How to build that perfect Bug

[IMPI]

The secret to having a successfull project can be summed up in one word: Planning.
You must decide on what it is that you want to achieve. Make a list.
Most projects have 2 major components.
The first is the base project. Remember the newest Bug is now 30 years old and a lot of stock parts will need replacing.
This does nothing for the looks or performance of the car (probably a lot with safety and reliability)
I believe that if you stick to the following list you will have a reasonable chance for success.
Body: Buy the best most rust free body you could find preferably one with no mods unless those are what you had in mind (plan)
Front suspension: Plan on replacing King and linkpins,steering damper, tie rod ends, wheel bearings, brake cylinders, Brake shoes, shock absorbers, brake hoses, steering box, steering box coupler.
Rear suspension: Plan on replacing axle tube rubber gaitors, Shock absorbers, brake hoses, Wheel cylinders, Brake shoes, rear axle seal kits, Hand brake cablesand possibly torsion bar doughnuts.
Gearbox: engine mountings, clutch cable, Bowden tube, clutch throw out shaft, shift coupler, starter bushing,oil seal at input shaft.
Chassis shift bushing at gearlever, master cylinder, clutchtube inside chassis, floorpan rust or collision damage, throttle pedal and mounts(the brazillian copies are crap) clutch cable hook on pedal assembly(they break)
Electrical system plan on replacing alternator bearings and brushes, starter bushes and brushes, solenoid, bendix drive, refurbish wiper pivots and motor. repair wiring using the correct colour wires and lugs DO NOT ALLOW OVERSPRAY ON ELECTRICAL PARTS. Do not fit add on switches for Wipers,flickers,ignition, headlights etc.
Upholstery be sure that if you fit other seats that they rplicate the original seat height otherwise the car never feels right.
The engine and any modifications intended for performance can now start. Lowering: only adjusters Cutting or removing leaves are dangerous.
Discbrakes follow the braking rules (only use top notch or new parts) I never rebuild brake components new ones are inexpensive enough same with hoses REPLACE THEM.
Plan your engine: a mild engine is often greater fun but if you insist First step Performance exhaust,second Twin carbs and dizzy third step bigger bores and crank. fourth step heads and cam. obviously other restoration type parts such as fuel pump and coil should be in good condition. The second step will already overtax the stock braking system.
I have found it more economical in the long run to do about 90% of these things in every restoration and have had great times with very few breakdowns
Armand

[Tony Z]

STICKY please Eben

[calooker]

And one important thing, MONEY, make sure you have it before you start, doomed to fail if finances run dry.

[66looker]

good advice thanks impi

[superfly]

what would you advise on a body of a project car , paint remover or sandblasting ? ..

[superfly]

on a Karmann ghia that is.

[vader]

Very sticky!!! Good on you Impi!

[IMPI]

On a karmann with lots of lead loaded seams I have used chemicals with great success. Karmann metal was hand formed and welded of a much thinner metal than beetles and careless sandblasting will warp the body
Armand

[IMPI]

On a karmann with lots of lead loaded seams I have used chemicals with great success. Karmann metal was hand formed and welded of a much thinner metal than beetles and careless sandblasting will warp the body
Armand

[zubz]

Hi Impi, excellent article especially for beginners like myself. Tell me where can one get adjusters and how much would it cost to lower the beetle? Somebody said normally they remove leaves, but as you say this is dangerous... Tx

[Ron&Gill]

IMPI, very good post. I have cut and pasted it into a word doc for my to-do list on the Mini-T, there are a lot of reminders there that I had forgotten about.

Thanks for that.

[vader]

Ditto!!!!

[johanb]

Thanks Impi

Just decided that I will impliment this advise on my bus rebuild

[Farhaad]

hi,impi
great advice. will use them on my ol "66

[Kwantum]

And one important thing, MONEY, make sure you have it before you start, doomed to fail if finances run dry.

QFT. Money, planning, and ability check. Many people think that bugs are a cool project car because they are cheap to get started on. Unfortunately, this low-cost mentality bleeds over from the purchase price into the cost of restoring. While bugs can be less expensive to restore compared to almost all other cars, it still costs a heap. For every one completed project, there are a couple dozen uncompleted one.

1) Look at the car and make a list of EVERYTHING. Nuts, bolts, rubber, etc. Every penny counts. Don't forget shipping and tax costs too.
2) If the car needs something done to it, and you are iffy on the particulars of doing said thing, add that too.
3) After you add up all the costs, add another 10%. This is the more accurate number
4) Once you figure out how much it will cost, figure out how long it will take you to get the money and the work done. A realistic number here is about 2-3 years.
5) After you add up all the time, multiply it times 2. This is how long it will probably take.

To think anything other than what I have listed will compromise some facet of your project. You'll either drive an unsafe car, an incomplete car, or a car you really aren't completely happy with.

In summation, your project will cost $15000 USD and take 5 years to complete.