News & BLOG

Project #Super71 - Front Left Wheel Well

I was able to get back into the garage and start working on the driver's side front wheel well and firewall area on the Super Beetle. This side of the car was pretty much the same and the passenger's side. Thankfully I now have the required experience and templates required to get this job done. I used the same templates and just reversed the folds in the metal after they were cut out of my sheet metal. I used an air chisel to hack out the old rusty metal what was wedged under the bracket for the steering box. After making some small adjustments I was able to properly fit the replacement metal in place.

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Project #Super71 - The Green Door

I wasn't looking for doors at Hershey in 2018, but I came across a solid set that had very minimal rust and were in better shape then the doors I had, but included perfect window regulators. I picked the pair up for only $50. How could you go wrong? Anyway, after I repaired the lower door post on the right hand side I was finally able to install them on the car. They fit pretty good but I do need to make some adjustments to the entire door jam and hinges once the body is once again attached to the pan.

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Project #Super71 - Right Rear Wheel-Well

I had a feeling this was going to be a problem area. You could see a strange buckling from the inside of the car behind the rear seats. This area was covered by seam sealer so the rust was not visible until removed. On the outside the metal was full of holes along the reinforced area of the wheel-well. I thought that maybe I could salvage the area without a large repair but I cam to my senses and ordered a new replacement panel from CIP.

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Project #Super71 - Right Side Door Post

Once I had the front wheel well in looking good and the rear quarter panel welded up to the heater channel I knew that the right side of the bug was now pretty solid. I could then remove the door on the right side and get to work on the lower post. This section of the car was pretty rough and it was poorly repaired in 1996 (I know since I did it wen I was pretty much a kid). I had a replacement panel to weld in place but it didn't have the inner section that the door actually bolts to. Thankfully that section was is pretty good except one of the bolt holes for the door hinge. I had to make some repairs that included tapping the heavy gage steel so the hinge bolt had something to screw in to. For years this door only used two bolts.

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Project #Super71 - Right Rear 1/4 Panel

As this project continues to march forward we find ourselves moving to the right rear quarter panel of the 1971 Super Beetle. The rear quarter panel on this Bug was a mess. The old heater channels were removed by hand and the metal that was supposed to be connecting the body to the channels were extremely thin and repaired a few times over the last 25 years. You could see that a rust hole at the bottom of the door jam and it wasn't going to fix itself. My best description for this VW and especially this area was "Mushy". There was nothing solid, so we were going to have to cut away any rusty or thin metal in order to get to something solid.

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Project #Super71 - Wheel Well Skin & Strut

Project #Super71 - Wheel Well Skin & Strut

Now that the front right section of this wheel well is nicely welded together and solid as can be, it's time to cover up all our hard work. It's really not that sad however. It's kind of exciting. I always like getting to a finishing point on any section of the Beetle. This bizarre area of the Super Beetle has eaten up a lot of time. It will be nice to cover things up and move on to a new section.

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Project #Super71 - Front Right Wheel Well

Project #Super71 - Front Right Wheel Well

As I was ripping this rusty part of the Super Beetle apart I couldn't help think about how strange it was. I spent many hours just thinking about it and looking at pictures to try and make sense of what this area of the bug looked like before It all rusted away. I searched online and had trouble finding solid examples of the inside workings of the inner section of the front wheel well area. I had no worries that I could fix it, but I wanted to copy what ever VW was doing back in 1971. After a few weeks I realized that VW really didn't have an idea what they were doing here either.

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Project #Super71 - Odd Ball Repairs

Not every spot on the Beetle can be easily repaired. Unless you completely disassemble your Bug you may not be able to replace metal that is less than favorable. In some cases it's simply not in the budget or time table. This was the case with Project #Super71 and the metal that is under the gas tank and sandwiched between the front firewall and the back of the spare tire well. In my case the metal was not completely lost, but could use some help.

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Project #Super71 - Heater Channel Assembly Install

Project #Super71 - Heater Channel Assembly Install

This weekend I was able to spend most of the day in the garage. The weather is starting to warm up slowly and that helps inspire me to tackle some larger projects. For the last few weeks I have been working away at chasing out the rust from the body or the Beetle and preparing all the mounting points for the heater channel / firewall assembly that was pre-assembled a couple months ago.

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Project #Super71 - Firewall Brace Repairs

Project #Super71 - Firewall Brace Repairs

Before we can install the front firewall we need to repair and prep the firewall braces for this 1971 Super Beetle. The braces on Project #Super71 were still pretty solid for the most part, but some patch work would be required. These firewall braces are important since they will help support the firewall and all the additional metal that all come together in this spot to support the front of the car.

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Project #Super71 - Firewall Area Repairs

Project #Super71 - Firewall Area Repairs

As we mentioned in our previous post, we had a lot of rust to chase out of the body of this Super Beetle. The front firewall was a mess and after we removed it we had several trouble spots that would need to be repaired before we could move forward with installing the replacement firewall.

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Project #Super71 - Chasing The Body Rust

As many of you are aware, when you start removing rust from your Beetle it can easily feel like a losing battle. Thankfully there are a wide assortment of replacement panels available for almost every trouble spot and year. On project #Super71 we are chasing the rust out of the front firewall, heater channels, and rear cross member areas. These areas are tricky spots since it seems like everything connects in these locations.

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Project #Super71 - Heater Channels & Cross Members

When we first fixed up this Bug in 1996 we knew it already had some rough patches that were repaired at some point in the late 80's. Our initial intention with the car was to just fix it up and get it on the road. So because of that, and my lack of skills at the time, all I could do was cover up any really bad spots with some galvanized sheet metal, pop rivets, expansion foam, undercoating, and some amazing body filler work. I have to admin that I was impressed by the end result at the time but there was no way to was going to last forever. Fast forward 20+ years and here we are... finally fixing all those problem areas the way it should have been done the first time.

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Project #Super71 - The Perfect Engine

As most of you are well aware, THEBUGNUT.com has an ongoing hobby mechanic restoration called Project #Super71. We are restoring a 1971 Super Beetle and sharing the progress online with all you fellow air-cooled VW enthusiasts. During the process we started doing some research on what motor we wanted to install in this Beetle once the time comes (Always good to be prepared). When this 1971 Super Beetle was first rebuilt and put on the road in 1997 it was packing a 1835cc motor with dual 40mm Webber carburetors. We loved that old motor and we’re thinking of installing something similar, with a few more extras to go along with it.

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One or Two Carburetors?

It sounds like a simple question to answer, so why am I having such a hard time figuring it out? Most people in the VW Beetle community are one of two kinds... Stock or Modified. Let's face it... there are probably more of us that like to tinker with our VW's than there are who wish to keep them stock. My hat goes off to those who properly preserve the history of the car down to every metric nut and bolt, but that is a special kind of person. The rest of us hacks can't leave our Beetle alone. Many of us also want to make them lower, higher, noisier, more colourful, or faster.

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News & Blog

Project #Super71 - Front Left Wheel Well
Hi Everyone, I know it's been a while since I last posted but sometimes life can get busy. I was able to get back into the garage and start ...
Project #Super71 - The Green Door
This is just a short post about the green doors I picked up at Hershey in 2018.I wasn't looking for doors at Hershey in 2018, but I came ...
Project #Super71 - Right Rear Wheel-Well
Hi Everyone, this time we are taking a look at the repairs that were required on the inside right rear wheel-well.I had a feeling this was ...


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