Body pp. 1, 2, 3, 4, 5, 6, 7, 8

 

Baja Bug Project

The first thing to be done with the Super Beetle is to bring the front end to its best. You could "just" chop off the front and replace the MacPherson-Strut suspension. Well, you might as well get a pre-1971 VW Beetle for cheap. Instead, add a new sway bar with good bushings, and a Super Beetle strut tie bar. The sway bar (second image) improves handling under cornering, and the tie bar goes across the top of the struts and strengthens the MacPherson-Strut suspension.
Add KYB gas-charged shocks, replace bushings, ball joints, tie rod and ends. I added a rebuilt steering box (not available in stock) and disk brakes. These were installed by French's Auto Parts in Yucca Valley, Ca. They squeaked at first for a few months when braking, but now are quiet.

 

All of the engine work, transaxle (and other work as indicated) has been done by French's Auto Parts in Yucca Valley, Calif. I was fortunate enough to have this highly qualified outfit just up the road in Yucca Valley. They have so far installed the front end reinforcements, as well as the front disc brakes.

 

• Removing the Tin

• • Before removing the fenders, use a Phillips screwdriver and start taking off the tail lights, front turn lights and headlights. This is a pain when you get to the wiring, and it's best you mark down which wire goes where before you take off the connectors. I'm going to re-wire the entire vehicle, but I still marked where the old wires went to ... and glad that I did.
  • Now the fenders, running boards, hood and bumpers come off. All the bolts have been sitting more than 30 years, so they are going to be uncooperative. If your VW is like mine, there will be some damaged bolts and damaged body areas ... places that you didn't see when you got the car in the first place. Well, there's no turning back. Just unbolt everything and deal with the damage later.
  • Remove the steel bumpers, front and back. Remove the front hood and engine cover, retaining the license plate and light.
  • Part of tearing into an old car like this '74 Beetle is that you find out what problems there are. The hood, engine hood, fenders, running boards and bumpers will be tossed, given away or salvaged for parts (I am using the hood as practice for when I paint the vehicle).
  • Scrape, remove or sand off anything you think doesn't belong anymore, like the old rubber seals, dirt, rust and ugly stock metal trim. In the rear, there is a lot of tin around the engine that needs to be taken off, and also there is the old firewall protective tar paper that I'm ripping out to get to all the wiring, and to replace later.
  

 

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