Beginnings 72 Coupe Resto

[Vinnie]

wow and more wow. I take my hat off for the work you do! I was wondering how replacing the back window panel would pan out, any update on that? and also; did you do anything to the panel underneath the back panel?

what are the areas you cannot get to? like the inside of the rockers for example. I’d always be scared that rust will come up from an area that was overlooked or unreachable.

one day I really want to do all this with my coupe...

 

[OzCoupe72]

wow and more wow. I take my hat off for the work you do! I was wondering how replacing the back window panel would pan out, any update on that? and also; did you do anything to the panel underneath the back panel?

what are the areas you cannot get to? like the inside of the rockers for example. I’d always be scared that rust will come up from an area that was overlooked or unreachable.

one day I really want to do all this with my coupe...

Thanks for the feedback

Still waiting on the window panel which is still in Sydney, my window panel and the panel below it are not rusted, just have a damaged panel and need to get the trunk gaps correct.

I was pretty lucky withe the rockers, doors and fenders being 99% rust free 

Nearly all panel work done except window panel and need to mount the fenders then check the aftermarket hood for alignment but will wait until engine installed

So far looks like the headers will clear the steering rack but had to modify the kickdown lever plus the dipstick tube

 

[OzCoupe72]

Decided this weekend it was time to get the engine and transmission installed so I can pass another milestone

Tried to install it with trans and headers attached but ended up having to remove the right side header

Luckily was able to refit the header getting it in from underneath

Next problem was lining up the engine mounts as I used an aftermarket locally made mount and it looked like the solenoid on the mini starter was hitting the steering rack so wasn't looking forward to removing the header again just to remove the starter

Once I adjusted the engine mounts and got the bolts in it was starting to line up with just enough clearance between the steering rack to starter plus the oil pan is pretty close

Lastly had to lever the trans mount into place then slip the bolts in and looks all good for now

Put the Holley 770 carby on with a 1 inch spacer but seriously doubt it will clear the hood so might have to go without the spacer, oh well can't have it all my way

Anyway happy with the progress with some plumbing/wiring jobs ahead before I start the engine then back onto the panel work

 

[73pony]

Nice. Looks great.

 

[Fabrice]

So clean, so nice!

One day I'll be that far...

Keep up the excellent work!

 

[Pegleg]

Looking great. Engine bay looks sharp and crisp

 

[mach71351c]

Nice job! Congrats.

 

[OzCoupe72]

Well it's my birthday today so decided it was time to start it up for the first time after many months

Surprisingly it fired up straight away although I had to prime the carby up properly by filling the fuel bowl

After getting fuel up I ran it until full temperature then shut it down to top up both transmission and power steering fluids

All up the C4 trans took about 3 1/2 gallons of fluid and the coolant a whopping 4 1/2 gallons or 17 liters due to a bloody big radiator

I don't have an exhaust system yet but to quieten it down some I whacked the Summit turbo mufflers straight on to the headers although it was still very loud

Anyway happy with how it went and having a birthday beer or two

Also a video below but not sure how it will work

 

[vintageman]

Nice, great job and happy birthday.

Tom

 

[73pony]

Very nice. Sounds great. Happy birthday.

 

[computercarguy]

I'm sorry, did you say 3 1/2 GALLONS to fill the c4?

 

[OzCoupe72]

I'm sorry, did you say 3 1/2 GALLONS to fill the c4?

Probably closer to 3 as was converting from litres

Having used a large convertor made into a higher stall, new cooler and lines it took nearly all 12 litres

 

[protouringstang73]

I love those valvecovers! Beautiful engine!

 

[OzCoupe72]

After a long 6 months wait my donor window filler panel finally turned up so it was time to get this installed so I can continue with the panel work

First thing to do was to separate the upper panel from the lower section by drilling out the spot welds then I got my blaster to blast underneath and all the edges

These areas were epoxy primed prior to welding in place.

Unfortunately the blasting had popped the panel causing some oil canning but this could be fixed later and luckily my blaster being a panel beater had the right equipment along with experience to fix this



Next was to drill out the old window panel, remove it and prep for welding

Main problem here is it is virtually impossible to drill out the spot welds at each end where it meets the quarters as these are underneath so the easier solution was to cut the ends close to the join then once the upper panel is removed simply grind off the spot welds or you could even drill them if you wish





Next was to clean up all areas to be welded and apply some weld through primer

One issue I faced was whether I could plug weld the ends and although possible I wasn't prepared to get my 6 foot frame inside the trunk to upside down weld a few plug welds so for the end sections I decided it would be a much better proposition to glue this area which would also help seal it more effectively

One thing must be mentioned it is very important to do a mock up fitment then install the trunk lid to ensure everything lines up. Luckily it was spot on lining up with the old marks!

Once all prep is done and alignment is checked it was time to clamp everything in place and weld it in

A tip when plug welding along the weatherstrip channel is to close up the mig shielding nozzle with a vice a little so it will squeeze into the channel







Next was the tedious job of grinding the welds smooth, removing old paint, repairing oil canning, epoxy primer, filler, epoxy then high build primer, blocking down and a last coat of primer, nearly ready for paint

One job finally done and what a relief

Hopefully after I fix a few panel gaps and get the aftermarket hood straightened out I will be closer to getting some color on the car

 

[OzCoupe72]

Well what can I say but good news and bad news.

After more than 2 years I finally got some color on my coupe, 3 coats single stage Baslac urethane - Bright Red

Drove 2 hours to Perth as I had rented a spray booth

Very hot day 42 deg C/107 F

Tried my best to keep sweat off the paint but got one area which should buff out

All in all a pretty neat job apart from some dust nibs and the sweat streak

Went to drive the car back on the trailer but it ran out of gas, no problem though just winched it on

My problem was going to be getting it off the trailer by myself as normally would drive it off but no time to get gas and prime the carb plus I had to get the trailer back on time

As I have done it before my plan was to roll the car off the trailer and put some large blocks of wood as a back stop

Got home and in a rush I prepared to roll it off the trailer but didn't allow enough room for it to roll to a near stop

When it rolled off the trailer it picked up speed then the back wheels rolled right over the wooden blocks and into the vehicle behind it

I rushed to the rear of the car to inspect the damage, I can't repeat all the swear words here but when I saw the damage my heart sank

Right now I'm very disappointed in myself and won't post the damage photos yet but I have damaged the rear tail panel, trunk lid and rh quarter

I should be able to repair the tail panel/quarter but reckon the trunk lid is not repairable

The good news - I have plenty of spare paint to repair my mistakes!

Photos before the accident below, back to kicking myself profusely

 

[Vinnie]

Sorry to hear that buddy! And you don’t have to post the accident photos if you don’t want to. I hope you can show us finished car pics soon

 

[OzCoupe72]

Thanks Vinnie

I haven't actually taken photos of the damage yet but might post some later once I calm down

Not game to open the trunk yet either as I fear the trunk floor might have been pushed in a little

My initial assessment is I will definitely have to pull the whole corner out which will help get the crease out of the quarter panel

I have some hydraulic rams (Porta-power) but doubt they will be strong enough so may have to pay a panel beater for some rack straightening

 

[Don C]

Back when our younger son was in college he had a '74 Super Beetle that he crunched the left rear on. I drilled some 1" holes in the floor of the workshop that I could use for anchor points and chained the front of the car to a couple of them and used a come-along to put a pull on it while I used hammer and dolly on the bent sections. It came out surprisingly well, didn't have to replace anything. It even had a little deflection in the C pillar that came out as I got the rest of it worked into shape.

We had planned on doing some upgrades to the car, anyway, and this was a good time to do it. Put in a 2,010cc engine from Bernie Bergmann, an upgraded transaxle with different gearing, wider fiberglass fenders, suspension upgrades, wide rims and tires, some gauges, and a few other things. For a Beetle it ran really well, pulled 75mph in 3rd, and kept pulling strong in 4th, don't know how fast, the speedometer ended at 90. Due to the stroking, the torque improvement was amazing, didn't have to shift from first to second until 30+mph, instead of 20 with the stock engine and transaxle.

 

[OzCoupe72]

Back when our younger son was in college he had a '74 Super Beetle that he crunched the left rear on. I drilled some 1" holes in the floor of the workshop that I could use for anchor points and chained the front of the car to a couple of them and used a come-along to put a pull on it while I used hammer and dolly on the bent sections. It came out surprisingly well, didn't have to replace anything. It even had a little deflection in the C pillar that came out as I got the rest of it worked into shape.

We had planned on doing some upgrades to the car, anyway, and this was a good time to do it. Put in a 2,010cc engine from Bernie Bergmann, an upgraded transaxle with different gearing, wider fiberglass fenders, suspension upgrades, wide rims and tires, some gauges, and a few other things. For a Beetle it ran really well, pulled 75mph in 3rd, and kept pulling strong in 4th, don't know how fast, the speedometer ended at 90. Due to the stroking, the torque improvement was amazing, didn't have to shift from first to second until 30+mph, instead of 20 with the stock engine and transaxle.

Thanks Don, inspiring story

I will be considering having a go at it using anchor points, chains and my pulling ram

The trunk lid I'm not sure I can fix yet but will check it out, new one $450 ouch!

Just disappointing for this to happen only hours from new paint, giving it a rest for a while until I get the enthusiasm back

 

[OzCoupe72]

Finally got up the courage to have a better look at the damage

Main damage is below the tail lamp, the crease in the quarter panel and the trunk lid which is a write off

Will have a break for a while and slowly have a go at pulling the worst of it out

Luckily the quarter crease is before the wheel arch so can hammer & dolly it although may have to cut the crease when I pull it then weld it up

Still kicking myself but will recover, I think?