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SleepAIR Build Thread
Hi guys,
After 10 years I've decided to sell my standard and start a new project with a super. My aim is a fast road car with stock(ish) look and detailed engineering. http://sleepair.freeblog.hu/files/2011/07/7.jpg Since I couldn't locate a r&p 1303 I decided to go oldschool and build a retro flavoured 1302. Finally I could swap my previous car for a '72 Marinablue 1302..so there you go, before-after pictures.. Before: http://img.carstyling.hu/usercars/00...1302617346.jpg After :D http://img.carstyling.hu/usercars/00...1313568638.jpg |
Car was in accapetable shape, but nothing more. Was driven daily.
http://sleepair.freeblog.hu/files/20...%C3%A9k1_2.jpg Let's see what is on the road.. http://sleepair.freeblog.hu/files/20...k%C3%A9k2_.jpg It had MOT till end of 2011, so I made a few short trip, then it was time to start working..(September, 2011) http://sleepair.freeblog.hu/files/20...z%C3%A9t1_.jpg http://sleepair.freeblog.hu/files/20...z%C3%A9t2_.jpg http://sleepair.freeblog.hu/files/20...z%C3%A9t5_.jpg http://sleepair.freeblog.hu/files/20...z%C3%A9t6_.jpg http://sleepair.freeblog.hu/files/20...z%C3%A9t4_.jpg http://sleepair.freeblog.hu/files/20...z%C3%A9t3_.jpg There are weak points, but body seems healthy, and most importantly have not been wrecked! Not bad from a 40-year-old car. |
Body prepared to come off
http://sleepair.freeblog.hu/files/20...z%C3%A9t7_.jpg Separated http://sleepair.freeblog.hu/files/20...z%C3%A9t11.jpg Not the best pan ever..but the frame head was changed to a newer one, it is still OK. (Note the original tow hook..not common these days) http://sleepair.freeblog.hu/files/20...z%C3%A9t8_.jpg |
The next step was Sandblasting..
http://sleepair.freeblog.hu/files/2012/05/homok1.jpg http://sleepair.freeblog.hu/files/2012/05/homok2.jpg http://sleepair.freeblog.hu/files/2012/05/homok3.jpg http://sleepair.freeblog.hu/files/2012/05/homok4.jpg ..than primer: http://sleepair.freeblog.hu/files/2012/05/homok5.jpg Few days later the body came back as well: http://sleepair.freeblog.hu/files/2012/05/homok6.jpg http://sleepair.freeblog.hu/files/2012/05/homok7.jpg http://sleepair.freeblog.hu/files/2012/05/homok12.jpg http://sleepair.freeblog.hu/files/2012/05/homok14.jpg |
More or less what I expected.
http://sleepair.freeblog.hu/files/2012/05/homok9.jpg Left quater was demaged (nothing else) and poorly repaired http://sleepair.freeblog.hu/files/2012/05/homok8.jpg http://sleepair.freeblog.hu/files/2012/05/homok13.jpg Towers are a bit... there are no towers http://sleepair.freeblog.hu/files/2012/05/homok10.jpg http://sleepair.freeblog.hu/files/2012/05/homok11.jpg Otherwise it's not too bad. |
The Body Shop
http://sleepair.freeblog.hu/files/2012/05/lakat6.jpg October, 2011 - bodywork began. http://sleepair.freeblog.hu/files/2012/05/lakat1.jpg http://sleepair.freeblog.hu/files/2012/05/lakat2.jpg http://sleepair.freeblog.hu/files/2012/05/lakat3.jpg http://sleepair.freeblog.hu/files/2012/05/lakat4.jpg I was storngly thinking to save more money and buy the complete front panels, but decided to go with just the repairs as they should be as strong or stronger than the aftermarket complete ones. Not my favourite picture. http://sleepair.freeblog.hu/files/2012/05/lakat5.jpg |
My buddy sent me a picture of the car and a girl with 3 legs :lmao:
http://sleepair.freeblog.hu/files/2012/05/panorama_.jpg Well, I was always a big fan of sunroofs so it was predictable that the car should have one. I managed to find a perfect example, rust free and fully working. http://sleepair.freeblog.hu/files/20...tet%C5%911.jpg Instead of cutting off the original and welding the new one, or cutting just the sunroof into the original roof (as we did on the yellow car and worked perfect) I've chosen the 3rd option http://sleepair.freeblog.hu/files/20...tet%C5%912.jpg so structurally all the pillars and the roof remained original. Turned out well I think. http://sleepair.freeblog.hu/files/20...tet%C5%917.jpg http://sleepair.freeblog.hu/files/20...tet%C5%918.jpg http://sleepair.freeblog.hu/files/20...tet%C5%914.jpg http://sleepair.freeblog.hu/files/20...tet%C5%915.jpg http://sleepair.freeblog.hu/files/20...tet%C5%916.jpg It's glue inside, no rust. http://sleepair.freeblog.hu/files/20...tet%C5%919.jpg |
Till January 2012 nothing happened than finally the pan was almost ready.
http://sleepair.freeblog.hu/files/20...lv%C3%A1z1.jpg http://sleepair.freeblog.hu/files/20...lv%C3%A1z2.jpg http://sleepair.freeblog.hu/files/20...lv%C3%A1z3.jpg http://sleepair.freeblog.hu/files/20...lv%C3%A1z4.jpg Was missing only the upper side, when I came up with an idea: a colore matched tunnel would look fine (planning no or few carpets inside). But, hey what color will the car be?:confused: |
So I had to find out the color ASAP..not an easy decision. After checking (nearly) all the factory Porsche and VW colors I decided to choose from the original ones to make the car as authentic as possible (thus keeping the value...seems I'm getting older or don't know)
For the 8/1971 - 7/1972 model year the following colors were available: Texas Yellow / Texasgelb (L10B), Brilliant Orange / Leuchtorange (L20B), Kasan Red / Kasanrot (L30B), Black / Schwartz (L41), Gentian Blue / Enzianblau (L51B), Marina Blue / Marinablau (L54D), Sumatra Green / Sumatragrün (L61B), Pastel White / Pastellweiß (L90D), Kansas Beige (L91D), Turquoise Metallic / Türkismetallic (L95B), Silver Metallic / Silbermetallic (L96D), Gemini Metallic (blue, L96E), Colorado Metallic (red, L97D). + the special editions like the Marathon Beetle/Baja Champion SE - Marathon Metallic (silver, blue L96M); Cabrio and Jubilee models (20th million edition) -Saturn Yellow (L13M) except USA and Europe "May Beetle" editions, that were available in Saturn Yellow (L13M), Blood Orange (L21E) and Willow Green (L63K). Since it is going to be a summer car it should be light & some others were out of my taste. I kept Marathon Blue (you know Christian Stelzer's ethalon), Turquoise and Silver Metallic plus the original Marina Blue and Kasan Red. Than I realized that an 1302 have to be built in oldschool so Marina Blue and Kasan Red final arrived. MB is quite rare in the GL scene and it was the original color of my car, while the KR is more sporty, looks better with chrome and it was a one year color for Beetles as far as I know. http://sleepair.freeblog.hu/files/20...2k%C3%A9k_.jpg http://sleepair.freeblog.hu/files/20...1302piros_.jpg Being different is cool, a 2 year only car in a 1 year only color is a ticket to this, so the winner is Kasan Red L30B. |
Since I knew the color, the pan could be finished. (April, 2012)
http://sleepair.freeblog.hu/files/20...lv%C3%A1z5.jpg http://sleepair.freeblog.hu/files/20...lv%C3%A1z6.jpg http://sleepair.freeblog.hu/files/20...lv%C3%A1z7.jpg However it's an interesting color (not so red but somwhere between red and orange) the pictures don't show it well, it seems more orange than it is (maybe the lights + cell phone). Actually I'm not sure about the tunnel, but let's wait it. If I don't like it than comes carpet :) There are things to do till body gets painted. http://sleepair.freeblog.hu/files/20...lv%C3%A1z8.jpg |
Cool project! Keep the pics coming :-D
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Nice, I would love to see some detailed pics of you unpicking the roof seams?
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May, 2011 was about preparing the body and after a LOT of work it was ready to go to the painter, a friend of mine. http://sleepair.freeblog.hu/files/20...be%20megy1.jpg http://sleepair.freeblog.hu/files/20...be%20megy2.jpg After an other 3 days (0-24) of detailing http://sleepair.freeblog.hu/files/20...el%C5%91k1.jpg http://sleepair.freeblog.hu/files/20...el%C5%91k2.jpg http://sleepair.freeblog.hu/files/20...el%C5%91k3.jpg Sealing (correct word here?) like 40 years ago http://sleepair.freeblog.hu/files/20...el%C5%91k4.jpg http://sleepair.freeblog.hu/files/20...el%C5%91k5.jpg http://sleepair.freeblog.hu/files/20...el%C5%91k6.jpg Let's do it http://sleepair.freeblog.hu/files/20...el%C5%91k9.jpg |
Before getting the clear coat. Cell phone pics again :-/
http://sleepair.freeblog.hu/files/2012/07/fu1.jpg http://sleepair.freeblog.hu/files/2012/07/fu2.jpg http://sleepair.freeblog.hu/files/2012/07/fu3.jpg http://sleepair.freeblog.hu/files/2012/07/fu4.jpg |
I have a '73 1303 witch is original Kasan Red so I think it was a color for '72 and '73 models.
Do you know this 1302 from Gerd Weiser? it's also Kasan Red. http://volksworld.media.ipcdigital.c...7Cbf31_gwd.jpg Good choice on color:goodjob: Even the smilie agrees. |
I could't work on the car for weeks..
Than made the pan ready to roll (June, 2012). And here is the point real play begins..let's see what is underneath. For start I bought a perfect steering box as mine was a bit tired and urethan busihings (black ones) everywhere. Rear: usual Porsche 944-affair - 944 23.5mm torsion bars - Original (new) torsion covers to be able use the poly bushing that came in my complete kit - 944 steel arms - 944 spring plates - 944 disc brakes with the stock floating calipers for now - yellow KONIs Still need to mount the 944 rear sway bar, buy the swans for the e-brake and the cup-brace Front: nearly all parts from Topline. - urethan bushings everywhere - camber+ kit - idler arm bushing - pitman arm bushing - lower steering column bushing - bumpsteer kit - 22mm sway bar with caster-fix bushings - billet sway bar clamps - race strut mounting bolts - new M/C - Strut brace required and KW Variante1 coilovers with dual springs, 30-80mm adjustability and a Remmele sticker :lmao: (maybe it was made exclusively for Remmele in the past as dual spring is not a common option) http://sleepair.freeblog.hu/files/2012/07/REMMELE.jpg All the above mentioned goodies in one picture: http://sleepair.freeblog.hu/files/20...es%C3%BCl1.jpg Note that long tube. It's my new fuel line with 10mm outer diameter and made from copper, so will last for ever...as the installation lasted for ever as well. Finally it goes in and come out as the original did, but won't do it again, was a real PITA. |
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However Mr. Weiser's car is in my top 3 favourite GLs, I haven't chosen the color to copy his awesome 1302..It seems just we have a similar taste.. and I discovered this in many other details, you will see. I would be very happy if can build something similar to that beauty :cool: |
Wow! What an awesome job you have done with that body!
And pretty fast on top of that! (I need that smiley of Erik too :lmao:) |
(July, 2012)
The car shop where the bug sits asked me to go ahead as they needed more place. So picked up some of the friends to put the body back on the pan. Fits well and like more the colored tunnel. http://sleepair.freeblog.hu/files/20...es%C3%BCl4.jpg http://sleepair.freeblog.hu/files/20...es%C3%BCl5.jpg http://sleepair.freeblog.hu/files/20...es%C3%BCl6.jpg Was more simple than expected, but as you know there is always one screw... Since we were in a hurry, I had no time to put everything in place.. there are no calipers, no pedals, no rear cup brace etc. The goal was to make it roll as soon as possible. Will change everything that is not brand new (srews, bearings, front brakes etc.) http://sleepair.freeblog.hu/files/20...es%C3%BCl7.jpg http://sleepair.freeblog.hu/files/20...es%C3%BCl8.jpg Here we are at the moment, it won't be a quick progress, but trying to work on it step by step. |
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Yeah, all pics in a week uploading looks quick, but one year is really fast, believe me. Most take years and years longer to restore just the pan and body.
For example, my car took me 9 years... So in my view, you must have worked your *ss off and did a great job! |
Looks awesome! In anticipation I was waiting for Marina Blue, and gutted to see it red. :( But it looks like its going to be great. Nice work with the sunroof.
My pan is 6 or so years in the making!... Looking forward to seeing more |
Starting to look like a car again. Very nice work.
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Nice job! I grafted a Rag Top in my 1971 1302. I love it.
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Thank you guys. Some more pics of the suspension
http://sleepair.freeblog.hu/files/20...andristol5.jpg Camber+ kit http://sleepair.freeblog.hu/files/20...andristol6.jpg http://sleepair.freeblog.hu/files/20...andristol7.jpg New and old bar http://sleepair.freeblog.hu/files/20...andristol3.jpg Billet clamps look impressive with the caster-fix bushings http://sleepair.freeblog.hu/files/20...andristol4.jpg Mounted http://sleepair.freeblog.hu/files/20...andristol2.jpg Ready to roll. Will have vented rotors with matching calipers. http://sleepair.freeblog.hu/files/20...omu%20kesz.jpg |
In the meantime I've refurbished the gauges purchased from ebay.
Before http://sleepair.freeblog.hu/files/2012/10/fordulat.jpg http://sleepair.freeblog.hu/files/2012/10/kmh.jpg After http://sleepair.freeblog.hu/files/2012/10/fordulat2.jpg http://sleepair.freeblog.hu/files/2012/10/km%C3%B32.jpg http://sleepair.freeblog.hu/files/20...kmfordulat.jpg |
I've decided to sell my original BBS LMs because they were 17" and I was looking for something older in 16" as 15"s are too small for my taste.
As BBS RS, BBS E30, Compomotive CXN and 3 piece Fuchs were out of my budget, I was after a set of BBS Mahle but finally I came accross a set of these rare Fondmetal baskets. I like the design, they are very lightweight and perfect in dimensions: 7x16 ET21.5 fronts, 8x16 ET11 rears..that means no spacers, less unsprung weight. They are not common even on Porsches. http://sleepair.freeblog.hu/files/20...fondmetal1.jpg |
I bought a nice set of brakes at SPA. I was confused about the color (was thinking on red as well), but finally choose black ones with vented rotors. They are 6 pots and extremely light, each weights less than 1,5 kgs with pads! Unsprung weight again.. :)
http://sleepair.freeblog.hu/files/2012/10/tarox2.jpg http://sleepair.freeblog.hu/files/2012/10/tarox1.jpg On the rear I will use NA 944 floating calipers and vented rotors now, than similar Taroxs if current setup is not enough. |
Last week we worked an other weekend on the car. We were focusing on wiring, but other smaller things were done too.
6 meters, 15 colors, 2 sizes: http://sleepair.freeblog.hu/files/2012/10/kabelek.jpg front: http://sleepair.freeblog.hu/files/2012/10/kabel1.jpg http://sleepair.freeblog.hu/files/2012/10/kabel2.jpg http://sleepair.freeblog.hu/files/2012/10/kabel3.jpg http://sleepair.freeblog.hu/files/2012/10/kabel4.jpg rear: http://sleepair.freeblog.hu/files/2012/10/kabel6.jpg http://sleepair.freeblog.hu/files/2012/10/kabel8.jpg http://sleepair.freeblog.hu/files/2012/10/kabel9.jpg http://sleepair.freeblog.hu/files/2012/10/kabel10.jpg http://sleepair.freeblog.hu/files/2012/10/kabel11.jpg almost done: http://sleepair.freeblog.hu/files/2012/10/kabel12.jpg http://sleepair.freeblog.hu/files/2012/10/kabel13.jpg |
Replaced the old strut bearings:
http://sleepair.freeblog.hu/files/20...ap%C3%A1gy.jpg Fitted the steering column and one gauge: http://sleepair.freeblog.hu/files/2012/10/rpm.jpg http://sleepair.freeblog.hu/files/2012/10/rpm2.jpg Front rotors: http://sleepair.freeblog.hu/files/2012/10/tarox4.jpg Calipers: http://sleepair.freeblog.hu/files/2012/10/tarox5.jpg http://sleepair.freeblog.hu/files/2012/10/tarox6.jpg and wheels are on: http://sleepair.freeblog.hu/files/2012/10/felni1.jpg I will use lower profile tyres, these are 205/55 by the way. http://sleepair.freeblog.hu/files/2012/10/felni2.jpg http://sleepair.freeblog.hu/files/2012/10/felni3.jpg |
What process did you use to refurbish the gauges? I just purchased a set on eBay and they need some love as well.
Thanks, Kevin, Quote:
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Looking very sharp! Did you craft a new wiring harness from scratch or did you base if off an existing one? What's your track width (front and rear) with those wheels and tires? did you have to get much wider fenders or still stock?
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I got them in "sold as is" condition, so they were taken apart in a local shop to see what we have. The tacho was OK, just the pointer had to be repainted and the counter sat back to zero. The rpm required new electronics (50 EUR) than it was re-calibrated to work well. After that I polished the faces and reassembled them with the chrome rings from (german) ebay. BTW the 52mm and 80mm (km/h) can be ordered from any VDO dealer (like the glasses if you need them), but the 105mm (rev. counter) was a longer story..finally I found a german guy who makes these rings (for 40 EUR or so)..I can send you the contact if you need. |
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Wiring is from scratch. The old one was in poor condition, I need some extra wires for the gauges and It's always good to know every color in your harness..just in case. Originally I was planning stock fenders but it won't work with the wheels, now I'm in the 2-4 cm range (1-1,5"). Both of front and rear fenders I actually have are SAID to be 4 cm widened. Have tried the rear ones on (made by Hoffmann Speedster), they seems OK with the wheels (will see under load & with own tyres) and that what counts. Based on Kerscher's website (http://www.kerscher-tuning.de/kaefer...e2=Kotfl%FCgel) +4cm rears are ok till 9x15 ET-39 with 225 tyres..I guess it's not valid as they have the same numbers for +6cm fenders as well. The +2cm sounds acceptable: they are recommended till 7x15 ET16 with 225 tyres, this is not far form my 8x16 ET11 with 205 tyres. In extra I have 944 NA rear brakes and not sure of the offset increase. If Lanner is right (I think he is), it is 22.5mm per side, than fenders have to be 4 cm wider on rear. Can anybody prove the track increase caused by the brakes? Fronts are made by Kerscher, 4cm widened as I measured. Belive or not I had no time to try them on yet :-/ The same website recommends +2cm ones till 7x15 ET16 with 195 tyres, so my 7x16 ET21.5 with 195/45 tyres should fit nicely under that. I use standard brakes in this sence (no offset increase) and IIRC the front track of the 1302 is slightly narrower than 1303. Also Lanner states stock wings are OK for 7" wide ET38+ rims, so +2cm in front should be enough here. Now I have to try them on to see how they fit. Getting +2cm fenders means no spacers and stockish look, keeping these ones means wider front track. BTW now the rear track is increased by a good 60mm compared to front..does it have any negative affect on handling? This is my first super, no experiences yet just numbers from the web..sorry for the brain-fart :o |
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I test fitted the fenders, the numbers above seems to be correct, so an other plus point for Lanner. Rear track increase is about 5 cm/side. These are from a crashed speedster, left one arrived in two pieces, just the right could be tried on. 205/55 tyre you see here will be changed to 205/45x16.
http://sleepair.freeblog.hu/files/2012/11/gfkh1.jpg http://sleepair.freeblog.hu/files/2012/11/gfkh2.jpg since right seemed OK I asked a friend to repair the broken one and fill out the holes. Based on this picture it turned out well, I'll try it on in a week or so. http://sleepair.freeblog.hu/files/20...%91%20tati.jpg On the front I've decided to go with 20mm spacers to fill out the arches, get wider front track and turning radius. Hope I'll be able to keep the stockish look at the end. During the mockup I had some issues with the left one, will try it again with all the bolts to see what we have there. 195/45x16, size is final, tyre is not. http://sleepair.freeblog.hu/files/2012/11/sv1.jpg http://sleepair.freeblog.hu/files/2012/11/sv2.jpg http://sleepair.freeblog.hu/files/2012/11/sv3.jpg http://sleepair.freeblog.hu/files/2012/11/sv4.jpg http://sleepair.freeblog.hu/files/2012/11/sv7.jpg http://sleepair.freeblog.hu/files/2012/11/sv8.jpg http://sleepair.freeblog.hu/files/2012/11/sv9.jpg :) http://sleepair.freeblog.hu/files/2012/11/sv6.jpg http://www.abandonia.com/files/games...nt%20Day_1.png |
I bought these bucket seats from the '70s. The stripes are red but far from the car's color. They are in acceptable condition, so will give a try as is and see if I like them with all black carpets around or not. Retrimming is always an option.
http://sleepair.freeblog.hu/files/20...z%C3%A9kek.jpg http://sleepair.freeblog.hu/files/20...Cl%C3%A9s2.jpg They are compact enough for the bug but big enough for me. Weight is 13 kg / seat, 7 kg less than my (recliner) Sparco Torinos, so an other14 kgs were saved. Let me know what do you think. http://sleepair.freeblog.hu/files/20...Cl%C3%A9s3.jpg http://sleepair.freeblog.hu/files/20...Cl%C3%A9s4.jpg |
Haha, the terminator!
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Hey there,
Any update on mounting your rear fenders? You said you were going to try and squeeze 4cm fenders over those wheels. Are the fenders shown above the ones you were talking about? |
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I worked 2 days on the car, first day was about the headliner. First, I used some dynamat-style stuff for noise reduction. http://sleepair.freeblog.hu/files/20...zigeteles1.jpg http://sleepair.freeblog.hu/files/20...zigeteles2.jpg http://sleepair.freeblog.hu/files/20...zigeteles3.jpg It is the TMI aftermarket product, a bit oversized, but ok for the price. http://sleepair.freeblog.hu/files/20...C3%A1rpit1.jpg http://sleepair.freeblog.hu/files/20...C3%A1rpit2.jpg http://sleepair.freeblog.hu/files/20...C3%A1rpit3.jpg http://sleepair.freeblog.hu/files/20...C3%A1rpit4.jpg Cutting the sunroof http://sleepair.freeblog.hu/files/20...C3%A1rpit5.jpg http://sleepair.freeblog.hu/files/20...C3%A1rpit6.jpg http://sleepair.freeblog.hu/files/20...C3%A1rpit7.jpg Finally http://sleepair.freeblog.hu/files/20...C3%A1rpit8.jpg |
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