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How To Restore Your Volkswagen Beetle
Perhaps the most charismatic automobile ever, the Volkswagen Beetle was the longest-running, most-manufactured automobile on a single platform of all time. From 1938 to 2003, more than 21.5 million "Bugs" were assembled, distributed, and sold on nearly every continent in the world.
Throughout the Beetle's successful run, many of these cars have been relegated to project car status due to their age or condition. Airkooled Kustoms, a VW restoration shop in Hazel Green, Alabama, brings its expertise in restoring these cars to book form with this all-encompassing compilation. Restoring your Beetle is covered through step-by-step sequences from unbolting that first nut through polishing the paint on your freshly restored Bug. The specialists at Airkooled Kustoms walk you through the proper disassembly methods, restoring versus replacing components, and reassembling your restored Bug, covering everything related to the body, undercarriage, and interior along the way.
Dedication
Foreword
Preface
Chapter 1: History of the Iconic Beetle
The Beetle’s Origin Story
Standards and Supers
How Mass-Produced Economy Cars Became Prized Collectibles
Lots of Good Volks Waiting to Meet You
Chapter 2: Why Restore Your Beetle?
Restoration Options
Things to Consider
Sourcing Project Cars
Make a Plan
Upgrades to Consider
Happy Parts Hunting
Chapter 3: Let’s Roll—Restoration First Steps
Safety First
BYOBC: Build Your Own Body Cart
Yikes! That’s a Lot of Dirt
Disassembly
Interior Removal
Chapter 4: Beetle Bodies Start Here
Blast, Dip, Strip, or Sand?
Your Naked Beetle
Rust, Dents, Dings, and Damage
Panel Replacement
Finish Metal Work
Chapter 5: Prime, Paint, and Polish
Primer
Paint
Clear Coat
Cutting, Buffing, and Polishing
Polish It Up
Caring for Paint Finish
Chapter 6: The Beetle Pan
Restoring a Pan
Pan Reassembly
Wheels
Suspension
Chapter 7: Transmissions
VW Transaxles
Repair versus Replace
Transmission Rebuilding
Inspection
Reassembly
Final Assembly
Chapter 8: Brakes
Brake Replacement
Brake Lines
Chapter 9: Body Mating
Safety Reminder
Body to Pan Reassembly
Chapter 10: Engine
Engine Disassembly
Engine Rebuilding
Stock Parts versus Aftermarket Parts
If at First You Don’t Succeed
Engine Break-In
Fan Belt
Fuel Line Safety
Chapter 11: The Electrical System
Wiring Harnesses
Wiring Harness Replacement
Troubleshooting
Fuel-Injection System
Chapter 12: Your Beetle’s Interior
Make It
Buy and Bolt In
Installing Sound Deadener
Installing Headliner Padding
Installing Headliner
Emergency Brake Boot
Installing Carpet
Door Cards, Armrests, Door Handles, and Window Cranks
Interior Items
Seats
Complete the Trunk
Installing the Dash Pad
Steering Wheel Installation
Emergency Brake
Chapter 13: Trim and Finish
Refurbishing
Recommendations
Installing Chrome Trim
Installing Glass and Seals
Running Board
Bumpers
Turn Signals
Headlights
Taillights
Miscellaneous Shiny Bits
Chapter 14: Exhaust, Carburetor, and Distributor
Fluid Levels
Brake Lines
Exhaust System
Carburetors
Distributor
Chapter 15: Before the First 1,000 Miles
License Plate, Registration, and Insurance
Gently Breaking In the Beetle
Troubleshooting
75-Point, 500-Mile Inspection Checklist
Chapter 16: Care and Maintenance
Protecting Your Baby
Kill Switch
Fuel Cutoff Switch
Battery Cutoff Switch
Keep It Shiny
Show and Shine
Maintenance
Transmission Troubles
Conclusion
Source Guide
Perhaps the most charismatic automobile ever, the Volkswagen Beetle was the longest-running, most-manufactured automobile on a single platform of all time. From 1938 to 2003, more than 21.5 million "Bugs" were assembled, distributed, and sold on nearly every continent in the world.
Throughout the Beetle's successful run, many of these cars have been relegated to project car status due to their age or condition. Airkooled Kustoms, a VW restoration shop in Hazel Green, Alabama, brings its expertise in restoring these cars to book form with this all-encompassing compilation. Restoring your Beetle is covered through step-by-step sequences from unbolting that first nut through polishing the paint on your freshly restored Bug. The specialists at Airkooled Kustoms walk you through the proper disassembly methods, restoring versus replacing components, and reassembling your restored Bug, covering everything related to the body, undercarriage, and interior along the way.
Dedication
Foreword
Preface
Chapter 1: History of the Iconic Beetle
The Beetle’s Origin Story
Standards and Supers
How Mass-Produced Economy Cars Became Prized Collectibles
Lots of Good Volks Waiting to Meet You
Chapter 2: Why Restore Your Beetle?
Restoration Options
Things to Consider
Sourcing Project Cars
Make a Plan
Upgrades to Consider
Happy Parts Hunting
Chapter 3: Let’s Roll—Restoration First Steps
Safety First
BYOBC: Build Your Own Body Cart
Yikes! That’s a Lot of Dirt
Disassembly
Interior Removal
Chapter 4: Beetle Bodies Start Here
Blast, Dip, Strip, or Sand?
Your Naked Beetle
Rust, Dents, Dings, and Damage
Panel Replacement
Finish Metal Work
Chapter 5: Prime, Paint, and Polish
Primer
Paint
Clear Coat
Cutting, Buffing, and Polishing
Polish It Up
Caring for Paint Finish
Chapter 6: The Beetle Pan
Restoring a Pan
Pan Reassembly
Wheels
Suspension
Chapter 7: Transmissions
VW Transaxles
Repair versus Replace
Transmission Rebuilding
Inspection
Reassembly
Final Assembly
Chapter 8: Brakes
Brake Replacement
Brake Lines
Chapter 9: Body Mating
Safety Reminder
Body to Pan Reassembly
Chapter 10: Engine
Engine Disassembly
Engine Rebuilding
Stock Parts versus Aftermarket Parts
If at First You Don’t Succeed
Engine Break-In
Fan Belt
Fuel Line Safety
Chapter 11: The Electrical System
Wiring Harnesses
Wiring Harness Replacement
Troubleshooting
Fuel-Injection System
Chapter 12: Your Beetle’s Interior
Make It
Buy and Bolt In
Installing Sound Deadener
Installing Headliner Padding
Installing Headliner
Emergency Brake Boot
Installing Carpet
Door Cards, Armrests, Door Handles, and Window Cranks
Interior Items
Seats
Complete the Trunk
Installing the Dash Pad
Steering Wheel Installation
Emergency Brake
Chapter 13: Trim and Finish
Refurbishing
Recommendations
Installing Chrome Trim
Installing Glass and Seals
Running Board
Bumpers
Turn Signals
Headlights
Taillights
Miscellaneous Shiny Bits
Chapter 14: Exhaust, Carburetor, and Distributor
Fluid Levels
Brake Lines
Exhaust System
Carburetors
Distributor
Chapter 15: Before the First 1,000 Miles
License Plate, Registration, and Insurance
Gently Breaking In the Beetle
Troubleshooting
75-Point, 500-Mile Inspection Checklist
Chapter 16: Care and Maintenance
Protecting Your Baby
Kill Switch
Fuel Cutoff Switch
Battery Cutoff Switch
Keep It Shiny
Show and Shine
Maintenance
Transmission Troubles
Conclusion
Source Guide
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