Home Forums Bullshit Russ’ Java Green 64

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  • Dozer
    Participant
    Post count: 37

    I’ve been so busy lately with trying to get this project started and working on trying to recover some of the old build threads that I forgot to start a thread for my first VW in like 12 years…

    Found this little 64 here in NE TN that has been sitting for 2.5 years. Managed to strike a deal with the owner and took her home. The car is pretty solid for the most part, running and driving but definitely needs some mechanical work to make it road worthy. Not really sure what my plan here is but I have ordered a 4″ beam that should be ready in about 5 weeks so whatever I do, I want to have it ready to roll by then.

    The back half of the car from the rear of the doors back has been re-sprayed at some point with base/clear as you can see where the “blend” is chipping away near the top corners of the back window. The right front fender has some damage but not sure to what extent yet until I get it pulled off. The front bumper “appears” to be factory but the rear is for sure an aftermarket. It has those aftermarket headlights which Ive never been a big fan of so they are getting replaced. The interior was crusty. The door panels were shot, carpet ratty and the seats had some bad covers on them. The headliner has been replaced at some point and in decent shape.

    After putting some gas in the tank and getting it started, and into the garage overnight, we awoke to a HORRIBLE gas smell in the garage.. 🙄  So we first pulled the tank and blew out the lines only to find 2 sections under the car that had original fuel line that was leaking onto the pan.

    Here are few pics of it after we got it home.

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    Rustabus
    Participant
    Post count: 1900

    Looks like a nice Rig!!!! 🙂 🙂 🙂

    Franz
    Keymaster
    Post count: 3460

    Bummer on the fuel line in the pan. That is a hard job to replace correctly.

    Dozer
    Participant
    Post count: 37

    Thanks Rustabus. Its in pretty good shape. Of course, as usual, the more you dig the more you uncover! It definitely needs more work than any of my other VW’s did but not going to complain! Just nice to have another one again.

    Stripped all the interior out last night to get a better idea at what the chassis might need. Looks like the rear half of the passenger pan is going to have to be replaced. Starting to get a few small holes about 1/8″ to 1/4″ just in front of the battery. I can feel a soft spot about 4 inches long in the passenger side heater channel just forward of where the heater tube enters it under the rear seat.

    I’ve already ordered new interior from Wolfsburg West so we started pulling the old covers off the seats and found what looks to be the original seat covers I think. The color charts show “Brown cord pattern/Brown” for this car so I guess its possible. They arent really usable, just cool to find hiding under the crappy ones that were on it.

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    Heres what was underneath:

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    First shipment of parts came in as well, so I have my tires, everything to completely rebuild the brakes, rear axle seals, fuel lines, new TRW steering box and a few other misc parts. The rest should be here Monday and Tuesday.

    Wont get to work on it today, our Jeep club has a trail ride and doing some trash cleanup along the trail since people are still too lazy to take their crap home and throw it away. Sunday I have most of the day to spend on it so I plan to get the underside and the pan head area under the tank degreased and then start wire wheeling the pan to see just how much I need to cut out.

    Dozer
    Participant
    Post count: 37

    A long day continuing to strip things down to see what I can find. Unfortunately, more issues everytime I remove something… 😆

    Definitely more rust repair needed than I expected. Ive never had to replace pans or repair rusted sections like this before. I have some experience with bodywork/paint but it was mostly the commercial stuff where they replace everything vs repairing it.

    My biggest problem/question is about a section of the passenger side heater channel near the back of the door and and quarter panel. Theres a section where it started rusting through. I feel like the only way to fix that is going to be to remove the body to cut it out and weld in some new metal. Heres a few pics of the section. Would I be correct in that assumption?

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    The front section of the heater channel looks ok and doesnt seem to have any soft spots beyond that from what I can tell.

    Also found something Ive never seen before. Both doors and inside the rear quarters behind the door panels were full of what looks like that Great Stuff expanding foam that comes in a can. Have no idea what thats in there for… 🙄

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    Found a few big ass holes cut in the rear firewall for some reason. I remember reading about some old gas heaters that required this, makes me wonder if thats what it was for.

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    The engine is pretty solid and is running well, but the wiring is a damn mess… even found masking tape, yes MASKING TAPE used on the headlight wires instead of electrical tape.

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    Taking the day off tomorrow so going to figure out what direction I want to go with it and keep making progress. Originally just planned to fix the battery section of the pan, restore the mechanicals and just roll it. But uncovering that rot is bugging me. Never been one to embrace rust, so thinking I may end up having to take the body off for the my first time ever.

    Franz
    Keymaster
    Post count: 3460

    The expanding foam is there to fill rust holes from the backside. So they could paint over it. The bottom of your doors and quarter panels probably have rust too.

    This is turning into a full resto quickly. Are you sure you want to do all that work? The more you take apart the more you will find.

    It may be time to punt if you want a nicer car. You could spend a bunch of time and money trying to get back to a painted shell.

    Send it to kcw and let us do a body/paint resto?

    If it were my car, I do a couple small patches and try not to dig any deeper. Do bare minimum. Once it’s driving and looking decent, you’ll forget about all that stuff.

    Dozer
    Participant
    Post count: 37

    Its definitely turning into a bigger project than I wanted it to be at this point. My plan was to just fix all the mechanical and just have fun with it until sometime next year then do a paint/body resto on it.

    Starting to wonder if maybe I should just go ahead and have you guys do the body/paint on it. Should I just give you guys a call and see what a ballpark estimate on that would be so I would know what to budget?

    I dont mind putting in the time/work. I have done bodywork/paint but it was back in my late teens so 25+ years ago. I do have the tools, MIG, etc but just havent done metal work on a beetle specifically. And now knowing how much rot may possibly be in those quarters/doors I cant see, havng someone do it “right” is something I would certainly consider.

    Patching it and and doing bare minimum is not something I think I could live with… knowing me and my personality, Im OCD about that stuff 😆

    Franz
    Keymaster
    Post count: 3460

    Sadly Russ, I don’t think the transport to and from KCW is going to help the situation. You could buy another car cheaper.

    Dozer
    Participant
    Post count: 37

    Transport wouldnt be an issue. I can transport to/from on my trailer. Give me an excuse to FINALLY get west of Nashville! Id probably make a road trip out of it and head down to see my buddy in Ouray for a few days as well.

    Only thing for me would be finding out what ballpark we might be in to make sure its in my budget to go ahead and do now rather than later, and what the timing would possibly be.

    Dozer
    Participant
    Post count: 37

    Spent some more time on the car the last few days primarily wire wheeling the pans and seeing exactly what needed to be replaced. The pans seem pretty thin so Im sure they arent original. The battery/rear floor board area has been replaced once already from the rear all the way up to about mid seat rails.

    Both pans have holes in the front area as well that I couldnt see before under the undercoating or whatever they painted them with. The biggest ones are about a 1/4 inch or so… Knowing this now, Im probably just going to go ahead and replace the pans.

    Do you guys have a particular brand you prefer? I know the Gerson heater channels are the best in that area. Not sure about full pans though as I’ve never had to do them on any of my past cars. The Wolfsberg West ones seem to be pretty nice.

    We pulled all the body bolts as well last night after realizing the pans were shot in preparation to get the body off. I guess at that point I will be able to tell the true condition of the heater channels.

    Franz
    Keymaster
    Post count: 3460

    Yeah we like the WW pans. If you have the body off, its fairly easy to replace the pan halfs.

    Dozer
    Participant
    Post count: 37

    Made more progress this weekend, and realized that taking @Franz ‘s advice to quit digging and do the bare minimum would’ve probably served me pretty well for a bit… but Im hardheaded.

    Finished pulling the glass, and then got the body off the pan. We put the body in my woodshop building for now until I can get the pans and chassis work done.

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    While removing all the body bolts, we started running into more rot that seems to be mostly in the heater channels.

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    The drivers side bottom of the firewall was definitely hiding some rot. When I started removing the 2 large 17mm bolts that bolt through the front crossmember, it spun the threaded plate they run through completely through the front of the firewall and tore some holes.

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    The drivers side rear body mount is perforated around 70% the inside of the mount bracket.

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    Then spent a couple hours degreasing a pressure washing the chassis so I can start tearing the brakes, beam, etc down tonight.

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    Im picking up a new bottle of gas tomorrow and hope to start getting the new WW pans in by the end of the week.

    Now its decision time on the body. Not sure if I want to tackle that much metal work myself. But since I have it at this point, I might as well take it the rest of the way and finish it out properly. No sense in putting $5k worth of new stuff on a car with the body in that shape.

     

    Franz
    Keymaster
    Post count: 3460

    Yep! That is what I was afraid of. Once you break all the bolts and nut plates you cannot put it back together until it’s fixed.

    Cool $500 car you have there. 😁

    I was serious about doing some work. We have space for dirty shop rust and/or paint project right now. But man, fixing all that stuff is going to be expensive.

    Dozer
    Participant
    Post count: 37

    @Franz when you get a few spare minutes, would you mind giving me a ring so we could discuss it? I’m definitely open to having you guys “do it right”. I left my number with one of the guys last week. At this point Im going to fix it one way or the other, no chance I just leave it like this or toss it.

    Dozer
    Participant
    Post count: 37

    Well, the more I tear down the more this car wants to hate me 🙄  Finished stripping the chassis and cutting out the pans, but while cutting the front section of the pans, I found some nasty rot inside the ends of the front frame chassis support. Its full of crud and figuring Im going to have to replace it.

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    After taking the front inspection plate off the frame head, I noticed some rust in the bottom plate. Looks like this is consistent with the bottom of the tunnel as well. Not sure what the moisture is. Its not water, seems to be some oily stuff similar brake fluid almost. Not sure how in the hell Im going to clean that stuff out of the tunnel or frame head though.

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    Franz
    Keymaster
    Post count: 3460

    If you jack the rear of the pan way up. You can wash all that gear oil and brake fluid out with some de-greaser.

    Some of those small rust areas are best to just patch up. I would blow all the loose rust out and make some small patches to weld in. You can put some rust killer on the areas inside that you don’t have access to.

    Dozer
    Participant
    Post count: 37

    Awesome! Thanks for the advice on that Franz! Would much rather patch that than to try and replace. The passenger side is stuffed with mud/crap in the bolt holes as well, but it hasnt rotted out like this side has.

    russ
    Participant
    Post count: 82

    that looks like a typical project the more you take off the worse it gets

    hopefully you continue on and save another vw, it’s definitely has potential

    Dozer
    Participant
    Post count: 37

    It’s my 5th bug but my first project… lol. So I’m learning a lot. We aren’t giving up on it, in fact I was ready to haul it to Franz and the guys to finish it but my 17 year old talked me into trying to finish it ourselves before he heads off to college. I know how much work it’s going to be but I couldn’t tell him no.

    It will get done one way or another!

    alykat
    Participant
    Post count: 448

    Sometimes the best way time, work, and cash wise,  is to just find a good, solid  rust free pan and just switch everything over.

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