Rear Shelf Project Part 2

Rear Shelf BuildRear Shelf BuildFinished sanding all of the edges, getting everything symmetrical. Applied 2 layers of felt to give it a little padding. I think Im going to use the same vinyl that I used for the trunk liner. Will hopefully have everything wrapped up this weekend.

Rear Shelf Project Part 1
Rear Shelf Project Part 2
Rear Shelf Project Part 3

Rear Shelf Project Part 1

Rear Shelf BuildRear Shelf BuildRear Shelf BuildRear Shelf BuildRear Shelf BuildRear Shelf BuildRear Shelf BuildRear Shelf BuildRear Shelf BuildRear Shelf BuildSo I decided to start on the rear shelf project today. Id priced some online, but just cant justify paying 60 dollars for a flimsy piece of material when I can build something a bit more beefy for a lot less. I wanted something strong that I may end up mounting speakers beneath, but still light enough that it can be easily removed. So I decided to make my own rear shelf out of 1/2 plywood that will be covered either in carpet to match the interior or some type of industrial material that will blend well. Remember to measure twice and cut once. Got this one on the first try, test fitted perfectly and it gives the look that Im going for with the stability of heavier material. I glued and screwed a support that will keep the shelf from bowing or sagging over time. All thats left to do is find the right material to cover it. That search begins tomorrow. And the best part, other than my time, it hasnt cost anythingyet!

Rear Shelf Project Part 1
Rear Shelf Project Part 2
Rear Shelf Project Part 3

New Window Regulator and Pop Out Window Latches

New Pop Out Window LatchesChanging Window RegulatorNew Window RegulatorWhen I replaced all of the door seals, scrapers, etc. last month, my gut told me to splurge and replace the window regulators while I was at it. I ignored that gut feeling and with the windows fitting much tighter with the new rubber, the drivers side regulator gave out last week. I was rolling the window up and it just began to spin. Lesson learned. Im sure the passenger side will be next, but Ill wait for as long as I can before I have to replace it. I ordered a replacement regulator from jbugs.com for $64.95. Price was reasonable, quality was acceptable. It pretty much matched the quality of the original regulator, only the support brace at the bottom of the regulator was different. The replacement was only ribbed on the top where the original was ribbed on the top and bottom. Other than that, it was pretty much the same. Now what really sucked is that my 1968 uses the same regulator as the 65, 66 and 67. They changed mid year in 1968 to the newer (and easier to replace) regulators. What I figured would take an hour or so to replace ended up taking 3 hours. Cussing was involved, plus a couple of bloody fingers. Fitment was pretty good, it was just a bear to replace, I had to remove the vent window assembly to remove the old regulator and install the new one. But once it was done, it worked perfectly. The window is still tight in the new rubber, so I hope this replacement regulator stands up to the test. While I was at it, I went ahead and replaced the rear pop out window latches. I cleaned the originals a few weeks ago and decided against buying new ones, but the originals just didnt clean up as good as I thought they would so I ordered new ones from Jbugs.com for 49.95 each (ouch)! The quality is as good as the originals though and youd never notice the difference between the new ones and the originals. Installing the clip that secures them to glass can test your patience, especially with new rubber. All in all, a nice evening project and Im happy with the result.

New Trunk Liner

New Trunk LinerNew Trunk LinerNew Trunk LinerGot my new trunk liner from Wolfsburg West today. Very pleased with the fit, quality and price (minus the cost of shipping which was more than the cost of the product). Just what Mabel needed to dress out the trunk a bit. Made from the same material as the original liner, youd be hard pressed to tell the difference.

Door and Window Seal Replacement Part 5

Door Refresh CompleteDoor Refresh CompleteDoor Refresh CompleteDoor Refresh CompleteSo this evening I had planned on working on the passenger door to get as far along with it as I could. Four and a half hours later, the project is complete. Everything went together so easily on the passenger door that I was able to finish. Didnt take a lot of pics because everything was pretty much laid out and explained when I did the drivers door, no need to repeat everything. So with this final post on the project, Ill share some thoughts, tips and other info that may help you if you decide to do this. First and foremost, I have to give props to the kit that Jbugs.com sells. Not everything was perfect, but the important stuff was good quality German parts that fit correctly and made the install so much easier. They also supplied a dvd to provide tips and info. They made good on a mismatched part (window crank handles) and the prices were very competitive. Alright, on to the insight.

Things To Know:
1. Plan your project out! Know what you need for your particular year of Beetle and make a list. Ask others who have already done this project for their input. I didnt order my kit, my wife bought it for me for Christmas. Jbugs and a couple of friends were very helpful and let her know everything down to the last detail that was needed to rebuild the doors. You cant always tell by looking what youll need to purchase. Some of the original parts may have been eliminated over the years. Dont forget the little things.
2. Again, spurge and buy the quality parts. Not only do they look better, but they fit better and are easier to install. Truth is, the quality parts arent that much more expensive.
3. Know the tools youll need in advance and have them on hand when you begin your project. Nothing worse than having to stop to buy or borrow a tool that you dont have but need. Soapy water and WD40 will be your best friends.
[Read more…]

Door and Window Seal Replacement Part 4

Check Rod BumperRubber Grommet For Door PanelFoam For Door PanelDoor Panel FoamWeather Cord For Vapor BarrierWeather Cord For Vapor BarrierWeather Cord For Vapor BarrierNew Vapor BarrierFinished Drivers DoorFinished Drivers DoorFinished Drivers DoorThe drivers door is complete! Installed the vapor barrier, door panel and hardware and now its on to the passenger side door. I think its important that if youre going to do a project like this, go ahead and replace the parts that are often overlooked. The check rod bumper being one of those. The one on my drivers door was no existent, it had broken apart long ago. I went ahead and took the one out of the passenger door so you can see what it is. Pic #1. The bumper was still there, but it was chewed up and compressed. Really didnt serve much of a purpose. I think both new ones was a couple of dollars. I installed new rubber grommets for the door panel clips, pic #2. The existing ones were hardened and basically fell apart. I also replaced the compression foam around the door latch and on the inside of the door panel, another step that is often overlooked. Pics #3 and #4. I bought the cord weather seal (pic #5) to install the new vapor barrier. When doing my research, seems like a lot of people were using this. Its cheap and easy to work with. This particular box was enough to do the whole door and still have a bit left over. I wiped down the entire inner door with alcohol to make sure it was clean and free of any oils, then proceed to apply the weather seal. It was a bit cool in the garage, so I took the heat gun and heated it up a bit so it would compress easier. Pics #6 and #7. Then a cut the vapor barrier to approximately the right size, stuck it to the weather cord, then trimmed. Very easy process. Pic #8. I had to cut the vapor barrier for the door latch mechanism and the slot for the arm rest rod. Before you apply the vapor barrier, be sure to clean out the bottom of door, make sure the drain holes are clear and that nothing is left in there to clog them up. I also cleaned and re-lubed the window regulator. When the vapor barrier was trimmed, it was just a matter of re-installing the door panel, door latch dressing and new window crank handle, buffer and spring that goes between the door skin and door panel. Window Crank and Trimmings Another step that a lot of people ignore and leave out. So, with the drivers side door finished, I couldnt be more happy with the results. Buying quality parts, this wasnt a cheap project, but well worth it. It looks so much better, its functional and its a very satisfying project. I cheated a little and started on the passenger door. Wanted to start on it while everything was fresh in my mind. Its much easier second time around, you already know what to look for. I got the passenger side door striped down, vent window taken apart and fixed the interior light switch on the passenger side, it just needed the contact cleaned up. Hard telling how long its been since it last worked. Tomorrow night, I plan to clean the door and start installing the new rubber. Im hoping that I have the same luck as I did on the drivers door. If you have any questions, please feel free to ask.

Door and Window Seal Replacement Part 1
Door and Window Seal Replacement Part 2
Door and Window Seal Replacement Part 3
Door and Window Seal Replacement Part 4
Door and Window Seal Replacement Part 5

Door and Window Seal Replacement Part 3

Vent Window PinVent Window PinVent Window PinLock KnobsNot a lot happening this evening to this project, but I did get the last order to complete this project. I had originally ordered the vent window pins from Jbugs.com but I wasnt really happy with them. They didnt feel like aluminum, more like brass, they even have a brass hue to them. Pic #1. I installed one yesterday on the drivers side vent window, but wasnt happy with it, it looked tacky. I had also ordered 2 vent window pins from wagen-werks.com along with original looking lock knobs. In pic #4 above, the knob on the left is what I ordered from Jbugs.com, the one on the right is the one I ordered from wagen-werks.com. The one from wagen-werks.com looks much better, just like the original on the 1968. Anyhow, I drilled out the vent window pin that I installed yesterday and installed the new. Not only did it install much easier, it looks so much better and it mushroomed perfectly using the tool that I bought. Pics #2 and #3. Thats it for tonight. I still need to make a trip to Lowes to get everything I need for the vapor barrier on the drivers door, then its time to start on the passenger door.

Door and Window Seal Replacement Part 1
Door and Window Seal Replacement Part 2
Door and Window Seal Replacement Part 3
Door and Window Seal Replacement Part 4
Door and Window Seal Replacement Part 5