The Restoration Project of the Käfer has started

In my other post of mid December 2011 titled A 1962 VW Beetle joins the ‘family’, I had outlined the new acquisition and mentioned about the plan to proceed with a sympathetic restoration of this fun car to which I have become emotionally attached.

Not without some delays, the resto project has commenced as of Monday 5th March. I have entrusted the work to my competent body shop friends of A & B For Cars who had done such a good job couple of years ago on my other car, the Mercedes-Benz 250SE Coupé.

Since the VW Beetle is a much simpler and smaller vehicle compared to the Mercedes, but also having gone through the previous Mercedes project experience, I am now more knowledgeable, hence confident that we will proceed with a relatively quick pace. An important factor pertains to human relationships. Through the years, I have built trusting and friendly relationships with the owners Gregory and Costa, as well as with their staff and Manos, the shop’s foreman who is looking after my Käfer! The target is to have the car ready for Easter. Sort of like a little ‘half egg shaped’ present. In addition, I have done some preparatory research on parts availability; as expected for such a popular car which had endured a long life with 18+ million examples produced, the issue of sourcing spare parts is de facto solved. There are many specialists involved with the VW brand both in Europe, the USA, South America and Asia of course.

We are currently verifying the “parts needed list” in order to proceed with placing purchase orders. The guys at A & B suggest that we take off the body, have it sand blasted and thus allowing for working on the floor pan with much ease and thoroughness. Budgetary estimates are being prepared for this (and only) scenario. So far the verdict is that we have a rather sound body with very little rust spots and an even better looking floor pan. Not so many worries (or additional expenses). 🙂

So here is what I saw yesterday after the initial stripping:

The restoration was started on 5 March 2012

Wheel arches show no rust

The rear LH valance from the inside: few issues here

The LH inner fender rust spot: not so difficult to fix

Inner door condition is good with some rust in the bottom area.

The view from the rear, prior to engine removal

Wed. 7th March 2012 update: ‘Houston we have Lift-Off’, the body was separated from the chassis

The body shell hovers over the chassis! Perhaps this temporary separation has occurred for the first time after a tight, faithful marriage of over 50 years!

Today as I visited the body shop, the Käfer was just being readied for lift-off! That is all the bolts holding the body shell firmly mated to the rolling chassis had been removed, ditto for the wiring. Manos, the shop’s Foreman was making sure that nothing was forgotten, the last item to be disconnected was the speedo cable. The body was manually cracked open and the lifter arms were adjusted so that by pressing the Up button it would be raised evenly and without much effort. Carefully coordinating the intermittent pressings of the button by an assistant, the body was lifted-off without any mishap.

Rear quarter panel is rusted nicely and will be replaced.

Upon closer examination of both body and floor-pan, the verdict revealed few more rust spots, mainly in the body undersides, in the area of the heater tubes which run alongside the door sills. A known source of pain for VW Beetles. In addition, few more rust spots became evident on the rear quarter panels onto which the bumper brackets are being mounted. Luckily such panels are readily available from a number of sources, among which the VWHERITAGE guys in the UK.

Other than these pains in the aforementioned areas, there were no further nasty surprises upon the separation of the body from the chassis, such having occurred for the first time after a tight and faithful German marriage, residing in sunny dry Greece, for over 50 years!

Watch the ‘separation’ video clip here below:

Here are few more impressive pictures from the operation:

I love this particular picture which captures almost an unreal sight 😉

The rolling chassis

Attention Low Riders: you cannot go any lower than this! 😉

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2 comments on “The Restoration Project of the Käfer has started

  1. Αντε με το καλο και εις ανωτερα!
    Μην ξεχασεις το δειγμα μπογιας.

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