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VW Beetle Wizard Roadster - Part 4

Updated on January 18, 2015

Build a VW Beetle Wizard Roadster

This is the fourth installment about my project to build a VW Beetle Wizard Roadster. If you have any interest in VW Beetle's you will certainly want to take a look at this. There is loads of information and pictures about the project along with an opportunity to see loads of other VW Beetle stuff.

Previous Wizard Installment

Check out these other Wizard lenses.

If you have already seen this page or are looking for the previous installment chronicling this project you may want to check out this link:

Getting On With The Bodywork.


You can see that the rear deck is now positioned. A lot of cutting is required to get to this stage, Take it easy and cut a bit at a time, don't get carried away.


You can see in this picture that the bodywork is starting to take shape. The screen surround has been fitted, and the rear deck and rear wings have also been put in position. It is important at this stage to check, double check and check everything again. Mistakes at this stage can be time consuming and costly to fix later on.


In this picture you can see the rear wings in position and the extent that the rear bodywork has had to be cut back. Quite a daunting task if you have never done anything like this before.

At this point I am trying to decide what to do with the rear valance. The engine I have will be difficult to fit within the standard bodywork and I also want to build a custom exhaust system which won't line up with the existing cutouts. So I may cut it out and fit a custom one.


In this picture you can just make out some of the panel damage that was suffered in the accident. This will require further work to put right.

Need some help with your project?

If you are interested in VW Beetle restoration, customising or just want to keep your trusty bug on the road, this book will help you along the way. Full of valuable information you will refer to over and over again.

Final Checks - Final checking and adjustment before fixing.


Another view of the rear end. Again you can see the extent of the metal work that had to be cut away to allow the new body panels to be fitted.


The inner body work has to be cut as well as the outer body work. This can be difficult to get to, so you may want to remove the outer body work first. It is not too important that the cuts are neat and tidy as they will all be covered by the new body work.


The new rear deck overlaps the rear wing. This can make fitting the normal wing beading more difficult as it normally sits between the wing and the bodywork. You can either modify the beading to allow it to fit, or, as I decided, you can fibre glass everything together, sand to smooth and have a much cleaner look. If you go down this route it has to be done properly as just using filler will lead to cracks developing later on.


A side view of the new bodywork. The engine cover has been positioned and propped in place with a length of timber and is not really sitting in its correct position, but it gives you the idea.


From the front you can see that the new rear deck extends to cover the old body work all the way to the door pillars. New seat belt fixings have to be welded in before the rear deck is fixed in place. The original upper seat belt mounts were cut away with the roof.


Final view of the rear body work before it all gets fixed in position.

The Next Volkswagen Beetle Wizard Installment

If you have already seen this page or are looking for the next installment chronicling this project you may want to check out this link:

Do you have any questions? Do you have anything to add? Or do you have any comments in general? Even if you have left comments before this is your opportunity to leave your comments or questions. I will try to get back to you if you have any questions.

If you have found this lens useful or interesting and you would like to help other people find it, please give it a rating using the stars at the top of the page.

Even better you can use the function in the right hand menu to email it to a friend.

What do you think? - Wizard comments required....

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    • profile image

      anonymous 

      8 years ago

      @anonymous: It is important that the floorpan is strengthened. My project had a Steel 2" x 2" box section welded to the underside of the floorpan down the full length of the heater channels. This replaces a lot of the strength lost by taking the roof off. Good luck with your project.

    • profile image

      anonymous 

      8 years ago

      you know the roof of a vw is allot of support to the car did you put any

      kind of support underneath the car i started one about 3 weeks ago

      when i raised it up on a car lift you can see it give about a 1/2 inch

      at the door's it look's like in time that it will become a problem email asp

    • profile image

      anonymous 

      9 years ago

      Looks great can't wait to see somemore Where did you get the kit . please let me no

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