Category: Disassembly

Sunroof drains

Background Sunroof Beetles have drains at the front and rear corners that are connected to tubes running down the A and C pillars. When the rear section of the Beetle roof is removed, a...

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Roof skin cut

Background Review the substructure roof cut discussion. The roof skin cut is the only one in the Ute build that requires precision (within a 1/8″); other cuts can vary by 1/2″ or more without...

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Water management

Background One consequence of cutting the Beetle in half is that a new barrier between the inside and outside is created along the truck bed front wall. The chassis under the truck bed is...

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Harness relocation

Background See also the pre-cut preparation discussion. The Beetle’s rear wiring harness is routed over both fenders inside the luggage area, and extensions go through both sides of the hatch lid. In addition, some...

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Quarter panel/fender cut

1. Window frame cut Mark a point 2 inches past the B pillar window vertical frame and cut down through the frame infrastructure beam support. This cut must miss the B pillar support itself...

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Rear end cut

There are faster ways to chop up the Beetle, but the steps outlined below get consistent results and greatly minimize the risk of a misplaced cut, damage to the wiring harness, or injury. Always...

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Substructure roof cut

Before making any cuts, review the pre-cut preparations. Always wear suitable eye, hand, and ear protection. There are several approaches to cutting the Beetle roof. The procedure outlined below is more complicated than simply...

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Pre-cut preparation

Before chopping off sheet metal with a reciprocating saw, a number of harness relocations, markups, and small item modification/removals will make the metal cutting job go easier and reduce the chance of unintended damage...

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Quarter glass

Background The New Beetle’s rear quarter glass fixed window is held in place with a special urethane formulated for high bond strength. Typically this type of adhesive has a 1200 PSI tensile and 550...

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Rear fenders and bumper

Background There are subtle differences between New Beetle models over the 1998-2010 production span. In terms of the Ute conversion, the major impact is on the re-use of backup and side marker lights. For...

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