Baja Bug: Body
After all the extra metal has been removed the fiberglass has to be started on. First photos is a facimile of the 7-piece kit made for the late model Super Beetle.
• Before cutting into the body, the fiberglass fenders need to be positioned, marked and drilled for holes. Have a friend hold each fender as you line it up. You can do it yourself by placing a tall object on the tire and rest the fender on it; I used a small cooler. This isn't an exact science, as I had to make two or three adjustments where the fenders started. For the rear fenders I choose to start above where the running board use to be. The same start was chosen for the front fenders, but later I had to move them down because of how the front piece sat.
• Do not drill and attach the fenders yet. Just position them and mark with felt marker the furthest end of the rear fenders. That is where you will begin your cuts in the back. At the front fenders, position them and mark where they end toward the front. The front is tricky.
• Beginning with the back of the VW, I start from the rear fender mark and draw a straight line to the back corner of the engine area. See photo at left middle. Now the tools needs are a good drill with a hand grip, plus a Dremmel for the tights spots. You need the Dremmel with a small cutoff wheel to get into that back corner and cut across toward the engine. If you're like me, cutting into a car is the most fun you will have with it, second to taking the thing out once it's finished.
• (Turns out I will have to repair the rear fenders and re-drill because the fiberglass rear engine cover had to sit further down.)
Next page = Body 3