October Y2K

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Last edited 12/12/2000

There are 78 thumbnails on this page, it may take a while for the page to load. It will be worth the wait. If you have any questions on the way I carried out any of this work just email me.

Dates of work October work.

	4th The bug arrived in Chingford. I checked out inside and out
	5th Removed bonnet and wings
	7th Bonnet repairs and front panel installed
	9th Hunted new roof
	10th More bonnet work, new bumper mount installed, new roof collected
	11th Roof channel work started
	12th Roof channel finished
	16th Near side door pillar repair
	19th OS bumper mount and heater channel work
	25th OS heater channel, gutter (rain dip channel), door post work.
	27th OS door repairs.... new bottom section, repairs to inside
	28th Continued door work, Tips on door strip down
	30th Minor tidying work

30th Oct 00

As it is my daughters 6th birthday party today the bug had to take a back seat, only minor works completed. I finalised the drivers door and spot primed it all over. Drilled and spot welded the front valance and tidied the rest of the car and garage.

28th Oct 00

Continued with the door refurbishment, removed all the glass and winder then filled some surface holes with... you guessed it. mig weld. Thanks again to the John Henry at The Bug Shop for info on glass removal. I made good use of his information... This is what I done, just slightly different.

Door strip down

Removed the winder and door opener, used a small punch to drive out the pins holding these in place

	Removed the door panel by inserting a small screwdriver between the door frame and the panel
	Lowered the window and removed the 4 10m bolts holding the window to the sash
	Removed all the 10m bolts holding the winder in place
	Laying the door flat on its front I then levered the window winder out and slide the glass out under it
	Removed the window winder, just pulls out with a riggle
	Pulled out the window felt all the way around the rear edge and along the top, (all one piece) again using a small screwdriver the prise out
	Removed the small screw at the top of the quarter light, then removed the light
	Removed the aluminum trim, you guessed it, screw driver again

Heres the inside of the door, stripped

and the outside

Started late today, at 4pm, finished by 6:30.... took it easy

27th Oct 00

So at 11am this morning it was off to the garage for a days work on the off side door... the drivers door. There was lots a filler all over the place, at first I thought that the task in hand was too great.... I'll give it a try and if I mess up.. I'll get another.

Well I didn't mess up.. I cut of and replaced the bottom section and restored the edges along the front and back. Well done Andy (the previous owner) some good filling work... sorry it all had to come out...

The bottom of the door, before and after. A nice straight cut though that steel, and the a new section put in
This is under the door, bad

Again, started at 11am and finished at 7.30pm.. long day, worth it though.

25th Oct 00

Continued the work on the off side of the bug, finished off the rear of the heater channel and then went on the the gutter (rain dip channel). Following that I cut out the rust on the door posts and then plated up.... finally the engine lid came off, the rust spots treated and then spot primed everywhere.....all in a days work!!!

Here is the roof channel, gutter, drip channel, call it what you want. I've posted a few pictures because there are no others on the net, well I can't find any. Hopefully someone will benefit from these.		Here is the section of channel cut out	Here's the section welded in, rough but done, nothing a grinder cannot handle
A few more roof channel pictures	It can be hard getting that mig into the channel...	Another view	And another, this time grinded with the old piece next to the finished product.
	Don't that look lovely jubly	Primered... Oh yes	Another, yes, done
I forgot the take photos of the repair panel going in. I cut up to the top of the primer, then welded in a complete replacement section from German & Swedish..
Here's the door post, not too bad, but worth a cut and grin. That yellow box is a voltage reducer, 240v to 110v for may grinder.
Arrrrrrr.... here is the donor roof, of a 1962 1200 in told, check out the smiley face....... As John Henry says, don't throw anything away till you finished. This I'll be keeping for good sheet VW metal HA
And finally, a picture of the bug going the sleep for another night, spot primed all over with a wing bolted on..... not long to go. That's my pocket rocket, CB600F Honda next to the 66

So, there we go, another days work, started at 11am, finished at 8pm with lunch, dinner and tea breaks.

19th Oct 00

Started work on the off side of the bug... completed bumper mount, cut out rear quarter, plated the rear section of the heater channel and the heater channel inside the front wing.

Pictures to follow.

Here is the rear bumper mount, not a lot of work, just cut and mig up... easy
Some more picts of the mount, see how bad it was. This is not always visable from under the wing. Have a feel inside, you'll soon feel the holes is yours are gone.
Here is the rear valance, welded up the wholes and replaced the seal mounting.
This is the corner and front end of the heater channel, bad condition, I've seen worse though... all done now. Here we have before
And after	I made up all of this section and miged it up	The front of the heater channel plated to shape, quite nice!	Under the rear section of channel, poor pic quality

16th Oct 00

Had a bit of a tidy up in the garage, then started on the near side door pillar. It was quite rusty, so again, lots of cutting and welding up.

First off, I got a sharp screwdriver and had a good poke about to locate all that bad rust, cut out with the faithful grinded. Made up a section from the roof sheet metal (keeping it VW, HA) and then plated in.

What do you think? I recon it come out OK!!!!

So here is the nearside door pillar. Not too bad, only about 2 hours work. The grind clean and cut	Rusted out	Some of the carpet gripper on the left was replaced too	It really looks worst than it is....
Made up the section from the left over metal from the roof section.... As John Henry say's don't throw anything away it ur done.	So a bit of a clean and plate in	Another angle
After some grinding and sanding, the final preparation in the anti rusting primer... all ready for the top coat.	Sand and paint	Another	You can see where I replaced the carpet grip on the left

12th Oct 00

Finished the roof channel. Initially I was only going to replace the section of channel above the door and rear near side rear window. Further investigation found rust on the channel running down the side of the N/S windscreen pillar. I decided to replaced the whole section from the front wing to half way along the rear window.

What a nice job too, have a look at the before and after pics. Still a little bit to do. And there is my wife collecting the empty tea cups.
And here is the bonnet corner, all nice and solid now.... looking OK......

11th Oct 00

Today was the day to start on the roof channels, what a long job. Slow and challenging, however, I managed to get quite a bit done. Here is the evidence.

Tips for renewing the roof channel:

	Get a donor roof, without one life will be real hard
	cut small sections out at a time, no greater than 5 inches. If the channels are real loose then this length can be greater.
	cut all donor sections over size
	take your time, this took me the best part of a day to complete

Here a small section of the roof channel is cut out and replaced, slow work.
Here I install a larger section that was completely rusted out.
And finally a before and after shot

10th Oct 00

I picked up the new roof today for those donor rain channels. I also purchase new rear bumper mounts from Volkspares in Leytonstone, London. I managed to get the near side welded in, it came out really nice, see the photos.

I finished the welding on the bonnet, gave it a sand and filled the seams on the welds.

Here a some pictures of the day

I started of with the removal of the nearside rear bumper mount. It turned out to be an easy job. I reduced the size of the replacement panel to keep as much original metal as possible. As you can see I also removed part of the rear valance, this I replaced. Tip: Cut along the top of the bumper mount with a grinder, lightly go through the outer plate leaving the existing behind.
Then onto the bonnet. Loads of welding & grinding here. See the crease on the underside in the second picture, thats from the 69 accident
The inner flanges were also renew were there was rust.
Collection of the donor roof in my 72 bay
One of the bonnet channel rubber holders was replaced too

9th Oct

Hunted out a new roof for those rain channel. Pick one up in Leyton, London by chance for £10. Yes a whole roof, without rust..... those channels will be done before I know it.

7th Oct 00

Work continued today with lots of cutting and welding.

First off was the bonnet, the corners were shot of and really rusted up. There was accident damage at the locking end... I found lots of filler here. The bonnet then had an overall clean
I also cut out the front valance panel and replaced it with a nice new section. Looks OK!!!

5th Oct 00

This was a long day. I was out in the garage by 1230pm and started on the wings....

Here is a pictorial of the day.

I cleaned up the bonnet channel, wire brush and grinder job		Then came the cleaning up of the wings. I went over them all with a grinder removing all traces of surface rust
In 1969 the bug was involved in an accident, it looks to me as a used wing was put onto the bug.... See the dark blue!!		In the same accident damage occurred on the bonnet too.... I'll post some pictures of the filler on the bonnet

So the day finished off with 4 wings cleaned up, rust spots removed. The bonnet was also taken care of, again rust spots removed and a load of filler was ground away.... The bonnet corners were cleaned too.

4th Oct 00

The first day for a new home for the 66 Bug. Towed all the way from Chadwell Heath, Essex to Chingford, London. A journey of about 7 miles, that took about 45 minutes.

All went well considering that the bug had been sitting for the past three years. Andy, the previous owner drove my car and I sat in the bug.... there was a couple of near misses.... when Andy braked a bit hard....

Here is the bug outside Andy's house, this is where it sat for the last 3 years. The guy next door, the AA man wanted to buy it... Andy wanted it to go to a good home!!!!

Here is the Bug in my garage, plenty of space to get the work done

Once home into the garage work started on seeing what work the bug needed. This can be seen on the 1st checks page and inside page.

The work started with the removal of all the wings, bonnet, running boards and off side and rear window. All this can be seen on the !st checks and inside pages