Build: Zippy the Wonderbug

Meet Zippy, or more formally, Zippetus Ferdinand Dandy and Zippy for short.

From the for sale ad when I bought him:

Looks happy, doesn't he?

So sad....

Alright, I'm going to catch you up on the 4 years that passed in the interim in a single post. Fasten your seatbelts, get your tissues handy and hold on!

I found the craigslist ad, which stated:

'59 Volkswagen ragtop, 75k miles, 6 volt battery system,
runs great, new tires, new top, little rust where you would expect it.

overall in good condition, very sound little classic. I drive it to work on occassion. $5000 or
best offer.

Now, I had happened to have sold a website I owned and had been saving the money, which was burning a hole in my pocket, with the goal of buying a running and driving VW, my dream car since I was a child. and this ad stated that it ran great and he drove it to work! That's the very definition of running and driving.

I wrote the seller 5 or 6 times over the course of the next week because that needed to be my car. By the end of the week, I was getting pretty worried that it was gone but he finally wrote me back!

**Me: If the car is as good as stated, I would like to buy it for your asking price. Could I use your tag to get it back home(a 2 hour drive)?

Him: Well, I don't know if I'd drive it that far. It's been sitting a while and I haven't started it in a bit.

Me: I'd still like to come look at it.

Him: Ok.**

So, in spite of the fact that we're already dealing with an ad that doesn't necessarily adhere to a truthful story, I loaded up the family and drove to Asheville.

Once there, we went into his garage. I saw plenty of rust but this guy had clearly put A LOT of money into it trying to make it a driver. I mean every mechanical system aside from the longblock had been replaced or rebuilt. Looking back on it now, I know that he was chasing problems trying to make his dream car drivable and he finally gave up. At the time, I just thought he was balls out good to his ride.

We did get the engine to turn over but it had sat so long, the gas was almost turpentine. The rust was a much larger issue than I initially thought.

**Me: I've got to be honest with you, I just don't think I have the money to get this to where it needs to be.

Him: I'll come down on the price.

Me: Well, I don't want to offend you with an offer, I think you're probably better off finding someone else. This is a desirable vehicle and you're going to find a lot of people that want it.

Him: Give me an offer. Any offer.

Me: I can give you $3k

Him: I'll tow it to your house immediately.**

And so ends the skit of Schwim buying a car.

So I got Zippy home and figured with some fresh gas, I'd simply drive Zippy until I died and then I would be buried in him.

As you can see in the after pic, this is not how it went down. Once I realized how badly I had misjudged the situation, my goal became fixing what was wrong without taking it apart or off the road. Again, you can see how poorly that worked out.

The odds were greatly stacked against me. The seats wanted to fall through the floor, the shifter would detach from the hockey stick, leaving you with no gears. The ground strap for the battery didn't have enough real metal at the floorpan causing poor starting, etc., etc. We could go on but you've seen the pic and know how that effort ended.

I did, however, think that I could get some floorpans in it, fix the transaxle issue and get it back together quickly. I separated the body and pan and did some welding:

But during this period, I fell off the wagon. I began chasing rust on the body.

There were many more spots, like the bottoms of the heater channels, front pillars, wheel arches, spare pocket, etc. I can't seem to find those pics, however.

And I began cutting. I purchased used stuff on The Samba that was in nearly as bad of shape as what I was replacing, I disassembled parts until there was no more to disassemble and then ..... nothing. Life happened, I got busy doing life and Zippy began returning to the elements.

It took about 4 years for the guilt to grow to the point that I felt I had to either sell Zippy or start working to put him back together. The points for selling Zippy were many. I didn't have the money, knowledge or space to work on him. It's not easy building a car in a yard that slopes. The reason behind keeping Zippy was one. I love Zippy. He's my dream car.

So, I slowly started doing small things.

First, I cleared off the lower half so I could see it:

Now's probably a good time to point out that Zippy is in my basement. When it's back together, I will literally have to take the exterior wall apart to get it out. I've not told my wife that part yet.

Then I started grabbing parts that have been sitting under my porch for 4 years, taking them apart and putting them back together in a bit better condition.

And I have got probably 40 hours of sanding JB Weld off of this steering wheel that I bought on The Samba for very little.

Which brings us to today. Today, I sanded on the wheel for a couple more hours, put another coat of JB Weld on and started working on getting the stock rear spring plates off.

I'm coming Zippy. Just hang on a bit longer!

Nice work.

JB super weld for a steering wheel?
Does it fill in the cracks and then you sand it smooth and you can paint it?

Just curious as I never thought about using it on a steering wheel.

65VW wrote:

JB super weld for a steering wheel?
Does it fill in the cracks and then you sand it smooth and you can paint it?

The wheel had obviously spent a looot of time in the elements. When I got it, it had thousands of cracks varying in severity between paint/finish spiderwebbing to completely down to the steel frame.

I wanted something that would bond well enough to keep the steering wheel material stable and solid where the cracks ran entirely through the material. I've worked with JB Weld a lot in in the past and the few times I had to sand it, it wasn't too bad.

I took a dremel and opened up the cracks so I wouldn't be trying to push the material into hairline openings.

At first, I was only pushing it into the worst with the intention of using something like glazing putty for the minor stuff. After a while though, I found it worked great for all of the different types. I went from mixing up and pushing into certain cracks to mixing larger batches, and then applying some, heating it a bit with a heat gun and then pushing it into the wheel with my fingers. After drying for a day or longer, I would sand the putty off until all that remained was the crack filling. The putty is softer than the wheel material so sanding results in a perfectly smooth wheel surface.

The only thing I haven't finished yet are the wings of the wheel as I have to be a lot more careful so I don't over apply or sand the details off. I'm working up very small batches, applying and heating then wiping clean with shop rags. So far, it's been doing well to fill the cracks in that area without messing up the surrounding material but it makes for much slower progress.

Some pics(If you click on that last pic, you can see the severity of the webbing as well as the quality of the fill):

Looks like a very time-consumig and dusty task... But the result is quite impressive.
Time will tell if the temperature extremes inside the car will have any impact on the repair.

Well, the manufacturer states that it's good for sustained 500°f and up to 600°f for short periods of time. I've used it on an engine's intake manifold with no ill effect.

Now my sound deadening method is more apt to be stinky, but that's quite a ways down the road :)

That is a lot of work but its nice to save an original steering wheel.

Have you had time to do any work on Zippy lately?

Almost none. I've been super busy, just not with anything I'd consider fun :)

I built a $150 HF blast cabinet for Zippy:

I built a small deck so my wife's birthday present of an inflatable hot tub wouldn't have to sit on a 10 degree slope :)

And because of all that, the basement is just an absolute mess. It's hard to even pass through, productivity is out of the question until I clean the mess up!

"THERE IS NO SANCTUARY!"

You need to audition with Kraftwerk!!
Dig those threads they have, haha.

A Classic with VW sounds.

Aha! "Kraftwerk - The Robots". One of my all time favorites!
May be you should contribute to the "Let's Rock" thread... ;)

Here's the German version:

Little known fact but I was actually the 5th Kraftwerk. You don't hear much about me because the 5th member was tasked with guarding the jellybean bowl.

So dawn broke on a lovely day replete with comfortably warm temperatures, clear skies and dry ground, great for working on top of. Obviously, I chose to spend it in the basement.

This welcomed me:

A mess, but workable. I just needed to clear enough space to work on the spring plates. I cleaned up the ass end of the pan and got to work, installing the high falutin' spring plate compression tool supplied by Atomwerk:

But the grade .25 nut got it's threads in a bind, leaving me no choice but to get drastic:

This left me no option but to do it like the rest of the unwashed masses, using a floor jack:

It took me A LOT of tries to get everything sorted. First try, I didn't thread the cover plate's bolts and it was under too much tension to do after setting the plate. Second effort resulted in me forgetting antiseize on the outer splined end of the torsion rod. Third try was because I'm obviously just a masochist killing time the only way I know how. Eventually, I got it figured out though.

I took the time to swap the bolts for grade 8 hardware. You can see how bad the bolt had deteriorated due to trapped water and mud in those plates:

With the passenger side done, it was time to work on the other side. There wasn't a lot of room to work over there, thanks to a transaxle and engine hanging out in close proximity so I wasn't looking forward to doing it. To add salt, this one was even more stuck than the last. Heat, hammers and lots of levers were employed and at one time, I sunk to the level of threatening the plate with a cut off wheel:

But I stepped away for a bit to have a think. I used the time to prime the test wheel from the blast cabinet. First I had to weld a couple holes that someone had drilled in the wheel. I guess it was some goofball attempt at affixing a hubcap. There were only two spaced directly across from each other and one still had half of a wood screw stuck in it:

Eventually, I hit it with some sandpaper, air, alcohol and finally primer:

Then I went to hit the spring plate for a bit more. Eventually, I got that damned thing off:

So I hit it with the wire wheel, some antiseize and reasembled in reverse order of removal:

Leaving me with some lowered spring plates:

I've still got the front end to deal with, which I'm looking forward to even less as that involves more angles and maths. If I had the money, I would totally just buy one of those turnkey narrowed front ends that get advertised on the Samba. Since that's not in the cards, however, I'm just going to try to put it together in a manner that won't cause loss of life.

Hey, now that's a nice success - another milestone accomplished!
And messing with these torsion bars isn't all beer and skittles. :D

Glad you dismissed the use of that angle grinder...

schwim wrote:

But I stepped away for a bit to have a think.

That's exactly my course of action... At least since I grew older... :lol:

Assuming you adjusted the torsion bars for some (slightly) negative camber too
it looks like Zippy will sit quite low with these spring plates. :shock:

The blasted rim turned out nice! And good to see the "welding cart" (as well as the "media blaster" :lol:) in action. 8-)

And by the way.. The deck for the hot tub is very well done too. I bet the family loves it! ;)
Someways I'm missing "thumb up" and/or "applause" emoticons...

Maddel wrote:

Assuming you adjusted the torsion bars for some (slightly) negative camber too
it looks like Zippy will sit quite low with these spring plates. :shock:

Oh, it's going to be low. Lower than it should be and not a centimeter more.

Maddel wrote:

The blasted rim turned out nice! And good to see the "welding cart" (as well as the "media blaster" :lol:) in action. 8-)

It was nice to get some use out of them. The blast cabinet didn't do so hot today. It quit passing media so I went with a grinder and some sandpaper.

Maddel wrote:

And by the way.. The deck for the hot tub is very well done too. I bet the family loves it! ;)

They love it and used it today, in fact. Family fun time!

Maddel wrote:

Someways I'm missing "thumb up" and/or "applause" emoticons...

I need to make up some fun smileys for us. I'll see if I can't whip something up.

I did a bit more cleanup and disassembled a seat bottom to clean it up. The outside storage was not kind to my parts:

The rust looked more like the growth you would find on something that had lived it's life underwater. It actually had bulk to it:

I got it apart and put the base into the blast cabinet but it quit spitting out media so I went with an angle grinder and some sandpaper.

I cleaned it up and painted it with some rust converter-type paint.

Then I had to stop for the aforementioned hot tub family time and to watch the solar eclipse(full eclipse here, the family all had their viewing glasses on). I'll try to knock something out tomorrow as well, time providing.

If it seems like I'm hopping around with no direction or grand scheme, that's because I am. I'm still trying to get my mojo back on this journey. I'm trying to find a place to store all this stuff while keeping some kind of work space available to me but it's just super tough to see past the mountain of stuff to do. I'm hoping that as I keep whittling away at it, it will one day seem like a manageable affair.

'Till the next day!

It's been raining to beat the band for the last few days so I needed something to do on Zippy that wouldn't require stepping outside. I looked at the top of the parts box and saw the hockey stick and clutch & accelerator cables and figured that was as good a plan as any.

I took the nosecone off, cleaned it, removed the gasket and replaced the mismatched mount nuts.

Assembly is the reverse of removal:

I imagine I already mentioned the reason it needed a new hockey stick. I suspected that a freehand drilling of the detent put it in the wrong place, causing my shifting issues. This is a picture of two sticks clocked identically to show you just how bad the PO did at locating that detent. They should be in identical locations:

I installed all the rubber grommets, greased & fed the cables.

And figured that since I had come this far, I might as well install the transaxle. It gained weight from the last time I lifted it 3 years ago. Either that or gravity is getting stronger.

I installed the shift coupler. It seems to be going into 4 forward gears with no issue. I'll have to adjust for reverse.

I also started installing the foot controls but will be taking it all apart a few times before it's sorted. I've also got to find all the stuff that I've lost over the years like the bowden tube, proper clutch cable wing nut, brake pedal stop plate, etc. I'm getting to the point where it needs stuff I no longer know the location of.

'Till the next day!

Damn, nice work and great progress.
Every bit you do gets you one step closer to being done even if you only have time once a month.

Time is my biggest issue too.

.

Hey Schwin,

It must be cold rainy and depressing in your area as it looks like Zippy has been hibernating.

For me, during the winter time I can barley motivate myself to do any VW work at all even just driving it..
Too cold, way to wet, and the grey is just depressing.

Are you planning to work on Zippy when the weather gets nicer?

65VW wrote:

Hey Schwin,

It must be cold rainy and depressing in your area as it looks like Zippy has been hibernating.

For me, during the winter time I can barley motivate myself to do any VW work at all even just driving it..
Too cold, way to wet, and the grey is just depressing.

Are you planning to work on Zippy when the weather gets nicer?

Hey there sir!

It has been horrible all winter and spring here. Just this week, we had our first decent days.

My plans for Zippy are somewhat muddled right now. The family is considering moving back to Florida which, due to finances, would require us to take only drivers so I'm seriously considering getting the pan running, then welding only the stuff needed to get the body back together(like heater channel bottoms, rear quarter with fender mounting locations) and leave the rest to do once the car is running and driving.

It's not optimal but to be honest, I'd rather have it running and driving in any condition than have to leave it because we don't have a place to store a project during the location change.

My first order of business is to try to make a front end from all the parts I have. I've been holding off on it because it seems like a job for someone with more smarts and tools than me.

Sounds like you have a full plate!
Are you moving there for work or did you just have enough of your current location?

Florida would be a nice sunny change for sure and sounds nice, and I hope you do get Zippy done enough to take with you along with all the extra VW bits we all seem to collect over the years.

Good luck and I hope all goes well when you do the move.

PS: I right clicked to copy some text in this post and I saw a "Read Aloud" option so clicked it...Cool!
Is that something you added to this Forum?

65VW wrote:

Are you moving there for work or did you just have enough of your current location?

Two things, mostly. My daughter is coming of college age and is considering UF Gainsville and my wife has wanted to move back since I moved us from there 15 years ago :)

65VW wrote:

Florida would be a nice sunny change for sure and sounds nice, and I hope you do get Zippy done enough to take with you along with all the extra VW bits we all seem to collect over the years.

We're going to be doing a brutal purge to make the move doable but I'll be doing my best to keep the important stuff. A bunch is in the air right now so I don't have an idea of how much I'll need to get rid of so my fingers are crossed.

Thanks a bunch for the well wishes!

65VW wrote:

PS: I right clicked to copy some text in this post and I saw a "Read Aloud" option so clicked it...Cool!
Is that something you added to this Forum?

That would either be a browser or browser extension deal, I think. I don't see anything like that on mine. What browser are you using?

schwim wrote:

...The family is considering moving back to Florida...
...My daughter is coming of college age and is considering UF Gainsville and my wife has wanted to move back since I moved us from there 15 years ago...

Wow! Now this is surprising news... :o
Thus no barn doors at the basement... :)

schwim wrote:

We're going to be doing a brutal purge to make the move doable but I'll be doing my best to keep the important stuff. A bunch is in the air right now so I don't have an idea of how much I'll need to get rid of so my fingers are crossed

I really hope you'll find a way to keep Zippy.

The barn door may still happen, I have to get the pan out of there somehow :D

I'm going to do my best to keep him. I'd love to drive a rag top down in the sweltering heat and humidity of the Florida summers :D

Good luck with everything and for sure get an AC when you setup your workshop there.
Hopefully the house prices in Fla are not thru the roof.

I was using IE at the time and with Chrome I do not have the Audio option and I think you are right that it is a browser setting.
Still kind of cool.

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