My first bug - a 1970.

Summer 1986

I have always wanted to build a VW based car.  After 20 years of thinking it through, I've started actually turning wrenches on it.

Goals and objectives

Form follows function - I'm left handed, 6' tall and 230 lbs.

EMP proof - look it up if you don't know

Durable

Simple

Maintain everything myself

Appear Street legal

In 2002 I found a perfect donor car in a Navy brat 1974 Orange VW Beetle.  According to the stickers on the windshield and bumpers, it spent most of it's time at a Virginia Naval hospital, probably in the care of various nurses, contributing to all sorts of fun, trouble, and memories.  It was sold at a Navy auction due to abandonment.  I purchased it from that person, who wanted to restore it, however, it was going to be a bigger job than he thought.

For those that are not fluent in VW, here are the specs.

MFG: May 1974 (Germany)

1600 cc Dual Port Air-cooled Boxer 4 engine

4 speed manual

30-PICT-3 carb (hey, it still works perfectly, but I've been eyeing a Weber)

50 Amp alternator

Ball-Joint Front

IRS Rear

4 lug wheels

Of course, it's loaded with all of the available options - none.

Here is a  representation of what it looked like when it was new.

The story in Pictures

Sept 2002 - New to me - the pictures were taken in December; note the Christmas lights.

March 2003 -

Oops, spit out #1 plug, new heads installed along with everything else that needed replaced or serviced along the way, like eliminating a lot of vacuum lines, cleaning the oil cooler, hoses and connectors, distributor, carb, gas tank, brakes, battery tray, etc. Basically anything that I needed for a buggy or to drive on the street was replaced or repaired. Anything I didn't need was ignored (body, interior, glass rubber, etc.).

April 2003 - Like a sewing machine -

April 2003 through April 2008 (5 long years) - New tires and tubes.  Spent the time plotting and scheming what, exactly, I wanted to build with it. Also, driving it for fun, in the snow, and teaching my teenage daughter to drive a stick. 

Note to all - She reserves plausible deniability regarding anything associated with the bug in any way.

April 2008 - Finally saved up enough cash and decided on a Berrien Buggy frame (Classic 2100) side-by-side tacked kit and Body.

Assembly

June 2008 - Received the frame and body.

Ready to take to Dad for welding.

We just had to open it and look.  Dad with decklid.

June 30 2008 - Extracted and mounted the engine, ready for a bath and some new parts.

July 2008 - Rear Torsion removal - I couldn't find out how to remove the rear torsion.  Every book and web page says to buy one at a swap meet.  So, here's how I did it. 

• I removed the rear wheels, so I wouldn't bend the torsion arms. 

• I removed the shift lever rod connection, and the battery. 

• I used my tractor and boom to gently roll the beetle onto it's side.

• Unbolt the Fender/Body connection to the Torsion Shocktowers (17mm).

• Take out the transaxle (after you find a 12 pt M8 Triple Square bit for the CV joints).

• Then grind off the weld to the body on the two little "tooth hooks" and make a cut through the tunnel with a reciprocating saw.  Make sure to avoid cutting the end of the shift rod and such.

    Simple, I guess it's just too straight-forward to explain in a book.

    (I Recommend buying one at a swap meet)

 Ford vs VW      Tipped      Cut away non-buggy parts   Transaxle drops out   

July 4, 2008 fitting the front torsion to the frame/body.

Fitting and finish welding the tacked frame with torsion.

The baja exhaust and the rebuilt torsion housings.