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Baja Forums -:- AzBaja.com Members -:- Projects and Builds -:- CLASS ZERO '66 BAJA BUG
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CLASS ZERO '66 BAJA BUG
Tell us about your Project, Were you at in tyour build. Post Pictures etc.
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ClassZero
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Post Post subject: CLASS ZERO '66 BAJA BUG
Posted: Sun Sep 15, 2013 07:23 AM
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For those who've been following along on the progress of my rolling turd, aka. Class Zero Baja Bug...I've gutted the interior and removed all of the fiberglass. Seeing the condition of the floorpans I've committed myself to replacing the floorpans, once done I will protect them with POR15 (rust/corrosion barrier) and a good, durable undercoating. On the list of things to replace is the electrical. I will be ordering a new 12V harness for the car and rewiring the entire car. I've got a long way to go though before that happens.

In the meantime, I'm still discovering areas that have rusted over the years which needs to be addressed. So I suppose this is where the BAD NEWS begins. Aside from having to replace the floorpans and also repair the body rot along the left rear quarter panel, I discovered that the sunroof tray/panel which the sunroof slides in and out of when opening/closing is rusted badly. Since the piece is welded in, this would need to be cut out and the roof above it would need to be repaired, primed and painted before a new piece could be welded back in. I plan on keeping this car indefinitely and it will most likely end up with one of my children at some point, so I need to take the time and do this job right. The other bit of bad news is that the fender bolts (right rear) are pretty badly rusted. I was able to unthread all but 4 of the bolts. Unfortunately, I torqued the heads right off of them because they were pretty badly damaged. I chased them with an easy out and to no avail. I did manage to break a brand new easy out however. So at this point, I'm looking of for options. I'm thinking about drilling the bolts out at this point and tap in new threads. Any suggestions on this?

Now for the GOOD NEWS. I spoke to my brother in-law tonight (the last person to drive the car) and I asked him about the motor and tranny, particularly what size the motor was and the condition of the tranny before he decided to store it. He informed me that the motor was rebuilt before storing it and he claims it only has approx. 2,000 miles on it. Also, the motor that I thought was a 1776, turns out to be an 1835cc with dual Zenith carbs (32's). Needless to say, I'm pretty psyched about the rebuilt 1835cc motor with only 2,000 miles on it, but it gets better still. I asked about the condition of the tranny and he informed me that a brand new tranny went in at the same time the motor was rebuilt. Ka-Ching! Ka-Ching! SCORE!! This was the best good news I've had in a long time. This of course means that the car will be on the road sooner than it would have otherwise and I won't have to spend money on a motor and tranny rebuild like I had planned originally. Yeahhhhh!!

Tomorrow morning, I'll be back out in the garage sweating like a pig to see what else I can get accomplished. I still need to pull the engine, remove all the glass, remove the rear auxillary gas tank, and the list goes on...and on....and on.


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Conundrum
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Post Post subject: CLASS ZERO '66 BAJA BUG
Posted: Sun Sep 15, 2013 04:23 PM
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Progress,,, hey don't make it too perfect for your kid or they might just sell it and buy something with A/C... LOL

Glad to hear your moving along! Even better knowing your engine, you should be able to get that running easy. Smile


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Post Post subject: Re: CLASS ZERO '66 BAJA BUG
Posted: Sun Sep 15, 2013 06:05 PM
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Weld a nut to a rectangle piece of sheet metal. Then cut out the offending piece and weld the new one in.

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ClassZero
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Post Post subject: Re: CLASS ZERO '66 BAJA BUG
Posted: Mon Sep 16, 2013 08:04 PM
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Conundrum wrote:
Progress,,, hey don't make it too perfect for your kid or they might just sell it and buy something with A/C... LOL

Glad to hear your moving along! Even better knowing your engine, you should be able to get that running easy. Smile

Well...I did it. I finally had a day to myself where I was able to work on the Bug, so I pulled the engine and finished removing the interior. Whew!! The interior...what a mess. If ever there was a candidate for total floorpan replacement, this car is it. I put my foot right through it. Also, I removed the rest of the headliner, so I was finally able to see the full extent of the damage done to the interior roof caused by the leaky sunroof. O.M.G.! What have I gotten myself into? I need to remind myself to take a deep breath....calm down. Frankly I'm not really sure where to begin in terms of repairing the rust damage to the interior roof. The other thing that I noticed is the workmanship, or lack thereof of whoever it was that modified the Bug in to a Baja. The word, BUTCHER comes to mind. No wonder there is so much friggen rust on the interior. There are holes everywhere. Apparently the guy who my relative bought the car from was the person who did the work, he evidently never heard of the expression "measure twice, cut once." I have a lot of metal patch work to do. Still...I am undeterred in my quest to get this car back on the road/off road again. At this point, I've become thoroughly convinced that I'm taking the right approach by not just tuning the tuning the motor up and start driving the car again. First and foremost, the car needs to be made safe, so it looks as though most of my time, energy and money will be spent on things like body work and new brakes. Given that the motor has just 2,000 miles on it and the transmission was replaced at the same time the new engine went in and that the car was free, I'd say that I'm still way ahead of the game. I have to be honest with you though...I'm a little bit intimidated with all of this body work. I'd welcome your feedback on that or anything pertaining to my project.

Here a few pics that I took over the weekend.


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Post Post subject: CLASS ZERO '66 BAJA BUG
Posted: Tue Sep 17, 2013 12:36 AM
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Do what you can and whatever needs a professional on, well at least you don't have to spend as much on other parts of the project that you initially had figured into it like the engine/trans, etc.


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Post Post subject: CLASS ZERO '66 BAJA BUG
Posted: Tue Sep 17, 2013 02:42 AM
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Conundrum wrote:
Do what you can and whatever needs a professional on, well at least you don't have to spend as much on other parts of the project that you initially had figured into it like the engine/trans, etc.
ClassZero, make a detailed list as you go along. Not just to memory but to paper. Once done group things together using logic or money/cost. Be patient. Read forums on your things needing done. Youtube can assist but definitely ask b4 using that as more than just a visual reference. For example: you said the pan was bad. Grouped with it could be heater channels if needed. Since the pedal assembly has to come out, good time for new master cylinder and check clutch cable & clutch hook. Even update pedal assembly if needed. You get the idea. Then ask specific questions for advice. Like for the floor, how to rip out and install new. This car was designed back in the 30's to be a car most anyone could work on. 80 years later we have much better hand tools overall and the entire car is mod'able by most anyone. It just takes your time and a little cash,, or a little of your time and much more cash when someone else does it for you. Patience, attention to detail, and notes are your best friends while working on a project. If you feel something is beyond your ability....and you want to learn, ask for local help. Offer free beer, lunch/dinner, gas money, etc for them to come supervise your work. Or if feel completely beyond your ability, as Conundrum already said, you can farm that part of the project out. Remember the "COOL" factor of wife approval and knowing answers to the kids as they get older, 50 million questions about the baja..... priceless. Enjoy it, Ray


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AzBaja
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Post Post subject: CLASS ZERO '66 BAJA BUG
Posted: Tue Sep 17, 2013 09:27 AM
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As you are saying this, I'm working on an Excel Spead sheet for my Car. Not sure how well the Copy past will play out. but this will give you an idea from the 1st few lines. See Below

Once somthing is done I change priority to a new task, or use cost to see what is next or were I'm working on the car. If I'm doing work over the front skid plate I might group or do task that need the skid plate removed etc. etc.

Priority/Order Project/Job/Install Status Parts Needed Have Parts Order Parts Notes Cost
1 Front Shock N2 Need to take in for repair
1 Clean out fuel tank Fuel Tank Cleaner No
2 Instal Fuel lines Ends


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Post Post subject: CLASS ZERO '66 BAJA BUG
Posted: Tue Sep 17, 2013 01:39 PM
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Want to see pics man.... PICS!

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Post Post subject: Re: CLASS ZERO '66 BAJA BUG
Posted: Tue Sep 17, 2013 03:43 PM
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ButchW wrote:
Want to see pics man.... PICS!

Yeah....I was just teasing you by promising to show you photos. Just teasing! Laughing

For some reason though, the links from Photobucket aren't working. Let me see what I can do.


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Post Post subject: CLASS ZERO '66 BAJA BUG
Posted: Tue Sep 17, 2013 04:10 PM
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Ok. Let's try this again.














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Post Post subject: CLASS ZERO '66 BAJA BUG
Posted: Tue Sep 17, 2013 04:12 PM
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Viola! It worked!


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Post Post subject: Re: CLASS ZERO '66 BAJA BUG
Posted: Tue Sep 17, 2013 11:57 PM
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Ya got a very good point there. Ironically that EXACT thing happened to my brother several years ago when he rebuilt, then later gave his Baja Bug to his son. The little turd sold the Baja and used the cash to buy some P.O.S. pick-up truck. My brother was pissed! So yeah....point well taken. Besides....who needs A/C anyway? Right? Smile

Conundrum wrote:
Progress,,, hey don't make it too perfect for your kid or they might just sell it and buy something with A/C... LOL


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Post Post subject: CLASS ZERO '66 BAJA BUG
Posted: Wed Sep 18, 2013 07:09 AM
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LOL Too funny how those things go! Sorry to hear that.

I learned after giving my brother a Baja and he trashed then wrecked it and wouldn't fix it, so I took it back and pulled the engine and sold it to a friend who finished killing it. Sad

It's hard to tell from a picture, but it really doesn't look too bad. That section that's really bad is easy to replace.


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Post Post subject: CLASS ZERO '66 BAJA BUG
Posted: Wed Sep 18, 2013 11:49 AM
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It's a little crunchy, but not too bad.. love the big fuel tank in back.. Hmmm I'm getting some ideas for mine. Looks like fun!

Was thinking about doing one for my kid who is in college now.. I gotta feeling he'd appreciate it.. Of course I've got to get MINE finished off first.

Keep the pics and progress coming! Love it.

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Post Post subject: Re: CLASS ZERO '66 BAJA BUG
Posted: Wed Sep 18, 2013 01:33 PM
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Conundrum wrote:
LOL Too funny how those things go! Sorry to hear that.

I learned after giving my brother a Baja and he trashed then wrecked it and wouldn't fix it, so I took it back and pulled the engine and sold it to a friend who finished killing it. Sad

It's hard to tell from a picture, but it really doesn't look too bad. That section that's really bad is easy to replace.

I must admit, after watching hours of YouTube videos, reading posts, articles, etc...I am feeling somewhat more encouraged. As you said the worst part of the car are those floorpans which are being replaced. Also the right and left rear quarter panels are a little crunchy in the corner area where it meets the front part of the rear fender. Those too can be replaced. I am somewhat concerned that the heater channels that run the length of the floorboards may also need to be replaced, because that's a project that I know I can't tackle myself. I don't have the skills.

I will have to accept the fact that I will make some mistakes along the way. If I mess something up...it can always be repaired. I think my outlook at this point is...well, I can't make it look any worse than it already does. Right?


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