Project Myrtle: Jim’s Baja Bug Build

For now. Can’t quite justify spending a packet on discs having not driven a bug with drums. If it’s crap I can always convert a bit further down the road.


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I got rid of mine as soon as I could afford to, even properly adjusted, modern cars would stop and I wouldn't.

 

Time to make the arse of this bug look a bit more like a baja!

I spent a fair bit of time getting the rear fenders and engine cover aligned nicely.


Then out with the angle grinder to chop the rear apron off.





Much better.

 

I'd stick with drums, a beetle weighs nothing at the front, drums are FAR more effective IME and in return you have to adjust them occasionally which, let's be honest, isn't going to bother someone like yourself. Add to that I expect you can adjust them from outside through holes in the drum. This is a real boon IMO. I wouldn't fit discs to anything without also fitting a servo personally and then you start to wonder why you went down that road at all. To save adjusting brakes? So you can race downhill in the alps without brake fade? It doesn't make much sense to me.

 

Advice from Nathan Baker on the Baja UK forum seems to be the same. He said he's had friends drive his baja that's on drums and has had to tell them to go easy as they're used to the more progressive braking that discs give.
The front brake backing plates have 4 holes in them, 2 to get to the adjusters and 2 to see the brake shoe thickness so are nice and easy to maintain.

 

My one and only Beetle sat for ten years. We pumped the tyres up, checked the brakes and HB did someting and set off being towed. Only while turning into another road (it didn't) did I realise the fronts had locked right up - I was only touching the brakes to keep the tow taught.

 

No need for a servo, I agree, that would spoil a Bug. I fitted a larger master cylinder and then moved the larger front drums' wheel cylinders to replace the rear wheel cylinders to restore the brake balance.

Smaller original rear cylinders went to a new home that could make use of them.

 

Look what turned up just in time for the bank holiday weekend!
Enough cable to hopefully make a new wiring loom for the baja. That should keep me busy for a while.

 

The Baja’s MX5 seats have been on the back burner for a little while but I found a bit of time to get the drivers back sewn up and both covers installed. The backs are made from 14 individual pieces, by comparison the T25 seats I’ve been doing recently only have 4!

 

Yeap I’m taking on upholstery work. Drop me a PM with some pics and an idea of what you’re after.


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would you come down under and do mine please?

 

James... surely if he’s paying travel expenses?!

 

I’d love that!


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I’ve been slowly bringing home all of the baja fibreglass bolt on panels to start prepping them for paint. A few of the wings have cracked bolt holes so I’ve been doing my first fibreglass repairs. Surprised at how easy it was which makes a nice change!



I’ve corrected a few minor imperfections with some glazing putty and then just sanded everything back ready to get some primer on it all the next time I have the paint gun out.

 

Chasing what I hope are the final major rust repairs on the Baja shell.

The classic rusty beetle roof meant chopping out a section of the roof, guttering and rear quarter. I’ve rebuilt the rear quarter section, and now just need to fabricate the guttering and roof to close it all up.




While on this side of the bug I noticed some blistering of the paint along the window aperture so stripped the paint off to investigate.


Cue chopping out 75% of the window aperture and welding in fresh steel. Just a few more repairs to go in to close this area up.

 

Hopefully only a day or so left on the shell metalwork.

Yesterday’s effort saw the window aperture finished off and the guttering and rear scuttle all welded in.




I’ve started stripping the paint off the O/S ready for shaping and priming.

 

That last photo, Jim, is access available to the outer rear panel beneath the pop out rear window once the interior trim is removed? I can't see if it's double skinned or not?

I dinged my panel, don't ask me how, but I was met by my flying offside rear hub cap while at a slightly odd angle of attack to the road, it put a half moon shaped ding into the panel. I wonder if it's possible to remove the trim and reshape the panel.


Edit looking good by the way

 

I remember being overtaken by one of mine on a dual carriageway, I didn't get it back!

 

Mine was one of those small center caps, made a nice ding, which I have left up until now, to remind me not to be an idiot when cornering