With explanations of the basic skills required for a restoration - including welding, painting, and panel beating - and containing over 700 colour photos, this manual contains everything you need to know to make your Beetle like new again. Showing how to carry out hands-on bodywork and mechanical restoration, interior restoration, and troubleshooting, you'll find solutions to problems that simply aren't covered in normal workshop manuals. Even those with no technical knowledge or restoration experience can now see how to completely restore a Volkswagen Beetle, from bodywork, interior, mechanical and electrical - an essential manual for millions of Beetle owners around the world.
Jim Tyler has experience of restoring a wide range of classic cars, from a 1949 AC Saloon and 1940s military vehicles to cars manufactured into the 1990s. He has written classic car restoration guides based on his experience, owners' handbooks and workshop manuals for modern cars.
Acknowledgements, Introduction,Using this book & Safety CHAPTER 1 - BUYING A BEETLERestoration/reshelling cars The workhorse Restored cars Customised cars Convertibles 'Lookers' Bajas Where to look Who to buy from Specialist dealers Classic car auctions General car auctions How much to pay Assessing bodywork Underneath Mechanical examinationMechanical/electricalInside the carOutside the carTest driveThe final analysisA caveatWhen you have bought your Beetle ... Inspection Under the car Rear of the car Engine compartment General Interior First service And finally ... CHAPTER 2 - MECHANICAL RESTORATION & REPAIRWork place & tools Safety Avoiding trouble Engine tests & removal Engine removal Height restriction Engine strip, inspection & rebuild Inspection Crankshaft grinding Rebuild Pistons & cylinders Cylinder heads: refit Cylinder heads: repair Rocker gear Valve guides ModificationsHead overhaulLapping valvesRebuild continuedFuel pumpTinwareTopcoat paintsEngine electricsCoil & condenserDistributorHT components C/B (contact breaker) pointsRotor arm Timing Static timing Dynamic timing Dwell angle Vacuum advance Engine won't start! Diagnostics Is there a spark? Low tension circuit High tension circuit HT leads, distributor cap, plugs Fuel Running in The fuel system Fuel tank Fuel tank sender unit Fuel lines Carburettor Specifications Inlet manifold Clutch Clutch fork shaft Clutch spares Clutch fork shaft rebuild Gearbox (transaxle) removal & refitting Swing axle cars Diagonal arm suspension cars Gearbox Brakes - overview Rear brakes Front brakes (drum) Front brakes (disc) Master cylinder Bleeding the brakes Suspension/steering Front suspension - torsion bar Beam axle Front suspension - MacPherson strut type Rear suspension Swing arm suspensionDiagonal arm suspension Wheel bearings Steering Steering wheel & column General electrical system - overview Restoration & electrics BatteryLights Fuses Windscreen wiper rocker replacement Rocker removal Refit Starter motor GeneratorVoltage regulatorHeat exchangers & exhaustHeating systemFinal setting upCarburationTransmissionBrakesCHAPTER 3 - BODYWORK & TRIM RESTORATIONPremises, tools, skills & equipment Welding equipmentUsing a MIG welderFirst steps with a MIGOther tools & equipmentUse & abuse of body fillerUsing body fillerPanel beatingRepair panelsRust proofingRestoration - car conditionPaint & undersealSeat removalSeat repairRear seatFront seatsFixed glass removalWindow aperture repairsWindscreen refitHeadlining removalHeadlining replacementDoor removal Door strip down Door panel repairDoor rebuildWing removalWing repairWing replacementRunning boardsBodyshell welded repairRear inner wing Rear bumper mountsFront end - overview Luggage bay lid removal/replacementFlitch replacementFltch repair panelsSpare wheel wellRemoval of bodyshell from chassisFloor pan repair/replacementFloor pan repairCombined floor pan halves/heater channel replacementHeat channel replacementFrame headFront crossmember (toe board) replacementRear crossmember (heelboard) repair'A' & 'B' post repairRefit bodyshell to chassisQuarter panel repair Window apertureLuggage/engine bay seal retaining stripsFlitch top rail repairUsing 'donor' car panelsPaintworkPainting equipment & facilitiesTypes of paintPreparationUnder the wingsFinishing touches'Boxing up'ChromeworkInteriorCase historyUpdateProfessional restorersSad but true ...CHAPTER 4 - ABOUT THE BEETLELiving with a BeetleDrivingIndex