Super Project 71

Last time you saw our Super Project '71, it looked fairly complete. So much so, we probably could have thrown an engine in the back and headed down the street without many problems (of course, if you don't consider lack of brakes a problem). Every car has it share of troubles--yours and ours are no different in that respect--but all in all, it is a complete car with very few insurmountable evils that can be clearly seen. But remember, everything can be fixed; if you have any two of the following: time, money or know-how then it can be fixed. But since we're lacking money primarily, we've got to make this project relatively cost effective, so we're going to do some of the legwork ourselves. We will always be under the supervision of the VW professionals when it comes to the technical stuff, and thanks to this, you won't have to when it comes time to work on your Super. For now, let's have some fun gutting the car.

There's nothing easier than tearing a car apart, and nothing more fun. In fact, besides driving it away completed, it is one of my favorite steps of the restoration/buildup process because it provides a first-hand account of what lies ahead. As well, it can give you clues to what the car has gone through in its life and what will really need extra attention. Not to mention, tearing something apart can show you how it was put together, definitely worthwhile in the end. But for now, it's all a mystery, a faded car held together by habit, gravity and willpower. What hides behind that quarter panel? What strange wiring is tucked under the carpet? Why did my finger just punch through solid metal? Ugg, rust.

In this section of the series, we will begin by tearing apart the interior, removing everything from the inside of the car that isn't going to get painted, which is everything (except for the steering wheel for obvious reasons). As well, we will pull out the gas-powered optional heater in the trunk, the fuel tank, air ventilation system and the wiring. Since the engine's gone, we don't have to worry about much at that end of it, but we will need to tend to the exterior badges, taillights, bumpers and rubber seals, not to mention the windows and the headliner. All in all, since there's a lot of work to be done, plan on getting plenty dirty in the process.

A note about the teardown: It is best advised to save everything. Get a bunch of boxes, crates or shelves in your garage and start labeling parts. We used a few dozen freezer-style baggies and grouped like parts together so we knew what we had and where it came from. There were certain things we knew we would need to replace, such as the rear-view mirror and the dash pad because they were both virtually destroyed upon removal, but they still earned a place on the shelf. It is better to have the old part handy while looking for a replacement (if necessary) rather than not have anything to go by during your search. As well, there are some things on a Super Beetle, for example, the steering column universal joint boots, that are no longer available, and cleaning up dirty, slightly damaged ones is better than not having any at all.

Another thing: Take ample notes and take pictures. It can get complicated sometimes, especially when you're putting everything back and you forgot where one of the half-dozen air vent hoses goes. Draw diagrams if that's your thing. For me, the pictures will be a handy reminder three or four months from now, and plus, you can drive out guests that have overstayed their welcome with a detailed slide show of the buildup. "And here is me unbolting the idler arm bracket..." Zzzzz.

Okay, easy stuff first. Get out a utility knife and cut away the rubber around the windows and push them free from their hold. Take your time with the windshield as it is fairly brittle and can easily break. You should be able to push out the quarter windows fairly easily, and the rear window can almost be kicked out, it's that solid. Once those are stored in a safe place, slash at the headliner until it falls out in dirty discarded strips of material. It's fun...and yes, you probably shouldn't be breathing all of that dust and the cloud horsehair fibers that's billowing around you. Get a mask and protect your lungs. Save the five metal bows for later, as you'll need them.