My 2010 technology 66 Bug

agggilli · Post by **agggilli** » Mon Oct 25, 2010 7:06 pm

Well I found a few doors, but the shipping ran anywhere from $135 - $200 no matter where I found it. This coupled with a door price range of $100 - $225 forced me to fix my own door. I ordered a new bottom section and a new door skin. I was not happy with the quality of the skin, as it was damaged upon delivery, however since lack of dents and damage is not guaranteed from the vendor, I decided to make the best of it. I got the new power window assembly mounted first before I cut the door apart and took a few measurements in order to try and get it back together correctly. After cutting it all apart the first chore was to make repairs to the lower hinge mounting to guarantee it would be solid for another 44 years. I welded all of the cracked metal then added new metal braces to make it all nice and solid. Next came the bottom section and then finally the skin. All and all we had about thirty man hours in it since Kris and I both worked on it together. I now have a solid door but now comes the massaging to make it perfectly straight and ready for paint. Anyway, here are some pictures of the process.

Here is the skin removed and the new power window motor and mechanism in place. Then the damage.

agggilli · Post by **agggilli** » Sun Nov 21, 2010 4:44 pm

I have been on hiatus for a couple of weeks. It was a year ago on November 10th that I brought the bug home. It seems like that time has flown past and doesn't seem that long ago. In that time frame I completely disassembled the bug to nothing, rebuilt the chassis complete, was diagnosed with prostate cancer, had surgery to remove it, and recovered. Then I fixed the main body, painted it, installed all new interior, all new electrical, made custom AC and console, etc.

So all and all an active year in 2010 for me. I still have quite a way to go, but the light is on at the end of the tunnel and I am anxious to put this baby on the road. I ordered the new 2" wider fenders yesterday and worked on getting the power door lock installation and power one piece window operating correct today on the passenger side door. I need to strip the inside paint off and this door is ready for a nice coat of epoxy primer. I took some pictures today to show the installation and also the lock I am using for those of you probably wondering how I was going to put power locks on a car without door plungers to activate.

Oh yeah, I found a NOS Driver door two weeks ago on the Samba up in Ohio for $200. Even though I spent all the effort and $ fixing my original, I decided I would go ahead and splurge and get the NOS one. I had a friend in OHIO that was coming down last weekend anyway, so I just had him pick it up and bring it down to me. My is it nice. It has never been installed on a car and is completely rust free and NICE! The hinges feel like butter they are so smooth. Although the other door turned out good, I decided that once I new I could get a new one for the price I paid, I would kick myself if I didn't.

I plan to get the doors and fenders on the car, then start ordering the engine parts to assemble the 2110 stroker after the first of the year. I hope to get her on the road by spring 2011, which is about 6 - 8 months later than I originally hoped.

Anyway here are some pictures of the new power door lock on the passenger door and some of the one for the driver's door so you can get a feel for how it operates.

agggilli · Post by **agggilli** » Sat Dec 18, 2010 8:23 pm

Well the doors are in primer and all block sanded out waiting for color. Unfortunately we have been in a cold snap, and I haven't been able to shoot any color on them. I did get the new fenders in and mounted last weekend. They too now need to be primed and blocksanded. Here are a couple of pictures with the fenders on. The camera lens seems to have some spots on it, sorry about that. I'm getting my engine parts list and build specs. together while it is too cold to paint. I hope to get this baby on the road by May 2011.

veedubber · Post by **veedubber** » Mon Jan 31, 2011 1:55 pm

Absolutely brilliant, really enjoyable thread. I have my own one to do soon, and this thread is great inspiration for that.

veedubber

agggilli · Post by **agggilli** » Sun Feb 20, 2011 5:58 am

Just a quick update, boy winter months really slow down progress when you don't have a nice heated garage. We finally had a couple of really nice warm days the end of this week, so I got a chance to work on the fenders and rear deck lid. I built a couple of raised saw horses and bolted the fenders on them. It made it much easier to sand them and primer them. They were not as nice as I was expecting. I should have bought them from CCC. Dang it! Oh well live and learn. So I sanded them, primered them. shot a guide coat, block sanded them. and then shot the final primer. I plan to wet sand them today and then shoot the color and clear this afternoon. I need to order a new hood from CCC (the original is rotted out in the front lower as well as some major inside out dents) and I don't feel like messing with it. Once it comes in I'll prime and sand it, then shoot the color and clear on it and the doors. I have the engine components on order, but some of them have some pretty long lead times. I guess that works out well, because I should have the body all done by the time I'm ready to start building the engine. As always, here are a couple of pictures of the work.

agggilli · Post by **agggilli** » Mon Feb 28, 2011 7:43 pm

I got the color and clear on the fenders this past weekend.

agggilli · Post by **agggilli** » Sun Apr 03, 2011 7:23 pm

The fenders are on, the running boards and sill plates are on, and I got the the bumpers and taillights completed. The taillights are bright LED units. The new hood is on, although not painted yet. All of the engine parts are on order and are supposed to be in by this next weekend. I am taking the week of the 18th off to hopefully paint the doors, hood and deck lid. The engine should be done and ready to install by then. I'm hoping to have it road worthy by the end of that vacation time. Here are the latest photos as of tonight.

rokemester · Post by **rokemester** » Sun Apr 03, 2011 7:33 pm

Wow the Bug is looking amazing! Thanks for sharing your progress.

agggilli · Post by **agggilli** » Mon Apr 18, 2011 7:10 am

I started the engine assembly last weekend and worked on it this past weekend as well. I came to a halt when I needed to order some crank shaft shims to set the end play and cylinder shims to set the deck height. I didn't know what I needed for those until I got it assembled enough to take the measurements. Anyway, now I'm stopped for at least a week or so while I wait for those parts. It really sucks living on the east coast and having all the parts on the west coast.

Anyway, I plan to get the doors and hood painted and on the car this week and hopefully have everything done but the engine, before I go back to work a week from tomorrow.
A brief description of the engine: 2110, Brothers VW supplied- New AS41 case, full flowed, clearanced, lifter bores bronze sleeved, BVW CW 4340 crankshaft, 4340 I beam rods w/3/8 ARP, BVW lightened FW, Mahle P/C, FK43 Ingle, SC steel gears, Steve Timms Stage 2 heads 42 x 37 and port matched intakes, Gene Berg supplied= 26mm oil pump, push rods, VW 8mm head studs, flow flow kit and 3.5qt sump. BRD Pulleys, welded and balance fan, CB Ultralite lifters and tapered pushrod tubes. Genuine 009 dizzy, Weber 44's and Scat 1.4 rockers.

Here are a pile of pictures (Caution: VW Engine Porn) I took of the engine parts and assembly so far.

rokemester · Post by **rokemester** » Mon Apr 18, 2011 4:33 pm

You are going to put the initial start up of your baby on YouTube right!! I can't wait to hear that baby come to life and see you take off in it. VERY COOL. You're getting so close

agggilli · Post by **agggilli** » Tue Apr 19, 2011 3:46 am

Yeah, I hadn't really thought about it but, yeah I don't see why not. I'm going to run the break-in on the stand before I put it in the car, but I should be able to do two youtubes, one of it running on the stand and the other with it in the car driving off. I spent yesterday doing final sanding on the doors and masking them off for the black. I am shooting the black today followed by two coats of clear. The maroon will be shot probably on Thursday. My headlights are supposed to be here today too.

rokemester · Post by **rokemester** » Tue Apr 19, 2011 4:24 am

It's going to be a very fine ride!

North Carolina is pretty far cruise, but our club's Volksfest just outside Columbus Ohio in August is a very nice show. Google COVVC, Central Ohio Vintage Volkswagen Club.

fatalifeaten · Post by **fatalifeaten** » Tue Apr 19, 2011 9:52 pm

Looking pimp. Keep it up.

agggilli · Post by **agggilli** » Sun May 15, 2011 4:35 pm

So I ran the engine break-in this morning. No leaks, good oil pressure, the factory tins and thermostat worked perfectly. Now I have to pull the heads back off and install the inner valve springs.

agggilli · Post by **agggilli** » Sun Jun 12, 2011 1:04 pm

Well I thought I would give a quick update on progress. It has been slow the past couple of weeks as work has been crazy, as well as the hot temperatures. The engine is in the car now, and everything is complete back there other than the actual installation of the rear deck lid.

I installed the P/W regulators and the power door locks for the final time and ran that wiring. i installed new door rubber seals from WW. Yesterday I did actually install the doors on the car. They fit up really well and seal and operate very nice. I did not take any photos of them installed, because I want to polish them first.

I installed a new WW gas tank, and it is VERY nice. At this point I need to install the electric fuel pump and regulator under the tank, bleed the brakes, Install the window felts, and finish the wiring under the hood for the security system and doors. This has been a long project, and it is finally drawing to a close. I still need to install the AC compressor and condenser, as well as the heaters, but I am going to start driving it first, and do that later this year. Anyway, here are some various pics from the last few weeks.