Week 3 (November 13 - 20)
 
 

I'm going to start each week with a commentary on that week's progress. I am amazed at how easily everything has gone together to this point. The chassis is more or less complete and most of the parts I need are in. The project is way ahead of schedule overall. I really look forward to putting these weekly updates together, to some extent it helps me plan the project. To those of you wondering, Fran (my wife and ever-patient partner) is still supporting me - so long as I keep the car in the garage. I appreciate the emails and any one of you are welcome to drop in and see the project up close - it's really cool to see!!

 

 My First Weld!

A little bit of the tunnel chassis had to be patched before the new panels could be attached. After an evening of practice, I was confident enough to turn the welder to the car.

 Let The Games Begin...

I am amazed at how much fun welding is. At first I was a bit hesitant, but now I'm right into it. I had to pick up some more MIG wire and I had to refill the gas cylinder - both of which were pleasantly inexpensive.

 

The Old Meets the New

I had to reinforce the joint on the driver's side due to a bit of rust-out. The welding beads are getting a bit smoother looking, but still not perfect. Luckily these joints are completely hidden when the body is put back on.

From The Other Side

The passenger's side was quite a bit cleaner. Everything looks pretty ugly right after being welded.

Original Parts

Most of the parts I've been able to get are imported from Brazil where the beetle is still being produced. Some of the panels have actual VW part stickers, but not this one. I was wondering what kind of conversation I would have if I called the phone number on this sticker.

 Primed, Painted and Undercoated

The front end is of the chassis is now completed and ready for the new front beam to be installed.

Even MORE New Parts!

My second order came in from California Imports today. Pictured here are ALL the components for the brake system and a few odds and ends for the steering arms.

 The Floor Begins

Totally confident in my welding skills, I put the passenger side floor pan in. Welding into the corner proved to be a bit of a challenge, but these joints will be hidden, so I wasn't too worried.

 And The Other Side

Don't ask me why the floor pans are two different colours. My only guess is they are easier to identify in the factory? Maybe there was a sale on grey primer at the local Brazilian Tire store? Whatever the case they will soon be wirebrushed, painted and undercoated to match the rest of the chassis. The "car" is upside down in this picture.

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