Tyler - How to restore Volkswagen Beetle: your step-by-step illustrated guide to body, trim & mechanical restoration: all models 1953 to 2003

First printed in paperback format in 2004. Reprinted 2006, 2010, 2012 & 2016.

First published in ebook format 2018 by Veloce Publishing Limited, Veloce House, Parkway Farm Business Park, Middle Farm Way, Poundbury, Dorchester, Dorset, DT1 3AR, England Fax 01305 250479 e-mail .

Ebook edition ISBN: 978-1-787114-65-4

Paperback edition ISBN: 978-1-845849-46-7

Jim Tyler and Veloce Publishing 2018. All rights reserved. With the exception of quoting brief passages for the purpose of review, no part of this publication may be recorded, reproduced or transmitted by any means, including photocopying, without the written permission of Veloce Publishing Ltd. Throughout this book logos, model names and designations, etc, have been used for the purposes of identification, illustration and decoration. Such names are the property of the trademark holder as this is not an official publication.

Readers with ideas for automotive books, or books on other transport or related hobby subjects, are invited to write to the editorial director of Veloce Publishing at the above address.

All ebook design and code produced in-house by Veloce Publishing.

Contents

Acknowledgements Introduction, Using this book & Safety

Acknowledgements

This book is very much the richer thanks to the help and goodwill of Simon and Barbara of the Beetle Specialist Workshop of Worcestershire, England, and most especially the encyclopedic knowledge and vast experience of all things Volkswagen of BSW workshop chief Terry Ball. It is a rare privilege to be invited to spend a substantial length of time in such a quality professional restoration workshop.

Introduction

As recently as the 1990s, the Beetle was easily the most prolific classic car on the roads of Britain but, in the following years, the situation altered and, in the 21st century, the Beetle has become quite a rare sight on our roads. The decline in Beetle numbers is almost certainly due to many having failed their annual road worthiness test due to body rot, consequently being scrapped or left to rot away; not just a few, but tens of thousands. The reason why Beetles have been scrapped in such awesome numbers is that the cost of restoring them professionally has been greater than the cars end value, and too few owners have been prepared to undertake (or have started and abandoned) DIY restorations.

In recent years, countless Beetles will have had shoddy welded repairs necessary to keep or make the car roadworthy, giving it another year or two of life on the road but ultimately leading to the cars demise as the cost of properly repairing the growing number of such temporary repairs rises. Many people will have started DIY restorations on their unroadworthy Beetles but, as is so often the case with DIY restoration, enthusiasm and/or money will have petered out partway through the job.

One factor which has undoubtedly exacerbated the reasons why so few Beetles are restored, either professionally or by enthusiasts, has been the availability in the UK of brand-new Beetles imported from Mexico, which have been available for far less than the cost of a good professional Beetle restoration. The ending of production in Mexico in 2003 might well cause a sea change, and encourage owners of old or laid-up Beetles to embark upon a DIY restoration, or commission a professional restoration.

Another factor that might prompt a reversal in the fortunes of classic Beetles is that, as the number of Beetles decreases, the car becomes rarer. Sooner or later, the monetary value of the remaining cars will rise - possibly to the point at which professional restoration becomes financially viable, and the incentive to finish those stalled DIY restorations increases. The very fact that the Beetle is a less familiar sight on the roads should, in itself, provide the motivation for owners of out of commission Beetles to get a restoration underway. The need for a book that helps the DIY restorer is stronger than ever.

The apparent shortage of Beetles is the reason for a change of emphasis in this book. In 1993 when Beetles were still commonplace, the emphasis was very much on restoring Beetles properly and against patch repairs, on the basis that properly restored Beetles have a long life ahead of them whereas patched cars usually last just a few years. However, in the current climate, ANY repair - however temporary - which keeps a Beetle on the road rather than it being crushed has to be considered acceptable.

Like any other car, many older Beetles suffer extensive body rot and/or near-terminal mechanical problems which render them unfit for the road. Some of these cars are hastily smartened up for sale to an unsuspecting buyer, others will be given a thorough restoration which returns them to their former glory. A few of the Beetles which come to the market are unsafe for use on the road due to extensive but expertly camouflaged rot or uncorrected collision damage. It can be difficult for the aspiring Beetle buyer to establish which treatment a viewed car has received.

This book should arm the prospective buyer with the knowledge needed to sort the good from the bad, help the would-be Beetle owner find the right car, bring it to the desired condition - whether the car is intended as a workhorse or a classic or show car - and keep it in good condition and where it belongs - on the road. This is not a workshop manual, but is, perhaps, a companion to a workshop manual. It is strongly recommended that the book be used in conjunction with a good manual.

USING THIS BOOK

As stated in the author's introduction, the primary purpose of this book is to guide you through the selection, purchase, repair and home restoration of a classic Volkswagen Beetle. The book is not intended to be a workshop, operations, or spares manual, but is intended to supplement these invaluable sources of information. Consequently, you would be well advised to purchase the manual(s) relevant to your Beetle before embarking on a significant repair, and certainly before starting a complete restoration.

All of the components/service prices are approximately those prevailing in the UK at the time of publication. These prices will be subject to normal market forces, and will, of course, tend to rise with economic inflation. You would be well advised to allow for these factors when calculating your budget.

It is possible that the goods and services mentioned will become unavailable, or alter with the passage of time. Dimensions given in the illustrations are in millimetres, unless otherwise stated. Line illustrations are not to scale. References to right side and left side are from the point of view of standing behind the car.

The author, editor, publisher and retailer cannot accept any responsibility for personal injury, mechanical damage or financial loss, which results from errors or omissions in the information given. If this disclaimer is not acceptable to you, please immediately return your unused, pristine book and receipt to your retailer, who will refund the pruchase price paid.

Safety

Important! During work on your car of any type, your personal safety MUST always be your prime consideration. You must not undertake any of the work described in this book yourself unless you have sufficient experience, aptitude, and a good enough workshop and equipment to ensure your personal safety.