64 bug project

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64 bug project

Post  bugdust on Fri 21 Nov 2008, 9:42 pm

I figured I'd put up a thread about the 64 bug I'm slowly building for my son. It's more of a amatuer resto-custom. I've owned it a while so I'll add a few pics of the little progress it's made so far. I was going to fix it up for myself originally.

The day I dragged it home. I had just stuck the fenders on with one bolt and the hood had two in it. Laughing



I was going to just run it with some painted chromies and ratty paint so I spent a lot of time removing the primer.



Then I decided polished 5-spokes would be better.


Rob striped a couple parts for it.



Then the body came off to replace the pans.


Then I bought the 67 and this project just stalled. Wink I ended up sitting the body back on the pan and rolled it outside. While I had the black 67 my son kind of claimed this one.

Once I sold the 67 I started back on this one. The body came back off and the other pan half replaced.


Before you know it the trans and beam were both off and the pan was on sawhorses.


Then the Masterseries was ordered and today I started blasting the pan. I had to stop so I'll blast the rest in the morning. This thing should be silver by this time tomorrow.


The body. It will get lower A-pillars and a couple small patches. The front apron needs to be pushed back out about an inch.


I have a 1600 dp for it. I'm going to build a narrowed airbag beam for a guy and he's going to make seatcovers and door panels for it. The plan is Porsche India Guards Red, polished 5-spokes, euro blade bumpers, full trim, probably tan interior with a fiberglass speaker box where the back seat would normally be. I'm going to build a 4" narrowed beam for it. It shouldn't be too bad for a first car. Very Happy

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Re: 64 bug project

Post  bugdust on Fri 21 Nov 2008, 9:43 pm

Got a little more done to the 64 pan today. I finished blasting the pan, welded another couple spots and got the first coat of the MasterSeries silver on the top. I'll get the second coat on tomorrow and do the bottom Thursday or Saturday. Then it will get the ChassisBlack.



Up close



Oh, when the paper says to put some in another container, they don't mean a plastic Solo cup. It ate through that pretty quick! The foam brushes worked fine.

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Re: 64 bug project

Post  bugdust on Fri 21 Nov 2008, 9:43 pm

Got the first coat on the bottom yesterday. This thing will be black by this weekend.

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Re: 64 bug project

Post  bugdust on Fri 21 Nov 2008, 9:44 pm

I know...more pics of a silver pan...woo-hoo! :?

This is the bug's 15 yr old owner putting the final coat of silver on the bottom.



We have put two coats on the top and two coats on the bottom and almost used 1 qt. of silver.

Tomorrow, we start the black! Very Happy

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Re: 64 bug project

Post  bugdust on Fri 21 Nov 2008, 9:44 pm

Well, I put a coat of Chassis Black on today. I am disappointed. It has been 24 hours since the last coat of silver. The instructions say apply the next coat after 3 hrs min, 48 max or sand with 220 grit if after 48 hrs. The instructions also state that if the black looks gritty to stir the paint longer.

I started the black and it looked gritty so I stopped and stirred it longer, probably 5 minutes total (2-3 the first time, another 2 or so the second time) As I apply it with the brush I notice it streaks a little like the silver is mixing with the black. The silver was dry enough to be handled without leaving handprints or feeling tacky. I know this because I picked the rear of the pan up to tilt it so the black would fill the pan-to-tunnel seam better since I forgot to stop & pick up some seam sealer. I also handled the spring plates quite a bit as I test fitted one of them a few times playing with the degree finder.

Anyway. It looks fine in the pics but in person it doesn't look so good. It streaked with the silver, looks gritty, and was a lot harder to get a consistent even coat (the silver was easy). When I do my 62 vert I will just use 3 coats of the silver and not use the black at all. This is not a show car at all but I hoped it would look better than it does. The pan will rarely be seen and I put the masterseries on for protection, not looks, so I'm sure it will be fine. I've just lost some confidence now and wish I would have left it silver. Mad



Hard to see the surface quality with the white ceiling reflecting but this is the black.

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Re: 64 bug project

Post  bugdust on Fri 21 Nov 2008, 9:45 pm

This is probably the last update for a while. My back is killing me and it starts to feel better so I go out in the shop and do stuff I shouldn't be doing, then I'm worse than I was.

The pan is painted top and bottom.



Next up is a bunch of little stuff. I have to install the new spring plate bushings & reinstall the spring plates, clean up the trans & install it, disassemble the beam, narrow it and get new tie-rod ends, etc, install it, rebuild the pedal assembly, install brake lines, etc. I still have to order a bunch of little stuff.

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Re: 64 bug project

Post  bugdust on Fri 21 Nov 2008, 9:45 pm

Well, I was feeling pretty good this morning so I went out and took off the axle boots (trashed) and all three trans mounts. The metal that goes across the framehorns is all bent up but I think I have another one. I pulled both rear drums (they don't match). I blasted the drums, trans, axle tubes, and most of the gas tank. I'll wait to post pics when I get everything cleaned, painted and put back in.

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Re: 64 bug project

Post  bugdust on Fri 21 Nov 2008, 9:47 pm

No progress yet. I have done a few little things, mostly been collecting parts. I'm going to try to figure out how much $$ I have into it so far tonight.

New parts I have right now:
muffler (same style glasspack that I put on the black 67)
all 3 trans mounts
axle boots
bowden tube
all metal brake lines
all rubber brake lines
single-circuit master cylinder (may upgrade to dual-circuit)
brake fluid reservoir
all brake shoes
all wheel cylinders
all brake hardware kits
brake line clips
clutch & brake pedal pads
urethane outer bushings
SAW adjusters
caster shims
longer bottom bolts
German engine gasket kit
pushrod tubes
w8ac plugs
Bosch blue coil
spring plate bushings
H4 headlights
body to pan gasket
urethane shift rod coupler
WW lower hinge pillar metal
WW rear bumper bracket metal
tie-rod ends (all 4)
axle seal kits

That's all I can think of. I'm about to order everything else I need to get the pan completed and the body mounted. I'm not going to bolt the body on until I get the underside done (going to build a rotiserrie soon) but I want to have all the stuff for it.

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Re: 64 bug project

Post  Mohawk on Sat 22 Nov 2008, 3:09 am

Looks nice. Keep up the good work cheers
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Re: 64 bug project

Post  bugdust on Sat 22 Nov 2008, 7:54 pm

Well, not a good day. I planned the better part of the morning - early afternoon in the garage to get some stuff done to the 64.

I had broke two of the spring plate cover bolts off in the left side. I had a little sticking out on one so I welded another bolt to it, added a little heat and it came out pretty easily. The other one... It got a little black masterseries on the back side (that stuff is tough as nails!!...I wasn't crazy about how it went on but it's some tough shit!! I'll use it on all my VWs from now on) so I hit it with a cut-off wheel on the back side. Then I drilled through the bolt. I didn't have any easy-outs and there wasn't enough to weld another bolt to. Anyway, I drilled a number of times going larger each time. I was a little off-center so I used a diamond coated engraving bit to take out some material on one side. I drilled all the way up to a 5/16" bit (bolt is M10 x 1.5) The next bit I have is a 3/8" which is a little smaller than 10mm but I'm going to get an 11/32" and run through it before I try to retap it. I couldn't get the tap started today. I spent hours screwing with this thing today.


I had to step away from the hole a couple times while my drill batteries charged (takes an hour to charge & a few minutes to kill...I have 3 batteries, need to get a quick-charger) and so I didn't get too pissed off at it. So, I decided to try out the little 20lb sandblaster I picked up at a yard sale for $10 last weekend. I blasted the trans crossmember and then I pulled a front fender off the bug to get a better look at the rust issues. Bad idea!

I figured hey, let's blast this to see what it really looks like. Now, I knew it needed the lower a-pillar replaced but I wasn't really ready for what the blaster revealed.


Now, this wasn't a huge suprise other than all the pin-holes in the heater channel. But, I didn't know the entire heater channel was swiss-chiss (the bottom plate is beautiful) and that the rear quarter panels have been poorly replaced and covered in bondo.




Looking under the car a little closer I found a few more bad areas. I'm not happy right now but what can you do.:hmm: I guess I need to get on that rotisserie pretty soon so I can mount this thing and start cutting & welding.

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Re: 64 bug project

Post  bugdust on Wed 03 Dec 2008, 9:05 pm

Update: I took a wire wheel to the quarter and removed the 1/4" of filler, blasted it (lower pressure, all I have is glass beads & StarBlast) and looked it over. The patch is solid but whoever did it welded it solid across (warped) and it looks like crap. I thought (for a split second) about cutting it off and redoing everything but I'm trying not to get too deep into this project. It needs to be on the road this spring. My son turns 16 in Feb but I'm looking for an April completion date. Anyway, what I decide to do with the channel may dictate what I do with the panel. I want to do a little work on it and then a thin layer of filler and try not to let it keep me awake at night later.


I got the trans cleaned up and painted. This is just a low-budget beater for my kid's first car so I just spray-bombed it. I'll change out the oil in it once I get it back on the ground(before I sit the body on it) Smile I bought the car all apart and the trans was only hanging on with one bolt on one spring plate, two on the other, and the rest of the bolts were loose, including the framehorn/trans cradle. I didn't know that when I got it and I flat-towed it with a towbar about 70 miles. Anyway, when I went to put the framehorn bolts in the right side was stripped. I may have done it but I don't think so. I found an 18x1.5 tap in a buddy's toolbox and cleaned up the threads and it's good to go now.


I took the backing plates off and I still have to clean them up. When I pulled the drums off there wasn't much of anything inside as far as brake parts. I scrounged up enough parts for one side and went by another buddy's house to raid his stash for everything else I needed (adjuster stars, bolts, push bar, e-brake lever & pin) he didn't have the clips.

I stopped at AutoZone but they didn't have the clips. There are 4 parts stores within a mile of each other so I'll get them in the next day or so.

FedEx dropped off a box today. :dancing:




Nothing exciting but all needed stuff. I've got to build a 10" extension for a buddy's volksrod project tomorrow then I'll get back on the 64. I have another 4-day weekend so maybe I'll get a little work done.

Oh, the kid got a normal haircut!

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Re: 64 bug project

Post  bugdust on Mon 29 Dec 2008, 9:00 pm

Decision time!!

I got the body onto the rotisserie. The body is rough. I have to decide if I will be time & money ahead by replacing the rusty panels or see if I can find a better body. Good bodies are like hens teeth (or hillbilly teeth) in this area. I'm low on project funds still so I have time to look around and think about it. I need to be concentrating on the pan anyway since I have almost everything to finish the chassis/drivetrain.

Some pics, no words needed. :hmm:
















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Re: 64 bug project

Post  Guest on Mon 29 Dec 2008, 9:33 pm

Hey bugdust great job u guys are doing .i have a pair of heater channel for ur body bran new u can have dem for free if u want ,every little thin helps. i live in palm beach.my name is ricky.

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Re: 64 bug project

Post  bugdust on Mon 29 Dec 2008, 10:45 pm

I'm going to watch a movie right now but I will PM you later.

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Re: 64 bug project

Post  VOLKSWAGENUT on Mon 29 Dec 2008, 10:54 pm

bugdust wrote:I'm going to watch a movie right now but I will PM you later.

ask him for pictures first...... Basketball
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Re: 64 bug project

Post  overspray on Tue 30 Dec 2008, 12:09 am

I know what i would do... trash it, heater channels, door post, rear bumper supports... what's it look like under the rear window?


Didn't i understand you to say it already had a couple panels replaced ? if so you're welding to patches that you said were already poorly installed...


Blast it then see what you have if it's still up in the air on what to do...just my 2 cents..... good luck

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Re: 64 bug project

Post  sploval53 on Tue 30 Dec 2008, 12:33 am

you might get into deep on that car
might be ezer to find a doner body
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Re: 64 bug project

Post  bugdust on Tue 30 Dec 2008, 1:24 am

Yeah, I know it will be easier to find a better body but I have time, money...not so much. If I can come across a good deal on a body I'll be all over it. This one will not get scrapped though. I'll either fix it just for the experience since I have never done heater channels or hinge pillars and then put it on another pan or I'll chop, channel and section it, suicide the doors and build a volksrod out of it. Very Happy

I'm leaning towards a better body. Realistically, here is what I have (it will be a no-brainer after this)
Needs:
both heater channels
both hinge pillars (I have new metal from WW)
both front fenderwells (I have new metal from WW)
both rear bumper mount areas (I have new metal from WW)
right rear tirewell to package tray area
both area above heater channel at B-pillar
bottom of front firewall (both sides, can be patched)
front clip from middle of tank (been hit hard, maybe more than once)
left door at hinge-hinge loose, sheetmetal bent a little
a few fender nuts missing
rear apron bent but solid
both rear quarters have been replaced but not great work
roof has been replaced at some point

original decklid is good
hood is aftermarket
all four fenders need work or replaced. I do have some aftermarket ones in decent shape
I have a few bumpers, may be able to make a couple good ones that will need to be rechromed

I was a welder for almost 15 years, thicker stuff mostly but I can do the work on this. It may not be professional but it will be the best I can do it. Hell, it may be better than some "professional" stuff I've seen.

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Re: 64 bug project

Post  Cave Man on Tue 30 Dec 2008, 8:59 am

overspray wrote:I know what i would do... trash it, heater channels, door post, rear bumper supports... what's it look like under the rear window?


Didn't i understand you to say it already had a couple panels replaced ? if so you're welding to patches that you said were already poorly installed...


Blast it then see what you have if it's still up in the air on what to do...just my 2 cents..... good luck

And your first build was a 50/50 graft? guess that why you say dont do it.

Lots of work there but when its done then he can decide if it was too much work or not. The work you have done looks great.

Like the rotisery too, looks handy. But I dont have a shop and no where to work on one much.
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Re: 64 bug project

Post  bugdust on Mon 05 Jan 2009, 12:02 am

A couple pics of a little progress





Looking for a body and replacement panels for this one.

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Re: 64 bug project

Post  bugdust on Sat 10 Jan 2009, 10:58 pm

The low budget build continues...it's a roller!! Well, sort of. I haven't narrowed the tie-rods yet. It's covered in dust & parts, tools, etc. I have a few more things to do to the pan, then I start the engine and bodywork.



Today, we got the shift-rod bushing in, front access panel on with new gasket, axle boots on, 4" narrowed beam on & put back together with caster shims. The longer bolts I bought are not needed...in fact, they wouldn't work with just one set of shims. Donald's kid, Cody, assembled most of the front beam by himself. He's 12. More soon.

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Re: 64 bug project

Post  bugdust on Mon 12 Jan 2009, 12:36 am

I'm only going to update the original thread on volksrods.com now
http://www.volksrods.com/forum/showthread.php?t=23391

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Re: 64 bug project

Post  bugdust on Tue 29 Dec 2009, 8:19 pm

I wheeled the red 64 body into the garage yesterday.

The car has had the roof replaced at some point and it was only welded on the outside, not aligned correctly and had rust through on the "new" roof. I had borrowed parts of the roof for the chop top project as well.

So, I braced the body, cut the roof off and started fitting the roof from a rusty 59 body I have.




I should get the final fitting done tomorrow and get it welded up.

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Re: 64 bug project

Post  Tanbug on Tue 29 Dec 2009, 10:58 pm

Shocked
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