as well as an estimate of the total amount spent in parts (I don't have receipts anymore for spray paint, etc.) Also, the formatting is a bit confusing because I copy and pasted if from my excel spread sheet


1967 VW Beetle Log

Date/ Work Done/ Hours/ Price/ Place Purchased/ Side Notes

12/9/2018 Car Purchase Arrived at 2:15 $2,000 1st Owner: North Carolina, 2nd Owner: Kentucky, 3rd Owner: Fortville, IN (5 years), 4th Owner: Chip (1 Year)
12/10/18 Zip Tie Hack 15 min $0
12/16/18 ACDELCO Battery Install 15 min $84.99 Menards
12/22/18 Oil Change 1 Hour $23.30 Menards/NAPA
2/8/19 Parts Order $360.49 Jbugs
2/9/19 Engine Removal 1 Hour
2/9/19 Carburetor Rebuild 1.5 Hours $16.11 Jbugs
2/11/19 Engine Dissassembly 2 Hours
2/12/19 Engine Cleaning 1.5 Hours
2/13/19 Engine Cleaning 1 Hour
2/14/19 Engine Cleaning 2 Hours
2/16/19 Engine Cleaning 1 Hour
2/18/19 Sand Blasting Intake Manifold 1 Hour
2/21/19 Engine Seal Removal 1 Hour
2/25/19 Front Brake Rebuild 1 Hour $18.66 Jbugs
2/25/19 Oil Cap Gasket 5 Min $1.28 Jbugs
2/26-3/16/2019 Cleaned Pistons, Honed Cylinders, and Installed New Rings 4 Hours $17.95 Jbugs
3/16/19 Put Cylinders back togeather 1 Hour
3/22/19 Rebuilt/Installed Heads 30 Min $275 Head Solutions Inc.
3/22/2019-3/31/2019 Derusted and Spray Painted Engine Tins 8 Hours
4/1/19 Sand Blasted and Spray Painted Engine Tins 2 Hours
4/2/19 Added another coat to all engine tins, Derusted fan shroud 4 Hours
4/3/19 Wire Wheeled the Fan Shroud, Primed, and Added First Coat 6 Hours
4/4/19 Added two more coats to the fan shroud 3 Hours
4/6/19 Wire Wheeled/Derusted/Painted Heat Exchangers 3 Hours
4/7/19 Finished assembling engine, installed new spark plugs, removed transmission 6 Hours $9.96 O'Reily Auto Parts
4/10/19 Power washed transmission 30 min
4/15/19 Removed/correctly installed drive gear, replaced fuel pump flange and gaskets 30 min $18.49 Amazon/EMPI
4/15/19 Wolfsburg West Order $282.96 Wolfsburg West
4/17/19 Continued cleaning tranmission 1 Hour
4/19/19 Replaced spark plug wires 15 min NAPA
4/19/19 First engine start (issue was spark plugs not in right order) 2 Hours
4/20/19 Replaced swing axle boots 2.5 Hours
4/28/19 Replaced shocks, cleaned pressure plate, replaced clutch, replaced bearing hub seals 3 Hours
4/29/19 Replaced rear break pads, springs, and cylinder 45 min
5/12/19 Brake fluid flush 3 Hours
5/14/19 Replaced fuel pump rod housing thing
5/29/19 Fixed Fuel Pump Gauge/Master cylinder welds/First Drive 2 Hours
6/13/19 Started constructing body dolly 4 Hours
6/17/19 Finished constructing body dolly 2 Hours
6/18/19 Removed body from pan 6 Hours
6/26/19 Heightened body dolly 1 Hour
6/26/19 Wolfsburg West Order $737.19 Wolfsburg West
6/26/19 CIP1 Order $244.77 CIP1
7/23/19 Cut out battery tray section/Removed front and rear axels 4 Hours
7/26/19 Welded in new battery tray section and other chassis repairs 6 Hours
7/27-8/4/19 Sand Blasted Chassis 13 Hours
8/4/19-8/7/19 Primed Chassis 3 Hours
8/5/19 CIP1 Order $159.98 CIP1
8/15/19 Cut out quarter panel/heater channel/rear cross member 6 Hours
8/21/19 CIP1 Order $92.75 CIP1
9/22/19 Sand Blasted and Primed passenger side heater channel area 2 Hours
10/29/19 KlassicFab Order $550 KlassicFab
TOTAL HOURS: 113.5 TOTAL $: 2,821.39
_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[rstrobel]

Well, this turned out to be a mess...I guess you live and you learn haha. I spray painted the inside of my KlassicFab Heater channels because there were a few areas that weren't painted very well. I used an extra 3 foot flexible spray paint hose that still had from Eastwood's "internal frame coating;" however, I didn't want to use that expensive paint. So, I went to Menards and found a spray paint that had a compatible head with the 3 ft hose and bought a couple cans of it. I made sure that everything was coated well, so I emptied a couple of cans in the heater channels. However, I didn't want the paint to be too thick and crack, so I poured out all of the excess paint that was in the heater channels. In hindsight, I shouldn't have used so much paint, but oh well...

I let them dry next to the heater for two hours.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[robert hogaboam]

Nice car. Great work you are doing. How old did you say you were. I have restored cars for 40 years and it is great to see a younger guy doing what your doing. 67 chevelle 68 912 67 bug 63 ragtop bug.

[rstrobel]

[rstrobel]

Yesterday, my brothers helped me weld in the heater channels. First, I had ordered the Klokkerholm heater channels, but I felt too bad putting them into the car, so I ordered the KlassicFab ones. The KlassicFab heater channels fit like a glove. I didn't have to do any modifications in the slightest. Before I could weld them in, however, I had to build another a different support structure. I built it so that I can hang the body from the middle rather than the front and rear. This allowed the doors to shut a little better.

However, the doors still didn't shut well, so I used a ratchet strap to adjust them better. Once they shut perfectly, I welded the heater channels in.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[rstrobel]

This is what the doors looked like before when I opened them one inch

This is what the door looks like now after the heater channel was welded in. The trim isn't lined up perfectly because the door is opened about an inch.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[buggdude67]

Very nice start to your project. I have always loved 67 VW anything. There's just something special about them. I was wondering what is the name of the original color, on your Bug.

[rstrobel]

[Rome]

You did really well with selecting and buying this '67 for that price, even with having to replace the rusted panels- a work in progress.

[rstrobel]

[rstrobel]

I was going through my camera roll the other day and found some additional pictures of the day where we purchased the beetle. It looked pretty good before the body was taken off

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[rstrobel]

On the 19th it was my birthday, and I got this cool card!

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[rstrobel]

Because of this extended spring break due to COVID-19, I was able to get a little more work done on the '67.

I finally started to tackle the front clip hack job...

I was able to source an original '67 front clip about two hours away from where I live. This will make replacing the front clip much easier, fitment-wise.

This is what the front clip looked like.

I originally thought that I would just use an oxyacetylene torch to melt the braze off, but upon further inspection I realized that cutting it off would be easier.

Once most of the metal was cut off, I was able to begin the removal process of the front quarter panel. Luckily, they only brazed the drip edge to the quarter panel in three places, so taking it off was no issue.

I used a metal rod with a sharpened tip and the oxyacetylene torch to unfold the drip edge. It was folded poorly by the PO, so I'll make sure to do a better job when I refold it.

I still had to undo the brazing close to the windshield. I used the oxyacetylene torch and was able to remove the fender within seconds.

Now, time to sandblast a few areas and reinstall the new front clip...
_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[rstrobel]

I haven't posted in quite some time; however, progress is still being made...


I started tackling the rear luggage tray area, since it is pretty rotted. Here are a few pictures after I did a little bit of sandblasting, so that I had an idea of what I was working with.

I disassembled the replacement section for the rear shock tower area, since the panels are not sprayed before they are welded together. This picture shows the rear portion of the replacement panel, as well as the original shock tower mount.

Before I replaced the rear shock tower replacement panel, I decided to tackle the rear cross members first. I again drilled out all of the spot welds in order to separate the panels. Also, since the "paint" that Klokkerholm uses is quite poor, I sandblasted and painted the metal.

The heater tube hole was also not correct, as it was originally oval. As such, I cut the original heater tubes out.

Then, I cut the flange off of the replacement panel and traced the original heater tubes. This created a perfect fit, allowing me to weld the tubes in.

Also, side-note, remember...rust spreads...even to the eye . Although I was wearing protective gear, a small piece of metal managed to get into my eye while I was grinding. This created a rust ring in my eye, causing me to have to visit the eye doctor numerous times.

While it was still a little cooler outside, I sandblasted and primed the front quarter panel in preparation for the front clip replacement.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[rstrobel]

Now that school is back in session, finding time and energy to work on the '67 is becoming more difficult.

Here is a little update, however...

After sandblasting and painting the front quarter panel, I tack-welded it back onto the car. Then, I slid the front clip on. This allowed me to get an idea of how it would fit and where I would need to cut. (I am making a YouTube video on this, since it isn't the easiest repair)

My sister got married this past weekend, so I washed my '93 Cabby and let them drive it. (dangerous move )

This is my other sister and I in the Cabby.

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle

[TinCanFab]

I have a tiny fleck of steel in my eye that turned to rust also from grinding about 12 years ago.
_________________
Check out my truck brought back from the dead... http://www.thesamba.com/vw/forum/viewtopic.php?t=420762&highlight=sprayed+blood

They're never really ever finished 58 rag build...
http://www.thesamba.com/vw/forum/viewtopic.php?t=658092

[rstrobel]

[rstrobel]

Now that I am on winter break, I am able to work on the '67 again. My plan is to finish the rear shock tower, rear luggage tray, and rear quarter panel area before summer break. Then, I'll only have the front and rear clip to do.

I ground down some welds on the heater channel end cap.

Then I painted the area.

I also purchased a front beam, since mine is too rusty for my liking

_________________
1967 VW Beetle
1993 VW Cabriolet
My 67 build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=716767
•(__)•
(O\!/O) <--- supposed to look like a beetle