My 1500S Notch Project

[Ossipon]

So here goes. Was asked for Pics in a prior post. But was out of town for couple of weeks. This is my 1964 1500S Notch (Gretchen). Thus far the drive train is looking good. Have been doing all the same things I did when I got a barn find Single Cab and 59 Bug years ago.
Am Showing her blemishes in my gallery submission. These will be my biggest headache.
So have a question, Passenger Floor pan sourcing. Is it better/easier to mod a Type 1 floor pan replacement or is there a good source for a replacement. I know I have to replace Heater Channel and Rocker support as well. The battery was on that side and looks to have leaked/cracked causing the major corrosion. The Front skirt where the spare sits is the other big issue. I think I will rebuild it as sourcing a Type 3 front skirt is not as easy.
I now will be joining the 1500 club as Gretchen (Her name) is definitely a member.
This will be my project for the next few years.
PS: Have the Front bumper as well as the original 1964 Tags when she was imported. And original manual/service Manual.

[Jason37]

For the floor pans if you don't need to replace the whole section, ISP west offers half length. If you need to replace the entire side, then Gerson offers type 3 specific pans.

For heater channels and the front clip, ISP West and Joel (Boo-Koo-Z) are good sources, I had a front clip sent via Greyhound for a reasonable cost.

The rocker doesn't look too bad in the pics and maybe can be saved with patching as getting early or notch specific channels is difficult.

[Ossipon]

[vwfye]

Cool car!
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64 No'back Speedster "Pearl"
1980s Sand Dragster "The Plunger"
LME "Little Giant Killer 3"

[BSQUARE]

[Bobnotch]

[Ossipon]

[Mike Fisher]

Don't bother looking for good used notch metal as they won't sell it.
Use square/fasty metal or have a Hot Rod Shop fab/weld new replacement sections.
Note the notch heater channels are sloped on the inside & your doors have the 3 bolt hinges that are rare!
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https://imgur.com/user/FisherSquareback/posts
69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
two 57 oval ragtops sold
'68 Karmann Ghia sold

Society is like stew. If you don't keep it stirred up you end up with a lot of scum on the top! - Russ_Wolfe/Edward Abbey

[Bobnotch]

[Ossipon]

[ALLWAGONS]

Super cool you have a Spanish delivery car. I collect Spanish language literature and materials. I've yet to find a Spanish manual. Did yours come with one in Spanish?

I have the introduction of the VW 1500. and both Vol 1 & 2 of the repair manual that covers up to '66.
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I'd be UNSTOPPABLE if not for Law Enforcement and PHYSICS.

I recycle old cars and parts, other than when I rot, that's as Green as I am going to get.

Thanks to my Tesla driving neighbors, I feel more relaxed driving my SUBURBAN and old VW's.

NON INFLUENCER APPROVED

[Ossipon]

[ALLWAGONS]

Oh! No worries, Good Luck with your build! I own a '65 sunroof Varaint that I restored using mostly NOS parts. Everything is out there.

Martin
allwagons
_________________
I'd be UNSTOPPABLE if not for Law Enforcement and PHYSICS.

I recycle old cars and parts, other than when I rot, that's as Green as I am going to get.

Thanks to my Tesla driving neighbors, I feel more relaxed driving my SUBURBAN and old VW's.

NON INFLUENCER APPROVED

[Ossipon]

So, after having it two weeks, I now know the following.
1. Engine was replaced in 1967 with a 1600 reconditioned case. My bet it is a 1600, but will not know until I get to the engine.
2. Rust is both worse and better as I deep dive inspect it. These are the problem areas and require replacement.
a. Heater Channels Left and Right. Thought originally only passenger, but on further inspection, the driver needs it as well. I should not be surprised. Will be ordering real soon now
b. Passenger Full Floor pan. This was ordered and has arrived. Will start on it once the right heater channel has arrived.
c. Driver front half floor pan. The area affected by the front of the heater channel has a weak area which would just be easier to replace.
d. Driver Front Fender: Rust out by Headlight and turn signal too much to allow patching.
e. Passenger side Door under aluminum cover. If I am going to do the others, this might as well be replaced as well.
3. Patch/Butt Weld or Fiberglass required:
a. Front Skirt: The initial review indicates I can butt weld and/or fiberglass the problematic areas.
b. Back compartment wall Driver side. Small hole in back wall that I think I can easily butt weld.
c. Passenger wall below glove compartment. Leak from bad welt and antenna seal.
d. Passenger fender: May need to be replaced, but will first attempt rebuild.
e. Door Skins. Rust pimpling down near the bottom, but not horrible.
4. Brakes: Full rebuild, two lines identified as rusted through. So am currently rebuilding cylinders. Deciding whether to update to dual over single MC. Will depend upon pitting of existing MC.
5. Usual Suspension needs, Ball Joints, Tie Rods, Damper, Stops, Shocks...
6. Engine: Currently the great unknown. Oil was still oil and not sludge when drained. Definitely replacing Exhaust.
7. Fuel: Boiling the tank and overhauling the dual solex 32s, Fuel line blows clear, but will likely need cleaning. Fuel pump will be rebuilt.
8. Electricals: Thus far, all the wiring seems sound with no shorts detected. Will be replacing filament bulbs with 6V LED when the time comes.
I looked at this as a two year project and I think I will be right. Will be taking before and after pics on each segment and will post.
9. Other: Re-rubber, welt and seal with new rubber components. Plus the unknown
My first step will be tackling the passenger pan. It is never good when you can see the passenger tire from the driver seat. What I see does not scare me, but it will be work and lots of fabrication/weld.

Enjoy

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Ossipon
VWs in my life:
Air
Type 1 - 59, 62, 63, 71 Super 68 KGhia/ Type 2 - 59 Single Cab / Type 3 - 64 Notch
Water
GTI 83, Jetta 81, 85, 87, 91 TDI, 98 TDI, 09 / New Beetle 99 / SportWagen 05, 13 / Tiguan 18 / T3 92

[W1K1]

have you pulled the fenders off yet?
there can be so interesting rust areas under the fenders
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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

[Bobnotch]

You might want to post up some pics, so we can help you with the terminality of some of the bits you need (an example of this is the metal under the aluminum sill plate, that's the inner and outer rocker assembly).Then we can help you make a list of what you need, and then see IF Joel or ISP can help you out. Some of the metal might be easier if it was rust free used, versus trying to shape it. Some parts you might need have multiple indents or other shapes that might be seen at a show (not saying you have to do a Steve).
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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

[Ossipon]

[Ossipon]

So, here is where I am at 1 month in and just really getting started. Unlike the West and NorthWest US, here in Kansas City it has been wet and muggy. I have been primarily just ordering body parts and evaluating what I will have to fabricate.
While I would like to do a Frame off restore, I do not have means or space to accommodate. Sooo, I will be doing my best to do a functional restoration without "restroying" anything
Have cleared the interior of carpet, rubber, Seats, etc.
+ Pans: Gerson Pans ordered and received. Passenger side cut out. Had hoped to follow in part 65NSqBack instructions, but face an issue on what he did in the front. The front right curve which he used to anchor is gone and eaten. As identified, the rust on that side is from a leaked battery which was not properly neutralized. Will make due. It also at at the inside fender wall at the bottom. Will likely be buying a used inside fender to cut and place that section. Will attack the Driver
+ Heater Channels ordered and received. Will install as part of Pan replacement
+ Front Fenders removed and attempting to salvage the Sea Blue beading.
+ Front Apron: Ordered and waiting on an early Apron from Joel M. Shipping by Greyhound is a joy.
+ Front L Fender: Same with above with Joel.
+ Front R Fender: Bondo removed and will be butt welding the prior patched area
+ Am getting ready to remove the gas tank this week. The fourth pic below shows the black porridge leaking from the tank. I will be taking it to be boiled and tested.
Until my next post. By then, I hope have pan and sheet metal pieces fitted and ready to weld. While I am inbetween will be doing brakes and lines.

_________________
Ossipon
VWs in my life:
Air
Type 1 - 59, 62, 63, 71 Super 68 KGhia/ Type 2 - 59 Single Cab / Type 3 - 64 Notch
Water
GTI 83, Jetta 81, 85, 87, 91 TDI, 98 TDI, 09 / New Beetle 99 / SportWagen 05, 13 / Tiguan 18 / T3 92

[Ossipon]

One small discovery which I had not paid much attention to until I was stripping the interior. The radio is not the usual sapphire. It is a Blaupunkt Essen. Similar to the Blaupunkt Frankfurt. It is LW/SW/FM (88-104). I assume this model was installed since the car came from Spain and not Germany or France. Does anyone have the Essen model in their car? Other than a small crack on the glass face, it is OK. I doubt I can source that, but have fixed/mated similar to minimize the crack previously, so am not concerned.
If it would stop raining in the Midwest, I would start the simple butt weld needs. I only weld when it is dry. And it certainly is not dry here right now.

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Ossipon
VWs in my life:
Air
Type 1 - 59, 62, 63, 71 Super 68 KGhia/ Type 2 - 59 Single Cab / Type 3 - 64 Notch
Water
GTI 83, Jetta 81, 85, 87, 91 TDI, 98 TDI, 09 / New Beetle 99 / SportWagen 05, 13 / Tiguan 18 / T3 92

[Bobnotch]