COMPLETED PROJECT ~ 1973 VW Super Beetle
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Completed Project: 1973 VW Super Beetle
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1973 VW Super Beetle Photo Gallery
Allow us to introduce you to "Sunny".

Our client has owned her for many years and would like her rebuilt to like new condition. We will be performing a complete "pan off" restoration.

Sunny will be receiving many upgrades such as a front disc brake conversion, a peppier motor (including upgraded electronic distributor & exhaust system), better tires and an upgraded sound system.

Sunny is a 1973 Volkswagen Super Beetle that was shipped to our spa from British Columbia.

We started by preparing the body to be lifted off the chassis. It is a bit more difficult to lift the body off of a Super Beetle (because of the strut front suspension) than a "Standard Beetle".

Sunny co-operated nicely!

The next step was to sand the body to determine why there is such a large amount of body filler.

We will be able to make a material list of metal we will need to order. We noticed there may have been a collision to the driver's side front area at one time. We also noted the replacement "Mexican" rear fenders. We will need to inspect the front fenders further.

Sunny's chassis looks quite nice. She will need both floor pans (very common on Beetles). The front frame head (main front suspension structure) appears to be quite solid!

The old rusty & damaged floor pans were removed and replaced with new heavy duty pans.

We removed the engine from the transmission. The transmission was sent out for a complete rebuild. It came back like new again. We degreased and cleaned the transmission and painted it to look as new. The engine was detailed and enhanced. (See You Tube videos)

The new floors received 2 coats of special POR15 rust resistant paint to both the top and bottoms of the pans.

Our next step was to work on Sunny's rusted out body panels.

The large new metal order arrived (which included new front and rear aprons,2 heater channels, rear bumper supports, front bumper supports, all four wheel well replacement panels & more).

Sunny's body received cross bracing before the rusted out heater channels were removed (the heater channels are the main structural sections of a Beetle body). There was an extensive amount of cutting, grinding and measuring and prepping of rusted out sections before new panels were welded into place. We "dry fitted" all panels to be certain of proper fit before they were welded into place. (All 4 fenders were also dry fitted to be certain all new sections fit together correctly).

Smoothing the body was next. Numerous hours were spent block sanding and applying high build primer between the various grits of sandpaper that were used (starting from 80 grit, then 120 grit, 180 grit, 240 grit, 320 grit and final sanding grit of 400.

The front hood and rear engine lid required repairs (numerous dents were hammered and dollied out after old body filler from previous repairs was removed. Both panels were then degreased, sanding and received the same grits of sanding with special high build primer applied between coats.

All four fenders were also sanded at all levels and dry fitted one final time before Sunny's new paint was applied. Sunny's beautiful new paint job turned out great! It is a Factory correct Saturn Yellow VW paint code is L13M.

Sunny received 5 coats of Factory correct Premium Single Stage Paint to the complete body, all 4 fenders and both the front hood and engine lid (both inside and outsides).

Next up for this transformation was repairing both doors. They were damaged previously and required some proper repairs (along with some new door hinges).

Sunny's engine was "freshened up" and received some upgrades. Watch two You Tube Videos on the fresh motor here.....

Engine video Part 1 http://youtu.be/2qhWWQdRXk0

Engine Video Part 2 http://youtu.be/Dvsh-cYBhDs

With the doors repaired and painted, it was time to prepare to install the body onto the rebuilt chassis.

The chassis received the rebuilt transmission and the fresh engine was also installed. A new front disc brake conversion kit was installed (replacing the factory drum brakes).

Sound insulation was installed over the 2 coats of special DOM16 anti rust paint that was applied to the complete chassis. The rear brakes were reworked with new rear brake shoes and new rear wheel cylinders and all new brake lines and flex lines.

With the body bolted to the chassis, it was time for re assembly! Sound insulation was installed to the complete roof, side panels and rear parcel shelf areas of the body. Both doors also received the same treatment.

A new headliner was installed next. The windows were installed with all new rubber seals. The old windshield was replaced with a brand new one. The dash received a special new cover to make it look new again. All new weather stripping was also installed. The doors and running boards were next.

Sunny received several upgrades. The stereo and 4 speaker system, electric washer system, shifter knob, upgraded radial tires, new "H4" Headlights, new Hella Tail light assemblies along with new front signal light lenses.

There was a lot of new wiring installed to both the front and rear sections of Sunny from several incorrect small repairs over the years.

Custom made seat upholstery (with suede inserts to both front and rear seats) with all new foam for better support. New three point "Euro style" seat belts for the front and new Euro style two point belts for the rear were installed over the all new thick pile black carpet kit. New door panels were installed to complete the all new looking interior.

The spare tire rim was sandblasted and repainted. The gas tank (with new fuel lines and grommets) was installed and the front trunk/under hood area was treated to a special two piece carpet kit!

Sunny turned out quite nice. She looks like a "Stock" 1973 VW Super Beetle, but has many enhancements that her owner should enjoy for years to come!

See the You Tube "Walk-a-Round" completed restoration presentation of Sunny here.....

http://youtu.be/RWo-uZDj62I




















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