1969 VW Beetle
Project Overview
This document provides a detailed account of the work performed, parts used, and diagnostics conducted on the 1969 VW Beetle.
Mechanical and Electrical Repairs
· Spare Tire Installation: Removed old tire and installed new tire; torqued wheels to manufacturer specification (75 ft-lbs.).
· Brake Light Switch Replacement: Removed turn signal switch assembly, replaced with new switch assembly, and wired to harness. Required modification of surrounding material to fit the switch inside the steering housing.
· Turn Signal and Hazard Switch Repairs: Diagnosed electrical issues with turn signals; rewired flasher and hazard switch wiring, fixed front left and right rear turn signals, and repaired turn signal stalk wiring. Disassembled front right turn signal, fished out brake switch wiring, and tested brake switch wiring. Installed a new emergency switch and worked on wiring. Reinstalled hazard switch and tested hazard and brake lights (brake lights and headlights working; front turn signals pending part order).
· Door Latch and Mirror Installation: Removed window handle, door panel, and plastic weather shield. Removed the window from the track, installed a new latch, and reassembled the driver side door. Installed rear view mirror on driver side door (required locating and drilling through body filler to mount); installed passenger side mirror and mounts.
· Glove Box and Latching System: Removed interior of glove box and latching system, bolted new latch using M4 bolts with washers and lock washers. Installed cable for trunk release (ordered roll pin), and new handle for gas tank door release cable.
· Trunk and Hood Release: Ground rivets off trunk release handle and replaced with bolts. Installed hood latch cable and handle inside new glove box; installed and adjusted glove box door to ensure level fit. Installed cable to hood latch.

· Electrical Upgrades and Troubleshooting: Ran power and signal wire to toggle switch to control center-mounted orange light; drilled hole for toggle switch for windshield washer bottle, ran power and ground wires, and completed installation (washer bottle operational). Diagnosed fuse box shorts (found terminals with varnish on brass blades), cleaned terminals to restore power to fuse block (work in progress).
· Wiring Harness Work: Cleaned up harness, wired relay and flasher (fuse continues to blow; ongoing diagnosis).
· Fuel System Work: Removed carburetor and sound deadener to fix wiring connections; checked fuel pump wiring and reconnected to run; installed new battery. Tried to get engine running (not getting fuel)
· \Worked on directional/running lights).
· Bottle Washer Installation: Installed toggle switch for washer bottle, fabricated mounting bracket with welded nuts, painted bracket, and completed wiring.
· Knee Panel Repair: Cut material to cover hole in knee panel, welded material, drilled to exact size, ground welds, and painted for a clean finish.
· Filler Neck Installation: Installed filler neck hose, painted metal pipe, installed neck and hoses with clamps.
· Axle and Transmission Work: Oil change, removed wheels and axle shaft to replace transaxle seals, cleaned rear axles, installed new seals, filled with oil-gear lube, reinstalled axles and wheels, and conducted a test drive.
Parts, Materials, and Supplies Used
· Two tires for the rear
· Two tires for the front
· Emergency switch
· Turn signal housing (front)
· Outside mirrors and mounts
· Radio delete plate
· Oil filter, Engine oil
· · Assorted bolts, washers, lock washers, cable, wiring, relays, toggle switches, hose clamps, paint, welding materials.