Restoring a 72 Super beetle

Just some notes on repairing a 72 Super beetle. My dad purchased it new, and used it for a commuter vehicle for quite some time. Once he retired and moved to Nevada, he didn't drive it much, and my wife wanted a bug, so we decided to restore it.

Initial evaluation

• Body

  Observations:

  • Body is generally pretty good shape, with little rust.
  • Need to check floor pan for problems, especially around battery
  • May be rust hidden under paint.
  • Most of the rubber molding seems in bad shape, dry, rotten.
  • Door mechanism seems stiff
  • trunk latch mechanism sometimes sticks.
  • Driver and passenger wiper arms seemed to be swapped

  Suggestions:

  • replace rubber with new as time/money allow. Especially: window rubber, both fixed glass and movable glass in door
  • replace rubber seals in engine compartment, for cooling
  • check/replace seals around doors, trunk and engine compartment
  • check/replace rubber for turn signals
  • check/replace covers for fresh air vents behind side windows
  • clean/rebuild/repair door latch mechanisms and latch plates.
  • replace window cranks, after speakers have been moved.
  • rebuild doors, check all rubber/seals and latch mechanisms
  • adjust/clean/replace trunk latch mechanism
  • replace rubber tank neck sealer and gas cap
  • check vapor recovery lines
  • check/clean/rebuild windshield wipers.
• Cosmetic
  • Need new paint, develop long term plan for appearance.
  • Determine electrical needs, possible redesign dash to accommodate proposed new switch and instrument needs.
  • Determine plan for seats, door trim panels, trunk compartment, interior carpet, headliner, seat-belts
• Electrical

  Observations:

  • Replaced battery upon receipt, also replaced battery ground strap.
  • car was stolen soon after original purchase, engine removed, electrical connections were cut at that time.
  • known problem with starter circuit. after long drive, starter may get stuck and fail to operate after it cools down.
  • "fresh air" air fan/flaps do not seem to work
  • turn signals were having trouble. problem traced to emergency flash switch, jury rig repair
  • Gas fuel gauge reads low, long term known problem

  Suggestions:

  • Check all electrical connections and devices
  • Double check all electrical connections related to engine
  • check rear window defrost circuit and resistance elements in glass
  • check/repair circuit for fresh air fan
  • check and replace as needed switches for turn signals and emergency flashers
  • strip out extra wiring for misc monitoring devices that no longer function
  • resolve radio issues. single antenna, single newer AM/FM radio in dash location, possible tape drive
  • remove AM radio in dash, mono speaker next to speedo
  • replace, possible relocate speakers for stereo
  • repair/replace gas fuel gauge circuit, either sending unit or fuel gauge (currently part of speedo)
  • install electrical circuit for after-market washer pump.
  • replace starter cable and starter motor and solenoid
  • Look into installing VDO engine monitoring circuits:
  • Oil pressure
  • Oil temperature
  • Tachometer
  • possible separate fuel gauge
  • Check/repair interior dome light fixture
  • Upgrade to halogen headlight bulbs, either sealed beam style or reflector/lens and H4 bulb.
• Engine

  Observations:

  • Engine has been rebuilt at least once, indeterminate time in the past
  • Oil replaced on receipt, filter screen not cleaned at that time.
  • lots of oil/grunge in around engine compartment, seems to indicate excessive oil leak.
  • Car was hard to start, trouble on acceleration, fresh fuel and additives added, which seemed to help
  • carborator received quick/dirty rebuild, new gaskets.
  • One stripped thread in carb body, for holding two halves of carberator together.
  • Fuel filter replaced
  • Signs of repair on vacuum line hoses.
  • still has some or all of California emissions equipment, no longer needed.
  • Has excessive plumbing fixtures engine monitoring devices.
  • Rubber seals between engine and body damaged
  • engine still runs little rough, missing some power, but drivable
  • no idea when last valve adjustment occurred
  • Air cleaner loose on carb, unknown when oil last changed in cleaner.

  Suggestions:

  • clean, continue to inspect engine.
  • start planning for a full rebuild, possible upgrade in displacement
  • replace distributor with Bosch 009, remove vacuum lines
  • investigate pointless ignition for Bosch 009 distributor
  • replace carborator, either with single stock Solex (less Cal smog devices) or dual solex/kadron
  • replace air cleaner(s) with paper filter element.
  • replace generator with alternator for increased electrical capacity
  • Clean up wiring in engine compartment
  • investigate electrical fuel pump and regulator or at least mechanical model compatible with alternator
  • investigate electrical cooling fan
  • install monitoring devices to go with suggested instrumentation (oil pressure and temp)
  • check exhaust system, possible after-market exhaust for improved performance
  • Check/replace engine/tranny rubber mounting blocks
  • check/replace fuel line
• Suspension/Brakes

  Observations:

  • tires replaced on receipt. best of current used as spare.
  • brake travel excessive, needs pumping.
  • unknown age of shock absorber, including strut cartridges
  • Drum brakes on all four wheels, unknown service history
  • Some amount of pulling to one side with brakes
  • steering damper fairly new
  • Steering wheel has cracks, not centered for straight ahead

  Suggestions:

  • replace shocks/strut cartridges
  • Flush braking system, adjust brakes at minimum
  • investigate replacing front brakes with disk brakes
  • investigate rebuild of master cylinder or replace if needed for disk brake conversion
  • replace all rubber bushings for front suspension, possible use eurothane bushings instead.
  • front end alignment,
  • check steering box, line of steering wheel with straight ahead.
  • check/replace rear brake shoes
  • check CV joints in rear
  • repair/replace steering wheel. consult cosmetic plan for possible after-market steering wheels.
• Interior

  Observations:

  • Dash cracked in several places
  • clutter of home brew instruments, including clock and oil temp gauge
  • no identifiable switch for rear window defroster
  • seats in fair condition, allow a certain amount of slosh
  • interior carpet worn
  • Headlining in good shape, but dirty
  • hooks for seat belts broken

  Suggestions:

  • determine new dash design, either replace with stock or build up custom
  • replace with after-market seats
  • replace interior carpet with rubber floor mat
  • suggest a full strip down to pan, clean, repair/replace and paint, including new side panels, floor and seat covering.
  • clean/replace headliner
• Custom

  Use this list as starting point for custom features. ideas include:

  • brass instead of chrome accents
  • two tone paint job
  • going back to metal dash, possible with wood overlay

last updated 6/16/1999