Assembly

The very last stage of the build and my most favorite part of the build where you see all your hard work pay off and the image that you had in your head come to life. the next part is to enjoy, to see the car as it is now click '68 weeks later'

25/05/2012

Now that the bidy is back home there is just a few bits to sort on the chassis before we attempt to put the body on it. The first was the steering and the body gasket.

Then with this done all the lads popped down to give a lift with the body. And ended up with this.

Now I’m happy, I’m getting there.

26/05/2012

Paint time, I was going to take the fuel and the wiper motor cover but I wanted to paint them myself so it was out with the 2k black and out these come.

While I’m on with making things shiny, I cracked out the machine polisher to polish up the body again and give it a good coat of wax. The bodywork looks stunning.

28/05/2012

Next up was the rest of the bolts in the body, this was too easy but after a little elongating they fit lovely. Not got a picture because it is just bolts.

29/05/2012

A lot of work went into today, the first thing to do was to sort the front struts out this was because the strut top was too small so had to be filed to fit the strut in it, this seemed like an easy job but took plenty of time. Next up was the brake system all that was left to do was the flexible hose from the body to the strut and then the copper pipe from the strut to the calliper. So that went on no problems. Next up was to bleed the brakes but this wasn’t easy so after it been 1am I decided to call it a night. But just as I was packing away I just put the front loom in as it was lying about.

01/06/2012

I also have to fit the engine tin wear sear round the back of the engine bay as once the engine it you can’t get to this so in it goes.

And then finally wheel the engine down to the workshop.

After a lot of messing about with jacks and what not, some choice words later the engine is in.

It took some doing but managed to get it in. can’t start it just yet as there isn’t any wiring done nor is any of the fuel system, but it slowly getting there.

05/06/2012

Now it is onto the most boring bit of the build the wiring loom, there seems to be wiring everywhere. Mine seem to bit on the years they changed things so it a lot of modifying. Any way I managed to get a photo although it isn’t much to look at.

08/06/2012

Well back to the beetle, next up was the wiring at the front of the beetle so basically the light loom, once this was all roughed to the ‘main’ loom then the fuel tank could go in, so that was next we put that in and it fit rather well apart from the filler neck been tight and I also needed the rubber seal/grommet that goes round it. I didn’t get any photos because I was too busy grafting and trying to make good progress. Now that the tank and the other bit of the loom is there it is time to fill it up and turn the engine over, so after some juice I turned the key and no engine was turning. Out some the tester, we had forgot to connect the starter motor. Try to start again, we have the fuel pump primed but it was firing out of the carb so once it was timed up it was to try again. And 2 turns later it fired a lovely idle and picks up great. Now that it starts I put the timing light on it and adjusted the timing so it was just right.

12/06/2012

More electronics this time it was more to neaten the electrics that are already there. So it was a case of cable ties and what not. And I still have no photos.

15/06/2012

Alarm time, not giving away details of the alarm wiring but it taken ages but it final works. Not that the alarm is done the sound deadening can go it. It feels like I’m getting somewhere now was easy really just cut to size and stick. And ive got a couple of photos.

16/06/2012

Nothing has changed but I have taken a couple of vids, one of the alarm working and the other turning over and firing.

29/06/2012

After been busy with college as it is the end of year and course, I now have time to crack on finishing this beetle first up was the heater pipes, I thought this was going to be a ten minute job but I was wrong, the pipes that fit to the body would fit between the torsion bar and the body, the only way to get round this problem is to lift the body so. I loosened all the chassis bolts and lifted it just enough to get the pipe in and then the flexi to go in. and the pipe that going on the inside could be clipped in.

30/06/2012

Got plenty of work done on the beetle, first up was the headliner, which is rather hard as it has to look neat. First up was all the bits apart from the roof, I masked the car off so that I didn’t get spray adhesive everywhere. Once these are in we moved onto the roof, I managed to get some in process shots.

And soon enough after a lot of pulling and pushing the headliner is in. and to make sure that the ends round the windows don’t peel back I put the front and rear screens in, as I can’t put the side windows in yet because I’m waiting on a delivery. The windows went in easy but the chrome trim didn’t as it was all twisted and what not.

The next bit to do was underlay for the carpet this bit was very easy and you just stuck in down and it was done.

The last job of the night was the dash which didn’t go in too bad once the steering column was loose.

10/07/2012

First things first the rear window seals have arrived so that was top of the bits to do. It was a tricky job but one of the windows did take some convincing to go in.

Next up was to sort the carpet out, this took some doing as it was a lot of random shaped pieces hand all you can do it make an educational guess, but after some chin scratching it all in which looks really nice and tidy. I managed to get some photos but the handbrake gator isn’t on correctly.

13/07/2012

After ordering my tyres for the empi 8’s I eventually got them fitted today, and put them on the car so I can look at how it will sit, I didn’t get a photo of how it sits because you can’t tell without the wings on. But I got a photo of them on.

The wiper mechanism cover was up next a few speed clips and bolts later it was fit, I also wired up the horn but there are no photos of that.

Next up was under the bonnet it has got carpet but it needed some board to mate the carpet sit correctly so I some board and cut it to shape.

After all that it was onto the bonnet lock this wasn’t too bad once I had found the correct screws it soon fitted, and happened to lock and fit correctly the first time which was a bonus, I also fitted the vin plate back on with the aid of two pop rivets and also put the pin switch in for the alarm system.

14/07/2012

First up was to Shultz the undersides of the four wings, the masking took forever as I didn’t want the Shultz to come through onto the other side, but it when on great and it didn’t start rain until I fished spraying which was great.

The next job was to spray pure guard onto the carpets so water does absorb as easy, I didn’t get a photo but it does look any different.

The last jobs of the day was to remove the glue from any parts of the body and to go round and tap all the holes for the wing bolts to go through as I hopefully will be fitting them tomorrow.

18/07/2012

Only had a spare hour or so I concentrated on getting the deck lid all sorted so this meant putting the handle lock light and drip tray on it which too some sorting but managed to do it, then we put the lid on and lined it up why took some doing because they bolts aren’t too easy to get to but eventually did it.

But on closing the deck lid I have noticed that the drip try hits the carb so I will have to sort that out later. The next bit to do was the spring which was a sod to do and was really tight, anyway managed to get it fitted.

19/07/2012

With having some good weather I thought that it would be a good idea to roll the beetle out the workshop so that there was plenty of space round it to work on it.

First job of the day was to test fit the rear valance and put the seal into place and the seal was a little tight but didn’t really cause any problem and the valance fit great so got that all sorted.

Next up was the number plate, 2 minute jobs just a few measurements and it was sorted. With the help of two rubber washers used as a stand-off and it’s sorted.

Next up was the rear interior which was the door cards and rear bench, the door cards needed a couple of holes in them for the clip holder thing to hold the rear bench to bolt to but other than that it all went in as it should, and the kick panels just slotted in place.

Then onto the front of the car it was to put the front wings on this was hard work as there weren’t the correct shape and with the been original they didn’t want to bend but after two of us wresting with them both wings were on with the wing beading in place.

I also put the bumper irons on but I think there wrong as they don’t look quite right, and as I put a bumper up to them you could tell they were wrong as they are bent and after using the hammer and what not they don’t fit so im off to buys some new ones. After that I fitted the front seat, simple one screw and that’s it.

Really comfy I was going to drive the car back into the workshop but it wouldn’t start, had a quick look but can’t find the problem all I know is that there isn’t any power to the coil, anyway that’s a day I got a couple of photos before it got put away for the night.

21/07/2012

It was back working on the beetle and it seems to be looking more and more like a beetle now as the first thing that we did was to fit the rear arches these were easier than the front arches because they are reproduction parts so they can be bent a little better.

I also fitting the passenger seat it was a two minute job as I knew how they fit from doing the other sides. Next up was to fit all the lights which weren’t too hard. And we also fitted the seat belt which took some doing but it didn’t take too long to make the fit correctly.

I also managed to fit the sun visors and the interior mirror a 2 minute job.

    
Next up was to hang the doors, this wasn’t too bad as we had fit them before they went off for paint so it only took a little bit or moving to get them just sat right, we also started on building the driver’s door.

27/07/2012

Eventually got both doors up after replacing the quarter light seals as they were in a sorry state and needed replacing, I also had bought some new bumper irons so I could mount the front bumper because I had the wrong irons or they were bent, after some convincing the front bumper went on and so did the number plate although that needs changing as it was the bent set I put on just in case I messed the holes up.

28/07/2012

Quite a set back as we were looking at the chrome trim the goes round the window we noticed it had to go on before the rest of the quarter glass and drop glass so it was a strip down and re build of both door which was crap but at least we knew how it went together, I also clipped on the chrome trim which made the car look great

29/07/2012

Got plenty done today first up was to finish the door which meant putting the door pin switches in this wasn’t too hard job really as there is plenty of space in the doors, the hard bit was to find the correct wire from behind the dash but after some reading of the instruction we soon found them and got it all sorted. Next up was to put the door cards on along with the window winders door pull and door handle so it looked like this.

I also got a couple of photos of how it currently stands as I’ve been forgetting about getting photos.

31/07/2012

First up was a nice easy job of putting the wing mirrors on this was a two minute job but it looks smart now that it’s done, then next up was a big job of changing the bushes on the torsion bar to poly and to lower the passage side this took some doing but we put in back together and the passage side is still sat high so it will require re doing but that it a job for tomorrow.

02/08/2012

It was back on with messing with the ride height again hopefully it will be correct this time, after some messing about it’s the same height which is nice low, next up was to finish the rear bumper so on with the bumper irons and then the bumper itself, this went on a lot easier than the front which was nice. And also to fit the running boards. Once these were all done it could go to the mot test station tomorrow

03/08/2012

Well it’s the big day for the beetle mot time; first thing to do was to move it out of the tent and give it a quick wash, so that it didn’t look as if it was a barn find. Next up was to drive it. Round to the front of the house, this wasn’t too bad but once it was on the street it was strange been able to drive it on the road, but to the mot station. Unfortunately it didn’t pass just a few little bits so off home to sort that out, it failed on wheel bearing tie rod end, and too much play near the spring plate, so replaced a bush, tighten the wheel bearing and a new track rod late it was ready, but they couldn’t fit me in till 2 so I risked it and when and got the tracking sorted out. Then it when to the mot station and passed, I sorted the tax out and notice that in the mile or so run to the tracking place I had rubbed a ridge in my tyres so it was pulled to the workshop to higher up a little bit.

04/08/2012

Right I need to higher the back of the beetle up so that it doesn’t rub on the tyres so up one spline, didn’t both side after some hitting with hammers it was done. I let it off the axel stands and one side was higher than the other so on with the axel stand again and mess with it more and it wouldn’t sit level, but it was getting late so called it a day.

05/08/2012

Time to sort the torsion bar out again, after looking on the internet it needed to be moved at both ends. So out it came and got changed once done lowered off the stands and that wasn’t low enough, back up try again and it was level. Eventually I can drive it; the first place that it needs to go is the fuel station so after a quick run there is was running great. Even managed to take it out and grab a quick photo.