1963 VW Beetle (Beater as we call it ) Restoration Project

[Xulfiqar]

@margallar I treated it with POR15 rust preventive paint and part of the process to prepare surface for application is to apply cleaner and degreaser designed for the exact purpose u mentionwd above. I will share pictures soon.

there is an issue with POR15 - its transparent to ozone and will delaminate if left like that. POR-15 is not actually a paint, its a moisture cured epoxy, and its recommended to cover it up with a coat of paint and primer to make it last.

You will need to make or purchase some large quantity of cavity wax and "go to town" on the chassis and shell if you want to make this job last.

[syedalinaqi]

@xulfiqar you are right about POR's sensitivity to sunlight, for that purpose we will spary black paint over it once POR is cured. That paint spray over POR is part of the process.

[syedalinaqi]

Front axle beam and the tranny were removed to expose any hard to reach areas. The floor pan was manually cleaned and treated. When all the layers of grime were cleaned the pan was treated with POR15 'Cleaner & Degreaser' to remove any remaining oily residue then with POR15 'Metal Prep' was sprayed with a hand operated spray bottle. Lastly POR15 Rust Preventive paint in black was sprayed and is left to cure over night, tomorrow whole frame is going to be painted glossy black as a last step.

Two quart of POR15 was used to cover the floor pan from both sides, all four wheels, front and rear axle along with transmission and there was nothing left.

Once we were done with everything Nasir sb paid a visit to the shop and approved everything Tomorrow we will start installing new parts of front & rear axle and will mount transmission and new hand brakes.

[syedalinaqi]

more pics ......

[syedalinaqi]

more ......

[syedalinaqi]

Today chassis was sprayed with black paint to cover POR15 coat so that its is not affected by UV rays. Later we assembled front and rear axle with brand new parts purchased form Wolfsburgwest. We mounted transmission with brand new transmission mounts and seals. Now chassis is back on wheels and now work on body will start soon.

[hash4u]

Was teasing Aun last night.
You guys should place plastic seats n roam around on chasis for a day.[emoji14]
To much money n effort put in stuff which wont show to admirers in the end.
A job well done indeed!

Sent from my GT-I9500 using PW Forums mobile app

[syedalinaqi]

@hash4u its not abt ppl its about my own satisfaction, also there is no extra money involved i bought POR from Dubai and shipped it via door to door cargo service for fraction of a cost. This chassis has not cost me more than 10k in terms of body work and paint job.

[nmshaikh]

Was teasing Aun last night.
You guys should place plastic seats n roam around on chasis for a day.[emoji14]
To much money n effort put in stuff which wont show to admirers in the end.
A job well done indeed!

Sent from my GT-I9500 using PW Forums mobile app

While the actual work may not be visible to the naked eye, the ride quality of the car when done, would vouch for all the hard work that was put at this stage.

[ansarghani]

Amazing work!

[syedalinaqi]

So i updated till the Floor Pan restoration stage, work continued as i was out of country for some time. Front axle was assembled with new bearings,bushings and seals and is as good as new. Body was mounted and work started on the shell. First step was to craft new cross panel which was underway when i took pictures. Paint was removed from front and rear quarter panels and new pieces of sheet metal were welded at locations where it had rust. Left side heater channel was welded. As car has a lot of rust at different locations it will all be treated before panel beating will start.

[syedalinaqi]

Work is progressing slowly due to the amount of filler and rust on different body panels. We are making sure to replace all rusted areas with new sheet metal to avoid any future growth of rust. During last one week passenger side door was repaired and paint removed from it. Pillar was strengthened with new metal and door was aligned. Rear wheel well was badly rusted and is now repaired.

[Sheryar]

Superb ...

[syedalinaqi]

Passenger side is now ready and door was aligned perfectly and that tuc sound with door closing is amazing

[syedalinaqi]

Body work on the driver side was started to find out the horror story. Car had 2.5 inch of body filler on quarter panel side, car was hit at some point of time and instead of doing body work and then painting they just filled it with filler and smooth that out. All the filler was removed and the best part was that there was no rust. Period correct Pedal assembly was sourced and installed.

[syedalinaqi]

Pics ....

[nnabeel]

Great work.......waiting to see the final result

[maverickfhs]

Subscribed.

This is a mind blowing project and am impressed with the quality of build.

Looking forward to the final outcome, good luck.

[contact_wolfpack]

Superb

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[syedalinaqi]

Car is now entering its final stage of body work. Driver side heater channel is welded with necessary body work, roof was scratched, rear quarter panel is also done, front hood was scratched and body work done.
All fenders were in good condition as far as lines are concerned but still due to amount of filler and rust we decided to buy new fenders from UK which are now already shipped. I always loved W Decklid but due to its high prices didn't had the courage to buy it, luckily one day i was surfing Samba and got a very very good deal on a used W decklid so i bought it and now that will replace the present decklid. Now as i have a pre 64 bug and i have already bought a W decklid what do u think about converting it to oval by replacing rear window with oval panel (Just a thought ). Suggestions required !!!