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Thread: 1966 Volkswagen Beetle Resto -

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    Default 1966 Volkswagen Beetle Restoration -

    Assalam-o-Alaikum Everyone .
    **** SO THIS IS WHERE WE START/SHORT HISTORY**** : So I had this craze light up for a Volkswagen Beetle A few years ago . After some time i managed to get a hang of a 1966 (1965 end in paper's) beetle from islamabad . it was lying around open to rain and the harsh weather . A lady had bought it sometime before i got my hand's on her . according to her she bought it for Travel purposes to her university and failed to maintain the car (Normal Case Y'know) . so I payed this guy , topped the car up with fuel and was on the chase for a 200-km journey from islamabad to my then Home city Peshawar with a backup safety car though on the very same day . Not to forget that after topping the car with fuel up out of nowhere the car starting dripping petrol , it was a broken/old fuel line underneath the car which we then covered with a plastic shopping bag (was changed on reaching peshawar) so we could continue the journey , the steering play and brakes were dreadfull that day , but nonetheless we managed to reach the city of flower's with two hand's,leg's and everything in it's usual places . though on reaching peshawar the fuel finished and the engine stopped firing (you won't believe it) just 5 metres within my house (i couldnt have thanked enough) . So we had to go and bring some petrol afterwards anyways .
    Details :
    Make: volkswagen
    Model: Beetle
    Year Of Manufacture : 1966
    Factory Color : White
    Plate : islamabad -
    Present Color : green
    ***WHAT WE DID TO IT AFTER WE GOT IT : ***
    Over the past whole year we have been working at Home and fixing all the mechanical Etc Issues of the Car - Brakes(bleedingthem,newbrakeoil,mastercylindersemi overhaul) - Steering(newgermansteeringdisc,newgoodusedsteering box etc) - Engine(timing,oil,newbracketsetupforimrovedthecool ing,newplugs, and many other tweaks you know how these engines are) - Electricals(pretty much working , did some work but will be doing complete new wiring job , its on the board) - all by ourselves and ma sha allah the car is fine , no doubt there must be and are many things still to be figured out but its kinda drivable(not so now 2016) .
    ***NOW THE THING'S WE'RE GOING TO HAVE TO DO TO IT **

    ****PLANS/GOALS ***
    1- Complete Engine Overhaul with New Piston/cylinders,oil cooler etc .
    2-Distributor overhaul with new part's
    3-Cooling system upgrade with a Used or New original German Generator/alternator (Needed if anyone can source)
    4-Body off for Rust Treatment , Curing , painting .
    5- Good used Rear Fender's (are out of shape) or reshaping these if possible . (needed)
    6- Paintjob
    7- Deepening the rear Original Vw 15x4.5(or are they 5.5) steelies to 7" or 8" (Pre-65 Non slotted Set or pair of steelies needed / Will exchange with my 1966 slotted lightweight 9.5/10 steelies too)
    8-rear torsion adjustement to lower it as much as it allow's us . With putting on new german torsion cover Bushings .
    9- New Front and Back Short shocks.
    10-Front Beam Shortening by 3-4" with Sway away Type Adjusters (i got 7" airkewld ones)(will use another beam probably/anyone have a beam up for sale or any sources?)
    11-Installation of 2.5" new Empi Drop spindles , New Empi long travel balljoints,new tie rod ends, bearings , Brake cylinders, pads , camber adjusters , caster shims (if needed) for the front suspension .** [DONE]**
    12- Planning on Air suspension upfront.
    13- (130-135-140-145-150-155-160 Pair of tires needed for the front) *Cannot find/help

    Rest of the idea's , Thing's to do will be discussed in the thread , these above are some basic *To do* thing's so .

    would also mention that many thing's will be discussed and sorted out overtime in the thread . I hope everyone enjoys this thread overtime and takes loads of help out of it . Will be updating the thread for Further Question's and Discussion's . Enjoy . tag the vw guys . .[IMG][IMG][IMG][/IMG][/IMG][/IMG]

    Horsepower is how Fast you hit the wall ,
    Torque is how far you take the wall with you -

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    P.S Did some DIY "Cheap Whitewalls" TODAY . 120RS paint and 70RS Tape . xD .
    did it on a Spare Tire though Just to check . Name:  ImageUploadedByPW Forums1438839536.726484.jpg
Views: 417
Size:  67.1 KBName:  ImageUploadedByPW Forums1438839561.061289.jpg
Views: 407
Size:  64.9 KB

    Tbh . I know Itll Come off over time . but i hope it doesnt and Also it isnt As clean as it Looks in the picture . But well , Did give it a try .


    Sent from my iPhone using PW Forums
    Horsepower is how Fast you hit the wall ,
    Torque is how far you take the wall with you -

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    Aoa guys . The engine has been giving me quite alot of problems these days . Engine oil consumption is hectic . Plugs get carbon on it after a day and engine starts misfiring . The rings and pistons/cylinders i suppose have worn out or theres someother prob . Tried everyone to get some new or good used pistons but no luck . What should i do now? Where to get them . Need 1500-1600-1700 cc pistons . Either of them would do .
    Horsepower is how Fast you hit the wall ,
    Torque is how far you take the wall with you -

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    Horsepower is how Fast you hit the wall ,
    Torque is how far you take the wall with you -

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    Quote Originally Posted by mishaqkhan1 View Post
    Hell everyone . My engine has been giving me quite alot of problems these days . Its drinking oil like anything . Plugs were drenched in carbon . Its misfiring . The rings and pistons/cylinders i suppose have worn out . Tried everyone to get some new or good used pistons but no luck . What should i do now? Where to get them . Need 1500-1600-1700 cc pistons . Either of them would do . :/ . HELP .
    You would not know the extent of wear till you dismantle the engine. It is never a good idea ...at least in the long run, to address just the compression issue by replacing the cylinders and pistons or a new set of piston rings. There is more to an engine than rings and pistons. Unfortunately some not-so-honest sellers try this technique to improve the condition of the engine just prior to putting the car up for sale. It is wrong on so many levels....go for a complete rebuild.
    Invest in precious metal.....buy a Volkswagen!

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    I agree with @nmshaikh advice.

    It is a good idea to go for a proper full overhaul and that too done by a knowledgeable mechanic well versed with VWs.

    I see your location is Peshawar. I am not sure but I think there is at least one mechanic out there who is familiar to VWs. Do find out from the old local owners.

    In case you do not find a suitable mechanic locally, consider taking the engine to Pindi/Lahore/Karachi where a VW specialist can rebuild it.
    If there are no Beetles in heaven, Im not going!!!

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    Quote Originally Posted by AsadIshaque View Post
    I agree with @nmshaikh advice.

    It is a good idea to go for a proper full overhaul and that too done by a knowledgeable mechanic well versed with VWs.

    I see your location is Peshawar. I am not sure but I think there is at least one mechanic out there who is familiar to VWs. Do find out from the old local owners.

    In case you do not find a suitable mechanic locally, consider taking the engine to Pindi/Lahore/Karachi where a VW specialist can rebuild it.
    I live in islamabad .

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    Quote Originally Posted by AsadIshaque View Post
    I agree with @nmshaikh advice.

    It is a good idea to go for a proper full overhaul and that too done by a knowledgeable mechanic well versed with VWs.

    I see your location is Peshawar. I am not sure but I think there is at least one mechanic out there who is familiar to VWs. Do find out from the old local owners.

    In case you do not find a suitable mechanic locally, consider taking the engine to Pindi/Lahore/Karachi where a VW specialist can rebuild it.
    Quote Originally Posted by nmshaikh View Post
    You would not know the extent of wear till you dismantle the engine. It is never a good idea ...at least in the long run, to address just the compression issue by replacing the cylinders and pistons or a new set of piston rings. There is more to an engine than rings and pistons. Unfortunately some not-so-honest sellers try this technique to improve the condition of the engine just prior to putting the car up for sale. It is wrong on so many levels....go for a complete rebuild.
    What do you mean by a complete rebuild ? what should i keep in mind of changing and overhauling ?

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    Quote Originally Posted by mishaqkhan1 View Post
    What do you mean by a complete rebuild sir ? what should i keep in mind of changing and overhauling and where to get these vw parts in pakistan at a good price ?
    I shall try to answer this question in a brief way.

    First of all, the mechanic you select *MUST* be a VW specialist. If you think an ordinary mechanic working on Jap cars would rebuild your VWs engine well, you are sadly mistaken. "normal" mechanics trying their hand at a VW engine are bound to screw up in more than one way. I have seen tons of examples.

    By complete overhaul, its meant that the whole engine is dismantled. Meaning the crankcase is opened and any worn parts inside are repaired or replaced.

    Many people go for a 'half overhaul'. It means the engine is dismantled only half way. That is, the cylinder heads, cylinders and pistons are taken off only. Thus the mech can only fix the valves (in the cylinder head), replace the pistons and/or rings, and replace/try to repair the cylinders.

    In a half overhaul, the vital components inside the crankcase, the crankshaft and camshaft are not attended to. Thus any wear in those areas remains. Since the engine works as a whole unit, a crank which does not run as it should (call it out of balance if you may to keep things simple) would result in swift wear of the piston rings. This is why you are being advised to go for a full overhaul.

    Having said that, some engines which have led good lives, with few miles on them, may get away with a half overhaul.

    It is difficult to explain clearly in words, pictures would have given you a better idea.
    If there are no Beetles in heaven, Im not going!!!

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    I shall again STRESS the need to get your engine by a VW specialist.

    There are many little details in the VW engine which, while not being rocket-science, can make all the difference between a sweet running and working-itself-to-death result. Ordinary mechanics would miss all those.

    Last but not the least......do be prepared to spend money where it needs to be spent. While you must be wise to look for the best parts at the best prices (not cheap parts at the cheapest prices) also look for a VW specialist who may charge you a bit extra but it would definitely mean a lot more trouble free miles.
    If there are no Beetles in heaven, Im not going!!!

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    Quote Originally Posted by mishaqkhan1 View Post
    What do you mean by a complete rebuild sir ? what should i keep in mind of changing and overhauling and where to get these vw parts in pakistan at a good price ?
    The complete rebuild would involve stripping the engine to the core...it involves splitting the engine block so the crank shaft is out as well. After cleaning the parts you would be able to see if there is significant play in that area including the connecting rods and the cam. It may (most likely) involve machining and new bearings, new engine rebuild gasket set etc. The cost would be higher but you are looking at something between 20-30k if the parts in your engine can be re-used. e.g if the crank is at standard it can be machined to 0.25, .50 , .75 (the next size basically depending on the wear). If the crank shaft is not within the limits to be machined another time then you would have to look for a good used crank shaft. Ditto for the cam. The connecting rods would need to be checked for other signs of wear and if ok they would require new bushings. The pistons and jugs may be usable and require just a new set of rings with just some honing of the cylinder walls. if they are deeply scoured then you may have to look for a new or used set. new sets are expensive and I am not sure if they are available but if it is just one cylinder that is bad, your mechanic may be able to find a good usable one and with a new set of rings you could have a satisfactorily performing engine.

    I have tried to describe the steps in very simple terms but this is essentially what you would need to do. There are factors that would determine the cost but it would only be clearer when the engine is split open.
    Invest in precious metal.....buy a Volkswagen!

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    Good simple write up by nmshaikh above.

    Hope this gives a fair idea of what is involved.
    If there are no Beetles in heaven, Im not going!!!

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    Mine beetle with Toyota 5AFE swapped, radiator on back and running fine in 42 degrees of multan
    1966 Volkswagen Beetle Resto  -16200831966 Volkswagen Beetle Resto  -1620085

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    Quote Originally Posted by AsadIshaque View Post
    I shall again STRESS the need to get your engine by a VW specialist.

    There are many little details in the VW engine which, while not being rocket-science, can make all the difference between a sweet running and working-itself-to-death result. Ordinary mechanics would miss all those.

    Last but not the least......do be prepared to spend money where it needs to be spent. While you must be wise to look for the best parts at the best prices (not cheap parts at the cheapest prices) also look for a VW specialist who may charge you a bit extra but it would definitely mean a lot more trouble free miles.
    whats so special about a VW flat to require a VW specialist?

    its a pretty simple engine to be honest and is not very difficult to repair correctly, at least when I would repair them. easy as dipping rusks in chai and eating them.
    ZRS - Zulfiqar Racing Systems ..... - professionals at work - at crackwheels.com

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    Quote Originally Posted by Xulfiqar View Post
    whats so special about a VW flat to require a VW specialist?

    its a pretty simple engine to be honest and is not very difficult to repair correctly, at least when I would repair them. easy as dipping rusks in chai and eating them.
    That's because you are a GURU
    I'm not afraid of the Devil,I date his sister

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    Quote Originally Posted by AsadIshaque View Post
    I shall again STRESS the need to get your engine by a VW specialist.

    There are many little details in the VW engine which, while not being rocket-science, can make all the difference between a sweet running and working-itself-to-death result. Ordinary mechanics would miss all those.

    Last but not the least......do be prepared to spend money where it needs to be spent. While you must be wise to look for the best parts at the best prices (not cheap parts at the cheapest prices) also look for a VW specialist who may charge you a bit extra but it would definitely mean a lot more trouble free miles.
    The info means alot . Will have to do a full overhaul . It has to be done in the upcoming time . But , right now im not in a position to spend 20-30k on the engine . Will have to collect some pocket money for that . But i would rather spend 5-10k on pistons and cylinders ( depends . After opening . I suppose 1-2 cylinders have gone bad ) just so that it stops DRINKING OIL like water . ( 1Liter runs about 3-5 days ) .

    The overhaul allthough will be done by my father who has done quite a few vw engine overhauls for the aircooled vw engines he used in his Ultralight aircrafts . He also did split one in Half and it runs . Or if he doesnt have time then will have to get it done from Khalid(pindi).

    BUT ,
    Still im facing the problem to find pistons and cylinders . Either new brazilian (german would be expensive ) or good used ones which would help the Oil drinking problem at the least . So kibdly help me with this

    To @nmshaikh @AsadIshaque

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    Quote Originally Posted by AsadIshaque View Post
    I shall again STRESS the need to get your engine by a VW specialist.

    There are many little details in the VW engine which, while not being rocket-science, can make all the difference between a sweet running and working-itself-to-death result. Ordinary mechanics would miss all those.

    Last but not the least......do be prepared to spend money where it needs to be spent. While you must be wise to look for the best parts at the best prices (not cheap parts at the cheapest prices) also look for a VW specialist who may charge you a bit extra but it would definitely mean a lot more trouble free miles.
    Quote Originally Posted by saadabdulrahim View Post
    That's because you are a GURU
    Quote Originally Posted by Xulfiqar View Post
    whats so special about a VW flat to require a VW specialist?

    its a pretty simple engine to be honest and is not very difficult to repair correctly, at least when I would repair them. easy as dipping rusks in chai and eating them.
    I second that . +1 .

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    Quote Originally Posted by AsadIshaque View Post
    I shall again STRESS the need to get your engine by a VW specialist.

    There are many little details in the VW engine which, while not being rocket-science, can make all the difference between a sweet running and working-itself-to-death result. Ordinary mechanics would miss all those.

    Last but not the least......do be prepared to spend money where it needs to be spent. While you must be wise to look for the best parts at the best prices (not cheap parts at the cheapest prices) also look for a VW specialist who may charge you a bit extra but it would definitely mean a lot more trouble free miles.
    Quote Originally Posted by saadabdulrahim View Post
    That's because you are a GURU
    Quote Originally Posted by KhanGarh View Post
    Mine beetle with Toyota 5AFE swapped, radiator on back and running fine in 42 degrees of multan
    1966 Volkswagen Beetle Resto  -16200831966 Volkswagen Beetle Resto  -1620085
    Wow man . Good work . I had a swap in my mind but cant sacrifice the legacy of the aircooled vw engine . also i dont need to race or drive fast . So the vw engine does it for me .
    #LOWNSLOW
    Its slow but its gonna get low soon . In sha allah .

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    Quote Originally Posted by AsadIshaque View Post
    I shall again STRESS the need to get your engine by a VW specialist.

    There are many little details in the VW engine which, while not being rocket-science, can make all the difference between a sweet running and working-itself-to-death result. Ordinary mechanics would miss all those.

    Last but not the least......do be prepared to spend money where it needs to be spent. While you must be wise to look for the best parts at the best prices (not cheap parts at the cheapest prices) also look for a VW specialist who may charge you a bit extra but it would definitely mean a lot more trouble free miles.
    Quote Originally Posted by saadabdulrahim View Post
    That's because you are a GURU
    Quote Originally Posted by nmshaikh View Post
    The complete rebuild would involve stripping the engine to the core...it involves splitting the engine block as well so the crank shaft is out as well. After cleaning the parts you would be able to see if there is significant play in that area including the connecting rods and the cam. It may (most likely) involve machining and new bearings, new engine rebuild gasket set etc. The cost would be higher but you are looking at something between 20-30k if the parts in your engine can be re-used. e.g if the crank is at standard it can be machined to 0.25, .50 , .75 (the next size basically depending on the wear). If the crank shaft is not within the limits to be machined another time then you would have to look for a good used crank shaft. Ditto for the cam. The connecting rods would need to be checked for other signs of wear and if ok they would require new bushings. The pistons and jugs may be usable and require just a new set of rings with just some honing of the cylinder walls. if they are deeply scoured then you may have to look for a new or used set. new sets are expensive and I am not sure if they are available but if it is just one cylinder that is bad, your mechanic may be able to find a good usable one and with a new set of rings you could have a satisfactorily performing engine.

    I have tried to describe the steps in very simple terms but this is essentially what you would need to do. There are factors that would determine the cost but it would only be clearer when the engine is split open.
    Indeed you have sir .
    Will surely look into it . Got a rough idea about it . More on google . But . My question remains unanswered as to where i could find new or good used piston cylinders at good prices .

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    Also DOME HUBCAPS needed . If someone has them up for grab or knows someone who might have a set for sale?

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    Quote Originally Posted by mishaqkhan1 View Post
    The info means alot . Will have to do a full overhaul . It has to be done in the upcoming time . But , right now im not in a position to spend 20-30k on the engine . Will have to collect some pocket money for that . But i would rather spend 5-10k on pistons and cylinders ( depends . After opening . I suppose 1-2 cylinders have gone bad ) just so that it stops DRINKING OIL like water . ( 1Liter runs about 3-5 days ) .

    The overhaul allthough will be done by my father who has done quite a few vw engine overhauls for the aircooled vw engines he used in his Ultralight aircrafts . He also did split one in Half and it runs . Or if he doesnt have time then will have to get it done from Khalid(pindi).

    BUT ,
    Still im facing the problem to find pistons and cylinders . Either new brazilian (german would be expensive ) or good used ones which would help the Oil drinking problem at the least . So kibdly help me with this

    To @nmshaikh @AsadIshaque
    excessive oil consumption?

    remove and check the oil spacer rings - I can bet you that the channels are blocked or the rings are siezed in place. Its a short while repair - as burnt oil here means theres burnt oil elsewhere too.

    the compression can be okayish but the engine can still be burning oil, is there oil in the exhaust muffler? have you checked the breather for blockage?

    Im assuming that your vehicle is used as a mosquito repellant spray vehicle if its burning 1 litre of oil in a couple of days unless your 2 days means you drive it 1000 kms.


    vw aircooled in U/L aircraft? - why? - subaru EJ22 is the best bet in that case.
    ZRS - Zulfiqar Racing Systems ..... - professionals at work - at crackwheels.com

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