Fender damage.
 

Well guys a couple of nights ago it happened. I was driving my 1302 to meet my girlfriend at the coffee shop and then......
I was making a slight turn to the left when I hit an uneven (understatement) portion of the road. Yeah my local tax dollors do NOTHING for the highways. Anyway, the tread on my left front tire caught the inner fender lip and bent it out, damaging the fender and breaking the paint. Oh yeah, my tire is now a little lighter as well. If only I could get that close a shave with my razor!:mad: Long and short of it is that my math wasn't as good as I thought it was while setting up the rims, tires and ride height. So I guess I'm off to purchase new wider fenders for the car. I'd like to pick your collective brains for a moment and get your opinions on a few things.
First of all what is up with 1 and a quarter inch wider rear fenders?
Why doesn't anyone make any fronts that are 1 1/4?
I really only need an inch for clearance but the only front fenders I can find are 2".
Also I don't want the front of the car to look akward with massive space between the headlights.
OK! Rant over!:laugh:

So I've decided to go with 2" all around. I'm also going to get new running boards. And I find my self on the fence on these. Do I:
a. go with the fibreglass boards that most folks offer with that funny angular indention about a foot back from the front fenders? (makes me want to get a set of magnesium slots, paint the car green and gold with extra heavy metal flake and don my polyester disco outfit)?
b. replace the factory boards (no trim)?
c. get those knarly smooth boards with the vents cut in them (paint the car teal and pink, grow back my mullet and blast Def Leopard)?
or
d. get a set of carbonfibre boards?

OK so maybe I just answered my first question:laugh:

Now, I find myself on the fence yet again. Should I go with early style headlamps and run a set of H4 911 lenses? I like the look of the later style lights on a GL but those fluted Porsche headlights make me feel all tingly when I think of them mounted on my car with body coloured trim. MMMMMMMM

OK now that I've calmed down I would like to ask if anyone has had any experiance with widened fenders and stock bumpers? Looks to me like it's going to be a REAL close fit. I'm going to need to relocate the turn signals anyway so I'm not opposed to getting new bumpers. Any ideas?

Cheers and Thanks guys!

Chris

My guess on why you see 1¼-inch wider rear fenders and not the same for the fronts are two-fold. One, more players tend to prefer wider tires for the rear than for the front. Two, Super Beetles have a wider front track than rear track in stock configuration. Having slightly wider fenders in the rear allows for not only wider tires in the rear but a wider track if one so chooses through spacers. (Remember, I am guessing here ... but I did give it a lot of thought when it looked like I might have to go that route.)

You pretty much obliterated "a" and "c" as desired choices. For what you are doing, you may prefer carbon fiber over untrimmed stock. You also have a third choice. http://www.800luvbugg.com/shop?frame=3.73.4622 I went with black/polished.

Here is a pic of my car with stock running boards:
http://img228.echo.cx/img228/3545/1302passide4fh.jpg
Granted, they still have their chrome trim.

Here are two pics (one with less glare) of the black billet running boards:
http://img350.imageshack.us/img350/7...ear3qtr8as.jpg
http://img350.imageshack.us/img350/7...ont3qtr0fl.jpg

As far as headlights are concerned, you like the fluted Porsche's headlamps. To me, you answered your own question there.

If you go wider rear fenders, you might want to install a front bumper on the rear. If you are installing wider front bumpers, I think you will be okay as you are. I do not have first-hand experience, however. This is what I remember from my info-gathering of yore.

Thanks...Yeah, after re-reading my post, I guess I was rather obvious about what I had in mind......
Your running boards are nice. There's a local fella that runs those on his bug and after every cruise-in he has to wipe my drool off of em.:laugh:

Anyway.... After tons of research and a one-on-one with a very dis-satisfied former "innovations in fiberglass" customer, I have decided to go with CCC fenders all around. I'm going to update the rear fenders because I like the look of the later model tail lights on a GL.
I've even been pondering those updated flush mount tails to solidify the newer look.
I've also noticed that CCC offers "Not so massive" glass running boards. According to their web-site the boards are stock size but designed to fit their widened fenders. I think that the boards being color-keyed to the body will further the clean European look I'm after.

The PO of the car beat me to the "front on the rear" bumper thing. So part of my job is already done!:agree: Thank you for the guidance on the front!!!!!

I've always looked at accidents as a hidden blessing or a "not so subtle" nudge to start projects that I've been putting off. This one is no exception. I will now get a chance to detail the inner fenders. I have a buddy that runs a shop that applies that "Spray-in" bed lining for trucks. If I take care of the prep work and the cost of the materials, as well as a six-pack of his favorite imported lager, my inner fenders and pan will be "West Virginia State Road Proof"! I may even get him to coat the underside of the new fenders to protect them from rocks being flung.
I also plan to incorporate the front turn signals and park lights into the fluted headlights. Sort of something like a new Mercedes. I've been wanting to shave the turn signals from the fenders for some time now.

I've recently made a major career change and now work where I cut my teeth. Believe me it was a "Mental well-being" change (long story perhaps for another post) But I am proudly back full-time in the automotive industry. I will be personally mixing the paint for the car. I hope to match the color. We have state of the art color matching equipment, and I will be blending the paint into the existing panels. So it should come out well. I see no sence in repainting the entire car just to match the fenders. After all the existing paint is in good shape. The paint mixing formula was no longer available in micro-fische form. The fine folks at Martin Senour were kind enough to fax me a copy of said formula. If anyone is having problems getting paint mixed for their pre 79 VW, feel free to PM me and I will try to get the formula for you to take to your local paint shop (providing they mix Martin Senour or can cross reference the mixing colors).

As always I have to thank you guys for this awesome site. Without it and you I'd just set here and bounce ideas off of the dog as he stares at me with his head ****ed to one side.:drunk:

Cheers

Chris

Had I gone with wider fenders (and no US-source of c/f), I would have gone with CCC if they had the right size for what I needed. And I would have probably gone with their running boards, too, with the same caveat about c/f availability. I have no personal experience but their reputation is unsurpassed.

Innovations used to be somebody else (name escapes me). They seem to have a mixed reputation. Some have speculated their negative rep is a holdover from their previous incarnation. I don't know either way.

CCain I couldnt tell from your post. I am assuming that your fenders are metal?
If they are fiberglass, it is VERY easy to widen them yourself. If you dont mind sanding. The mat and resin will be less than $50. to do all four fenders.

Yeah, they are metal. I bent the inner lip out and cracked the paint. Kinda torqued me off due to the fact that the fenders were original to the car. I've decided to replace them with steel fenders which I'm going to flare. I'm goning to fix the drivers fender then hang the originals in the shop for safe keeping. I have some light background in metal work and body work so it shouldn't be too bad of a job. Besides, I like putzing around the shop. I'll post pics along the way but I hope they come out like the fenders on the Kafer Cup cars or the ones you get from Germany.

Well gang....
I started work on the new fenders. A buddy of mine across town had a set of early Super front and 74 rear fenders which I got for a song.
I took all the paint off of 'em. It's nice to work with bare metal and not have to worry as to what lies beneath. Anyway I finally got them all cleaned up and started marking and cutting for the flares. Looking at the pics, the fender will be cut out to the black line just about 2 inces above the fender lip.

The first photo is the fender as it was and the last pic is an abstract of what the fender will look like once the metal is welded into place.

More to come......

Cheers

Chris

Here are some pics of the front fender with the flare in place.
I still have to finish welding (I ran out of wire tonite) then all that's left to do is:
Clean up the headlight bucket, etch the metal, prime, sand, sand, sand some more, seal and paint.

Very nice sheet metal work:righton:

I have one fender buttoned up and under primer. I still need to tweek it a little but I think it's going to come out OK!:D
http://i10.photobucket.com/albums/a1...2.jpg~original
http://i10.photobucket.com/albums/a1...2.jpg~original
http://i10.photobucket.com/albums/a1...2.jpg~original

Really nice work dude:agree:

Wow,

Very nice work....

Keep us posted.
Alex

Thanks guys!

You did a very good job. May I ask how you did it? Did you use an english wheel?

Mike

Y'know, ccain529, until beetle1303 posted this, I had forgotten you did the work yourself. I am very impressed. :agree:

Thanks Mike!
I cut out the old metal and stretched the fender lip out to the angle I thought was close. Then taped up some poster board and traced off a template. I cut the metal for the flare and bent it slightly then tacked it all in place. It was sort of a compound curve and I had to shrink the metal in places to get it to weld properly.


Thanks Oasis!


Tonight I took the measurements from the drivers fender and prepped and cut the passenger fender. I reused the template for the drivers fender. flipped it over and used it to cut the metal for the passenger side fender. After all the metal was tacked in place it remeasured and found that the fender was out less than a 16th of an inch. after some gentle nudging from the body hammer it's now dead on!;)

OK guys....here's the latest:
Last night I finished flaring the last of the fenders. I am real glad that I can walk away from the welder for a while. I etched the bare metal and I am now getting ready to lay down a coat of sand-able high build primer and start fine tuning the bodywork. Please pardon the my shop.....I do all the rough bodywork in what my girlfriend calls "The Dog House":D
http://i10.photobucket.com/albums/a1...5.jpg~original
All 4 welded up....
http://i10.photobucket.com/albums/a1...6.jpg~original
Rear fender after metal etching....
http://i10.photobucket.com/albums/a1...7.jpg~original
Ditto....

Looking Good:agree: . You sure you havn't done this before. Looks Pro.

What did you use to shrink the metal? I am looking to get wider fenders and I like the way yours turned out and it is different and cheaper than fiberglass.

Mike

Hey Mike,
The technique I used to shrink the metal was to take a torch and heat the metal where I felt it needed to be shrunk. Then (while the metal is still very hot) use a garden hose to cool the metal rapidly. This will shrink it quite a bit. I've used the same technique to remove dents in larger panels.
Lets say you have a long, relatively narrow piece of metal and you need it to bend slightly, but the tensile strength of the metal prevents it. It you heat it on the inside of where you imagine the bend to be and then cool it rapidly it will bend. This can be tedious and time consuming. Be careful because it can cause a bit of warping. I would suggest running a few test panels just to get the feel of it. But whatever warpage you get can be addressed later with a hammer and dolly.

Thanks

Thanks ccain529 for the info. At this point in my build I am far from working on my fenders but I think I am going to give it a shot as your fenders look much better than hugh fiberglass fenders. I will post some pictures when I get there.

Mike

Thank you!! Good luck with your build! Keep us posted!

Your fenders look great. I like the fact that you're making something yourself. :righton:

That's a good technique of shrinking metal. You can also use what is called a 'shrinking disk'. I'm gonna have to get one for my fenders.

After all is said and done...I shoulda bought 'em already made! These things kicked my butt!

Well here they are folks....primed, wetsanded, painted and cleared! All that is left is to mount the tail lights and wire up the front bumper turn signals.

http://i10.photobucket.com/albums/a1...2.jpg~original
http://i10.photobucket.com/albums/a1...9.jpg~original
http://i10.photobucket.com/albums/a1...2.jpg~original
http://i10.photobucket.com/albums/a1...1.jpg~original

The paint isn't an exact match but I plan on painting the entire car next year.

Cheers

Chris

Wow, those look great. You did a fantasic job. I wish they came from the factory like that!

Mike

Amazing fab skills as well as prep and painting skills. Well done. I wish i had space, time and these skills...

Congrats again

Chris

:agree: :agree: I'd give more than two thumbs up if I could ... wait a second ... never mind, that's not a thumb. Really well done!

sweet job dude thanks for that Idea I'm putting my 69 in the body shop this work I may try that as well cheaper then Remmele CF (i wish) but this then this will be just fine great job though ;)

Me too!!

Thank you!!

OMG!! I peeing my pants!:laugh:

Thanks! And keep us posted!

Thanks sooo much guys! It's your encouragement that keeps me going.

Say, have you ever noticed how one small thing mushrooms into a major undertaking?!:mad: In the direct mid-day sunshine yesterday the car looked pretty good. The paint wasn't a perfect match but then again I didn't expect it too. Well, this evening after work, I went down to the shop to see how well the paint had cured and to start work on the wiring and bumpers...BIG MISTAKE!!! I pulled the car out and in the evening sun those fenders aren't even close to matching! Looks like an old black and white police car!:rolleyes: Well, never one to be satisfied, I've decided to respray the whole car. I was planing to do this next year but....I just can't live with the fenders being so far from matching the rest of the car! And not that there is anything wrong with that style (note the disclaimer) If my fenders don't match, I may as well make a "Rust Rod" out of it!
Damn OCD! And yes, all the labels on the oil cans in my shop are facing out!:laugh: So stay tuned I'll probably start yet another thread on the progress of the respray.
Gotta run, I'm going down to the shop and start striping the car down.

Cheers

Chris

Hey man, first off.... Great job on the fenders! Second, thanks for posting that up and opening my eyes on my own project. I initially wanted 'kafer cup' style glass fenders for my ride, but $ and international shipping were a huge turn off. That and it goes against every fiber of my DIY being to simply buy something. Then came your post... duh, why was I trying so hard to widen from the inside with all of the complex angles/shaping/excessive welding and hammering. Especially since I am in the process of widening some jetta fenders using a similar method to your fenders. I'm scrapping my first beetle fender mid stream and trying your method.

here are some pics of my short lived fender project (2hrs)

if these pics begin to clutter your thread, let me know and I'll pull em.

http://home.comcast.net/~kellyharpe/IMG_3876.jpg
Inside edge trimmed off.


http://home.comcast.net/~kellyharpe/IMG_3919.jpg
here the rest of the fender is with like 3" of extra metal, but 2.5" was what was going to be final.

I'll post up my own thread on my fender job once I get my project moved over to my new garage.

Thanks again for posting that up.

Thank you! Looks like you are a better welder than me!;) Keep us up to date! I am very interested in how your's will turn out.
I wish I had the skills to be able to make molds! I would like to make a few mor sets and keep 'em in my shed for later projects!
If you look at mine real close you can definitely tell I don't do this for a living!:laugh:
I was ready to shell out the bucks for the widened fenders but I didn't like the way they made the headlights look so far apart.

Yeah, I'm with you on the molds... I'm not afraid to give it a try, but I'd like to start with some smaller pieces, like say a gas door. hehe I've got a friend who works with carbon fiber and he tells me there's nothing to it or 'glass for that matter. Well, nothing aside from the price that CF is at right now. :eek:

check out www.ghiaspecialties.com
the owner John Kelly has a very good dvd and a shrinking disk(I own them both). Lots of good info on body work
Bryan

OK...Well after many tiring days and nights...the repray is nearing completion!
The next time I do this I will pay someone!!!
OK so it's not perfect but I think it will be sufficient for now...There may be plans in the works to change the color completely down the road.
http://i10.photobucket.com/albums/a1...1.jpg~original
http://i10.photobucket.com/albums/a1...2.jpg~original
http://i10.photobucket.com/albums/a1...1.jpg~original
http://i10.photobucket.com/albums/a1...1.jpg~original

Slick! Thats one way to match the paint on the fenders.:cool:

A little more progress today....
http://i10.photobucket.com/albums/a1...8.jpg~original

Will this ever end?!!!
I wasn't satisfied with the mono-color of the car and there were a few imperfections on the hood and roof that bugged the crap outta me. So, because I have no life, I decided to try something a bit different. I've never been a big fan of two-tone bugs, but I had some extra paint and figured that I couldn't screw it up any more than it is! I stole the idea from the cover of HotVW's because I liked the way it looked. The black that I used has small metallic and mica flakes that give off a burst effect when in the sun. And I chose yellow as a contrasting dividing line between the blue and black.
Eh...I think it looks OK. I'd still like to paint it yellow.
I wasn't going to repaint it a different color because I didn't want the extra work of painting the inside and under the hood and stuff.....Geeze! 3 months later, and all of that "extra work" seems like a cake walk. Yellow69 and I were talking one afternoon and she suggested I change the name of the car to Beelzebug! That fits because this little thing is the metal embodiment of Satan himself and has sure put me through hell!
http://i10.photobucket.com/albums/a1...7.jpg~original
http://i10.photobucket.com/albums/a1...1.jpg~original
http://i10.photobucket.com/albums/a1...2.jpg~original
http://i10.photobucket.com/albums/a1...3.jpg~original

A few more....
http://i10.photobucket.com/albums/a1...7.jpg~original
http://i10.photobucket.com/albums/a1...8.jpg~original
http://i10.photobucket.com/albums/a1...3.jpg~original
http://i10.photobucket.com/albums/a1...9.jpg~original

I still have to paint the hood and it's trim, the license light nose thinggy (I never learned the proper VW nomenclature for that one! Sorry purists!) and wrap the rest of the car up and buff it.

Cheers

Cheech!

:eek: You mean I'm finally getting credit for something? :laugh:
j/k....or am I? hehe
Bee's (yeah thats short for Beelzebug :p ) lookin' sex-ah! Be patient. ;)

I like it. :agree: For some reason, it makes the wheels look even better on the car.