Bill's Blue Bug     
Body
The body started off in pretty good shape.  Problems included:
  • Rusted heater channel bottoms
  • Crashed front/rear clip
  • Maaco paint on top of two more layers of paint; rust in spots
  • Bent doors with sagging hinges

Here's the crunched front clip with missing fender nut inserts and holes drilled through to mount the bumper brackets.

The front clip was replaced.  Here's the marks for cutting out the old.  The new bumper bracket mount panels were layed along side the car to

A sawsall took care of it. 

  • Klokkerholm panels from OEVeeDub
  • Good fit
  • Weld nice

  • Front clip welded


  • Rear clip welded
  • Exhaust slots filled

There was damage to the left rear quarter panel which I did not recognize that resulted in a big gap between the side of the deck lid and the engine compartment rim.  The body shop removed the left side of the rear apron and repositioned it after pulling the rim out.  Now the fit is right on.
  • Inverted for heater channel bottom replacement

Not shown is the piles of crap that came out of the quarter panel bottom.  Tools, money, bulbs, dirt, rust, fasteners -- a time capsule of sorts.
  • Rusted heater channel bottom

  • Heater channel bottom stripped and primered

Removing the bottom of the heater channel was a big chore.  I should have got a spot weld cutter...  The paint is weld through primer.  Under it is Eastwoods rust encapsulator (except for flange where there is only weld through primer).

  • Repaired heater channel lip where rusted out

  • Upright to weld in new channel bottoms and patch ends

  • Repaired rust on front left

  • Cowl hood seal channel replaced
  • Top seam to body later sealed with silicone

This is the only place where the channel is used.  The other hood and decklid channels were removed and the Mexican Bug seals that mount to the hood/decklid lip were used.  A lot of rust was under the channels and I'm glad I was able to get rid of most of them.

  • Filled dash after paint stripping

Later the instrument panel opening was trimmed further for the aluminum insert I made.  Two other holes were drilled where the ash tray used to be for light switches.  The stereo hole was enlarged a little for DIN size mounting.

  • Repaired grill broken by old ski rack
  • Used grill from junk yard car

  • Ready for a date with stripper

  • Stripped clean

Don't let just anyone go at it on your car with a blaster.  The guys at Class A Stripping are pro's -- no warping.

  • Epoxy sealer applied
  • Ready for body work



  • Back from paint shop
  • Porshce Lapis Blue Metallic

  • Smoothed out rear end
  • Liscense plate goes on bumper

  • Filled in fresh air grill

  • Powdercoated window trim
  • Hot rod mirrors

  • Fathers Day






  • Carbon fiber front spoiler by Carbon Joe