G Day from Sunny Western Australia everyone. I thought I would start a small build thread after the very warm welcome I received from the members here in the newbie introduction section (cheers guys, motivation can come in many forms and positive comments and a friendly group is a great start, well done). This will be more a photo journey than a how to, I am not a mechanic or fabricator but I love to give things a go and I'm trying to do most of this myself with some support from a good mate who is a Volkswagen tragic also. I imagine the finish threads will be more in the 2030s than 2020s. But here goes. This is what I have started with.
1968 Beetle pan.
Australian mad fiberglass Manta body (in various states of disrepair.
The rest I will need to source.
(https://i.postimg.cc/QNBzd0mL/Messenger-creation-6988330325465549902.jpg) (https://postimg.cc/bdhg604L)
(https://i.postimg.cc/fTmgxy1x/1.jpg) (https://postimg.cc/KRcNbGGz)
(https://i.postimg.cc/Ls6CKTh9/20260508-160723.jpg) (https://postimg.cc/w1ZcDDhZ)
Just need 4 wheels and a couple of seats, a bit of wiring and an engine...
The body looks attractive and unlike MantaRay's I've seen in the UK. But buggys are all about difference and individual character so keep the images and story coming.
Don`t rub it in. It`s tossing it down with rain up my way and has been for days :'( :'(
Looks like a nice clean chassis
Has it been shortened yet?
No Yaroon this one will not be shortened. In Western Australia only buggies that have proof of previous registration as buggies can have the shortened pan. I will need to get this engineered as the standard pan so I will actually need to lengthen the fiberglass body unfortunately.
The Aussie Mantas originally had a curved windscreen with a fiberglass surround. I have popped a couple of pictures below. On mine, this has been broken off over time so I will convert to a flat section and use the traditional flat buggy screen.
(https://i.postimg.cc/bNcJ5ctH/Screenshot-20260604-065500-Google.jpg) (https://postimages.org/)
(https://i.postimg.cc/HswxDZw0/Screenshot-20260604-065419-Google.jpg) (https://postimages.org/)
(https://i.postimg.cc/jjmKJP6j/image.jpg) (https://postimg.cc/cKRPpKbq)
Quote from: Hugh on June 03, 2026, 08:05:42 AMJust need 4 wheels and a couple of seats, a bit of wiring and an engine...
The body looks attractive and unlike MantaRay's I've seen in the UK. But buggys are all about difference and individual character so keep the images and story coming.
You make it sound so simple :) I do like the shape of this one. They are reasonably rare here. most have the taipan or Manx, so I thought it was worth saving. The only thing I wasn't sure about was the original curved windscreen and I'm guessing the previous owner of mine felt the same way 30 years ago and tried to remove it so Ill work with what I have and learn to fiberglass. (who said they cant teach an old dog new tricks hey)
Quote from: Paul1953 on June 03, 2026, 11:21:36 AMDon`t rub it in. It`s tossing it down with rain up my way and has been for days :'( :'(
Yea, I feel you mate, bloody terrible morning here today.
(https://i.postimg.cc/qRqhpsJ6/20260501-062637.jpg) (https://postimg.cc/ZBkKcyyJ)
(https://i.postimg.cc/zX2J1sL0/20260506-174651.jpg) (https://postimg.cc/3dpMXbFv)
So having been buried for a number of years the gearbox and front beam were a little bit worn and dirty. Surprisingly enough though when I opened the gearbox, I actually wondered if they had kept digging it up and changing the oil and re burying it.
A real testament to Volkswagen engineering I guess it really did look new inside.
(https://i.postimg.cc/kgMfWHwf/2.jpg) (https://postimg.cc/xc7v2twz)
(https://i.postimg.cc/43mPShDQ/4.jpg) (https://postimg.cc/PLn1LNrC)
The steering box however did not ;D
(https://i.postimg.cc/63Z09x50/3.jpg) (https://postimg.cc/Fd9cZqSd)
Quote from: stolts on June 04, 2026, 12:39:37 AMThe steering box however did not ;D
(https://i.postimg.cc/63Z09x50/3.jpg) (https://postimg.cc/Fd9cZqSd)
From my experience, over here that would be a good one ::) ;D
Strip the steering box and give it a good clean it will probably be fine having stood for years rather than used and abused.
Strip it, clean the old grease out, reassemble with new oil seals and refill with the thickest gear oil that you can find or John Deere Cornhead grease if available, adjust and you're good to go.
Tip: if anyone is struggling to find something to tighten the screw on the big adjuster try a lawnmower spark plug box spanner, mine's a perfect fit ;-)up
(https://i.postimg.cc/WzHfPs72/IMG-20260608-145044.jpg) (https://postimg.cc/BP2CT9yy)
Cheers everyone, good advise with a good clean and a few parts, seems as good as new.
(https://i.postimg.cc/wv2r7VR0/9.jpg) (https://postimg.cc/Q9BmzcbT)
Quote from: Manxdavid on June 08, 2026, 01:38:13 PMTip: if anyone is struggling to find something to tighten the screw on the big adjuster try a lawnmower spark plug box spanner, mine's a perfect fit ;-)up
Now that is bloody ingenious, I love it.
Bit more of an update, The wire wheeling of parts to see what can be salvaged and what needs to be replaced. I am really trying to salvage any parts I have and only replace what is beyond safe practical use. (or if I cant make it look shiny enough) This project is really about salvaging an old classic that would have otherwise been lost to the ground and rusted away.
Gearbox got a bit of a touch up. taking a punt at this stage that it was in reasonable condition inside. Im sure most of you are aware once you scuff off that first bit of crud, there is no turning back and my OCD wont rest until its clean ;D .
(https://i.postimg.cc/N0mQSm3k/5.jpg) (https://postimg.cc/mcZxFz2P)
(https://i.postimg.cc/WbkYM80p/10.jpg) (https://postimg.cc/QHjqDp6v)
And half clean and painted
(https://i.postimg.cc/zXQ5fx8r/20251101-135630.jpg) (https://postimg.cc/D81RjdSj)
(https://i.postimg.cc/tgQj37sv/20251101-141540.jpg) (https://postimg.cc/4Y5qZfbp)
Unfortunately I didn't take any photos of the inside of the gear box but I think I mentioned before it was clean as a whistle. even the oil looked fresh, so a quick strip and clean and new gaskets and shims and we were away.
(https://i.postimg.cc/HsFDmj9d/20251231-122304.jpg) (https://postimg.cc/JG3dcrF2)
Next stop, front beam.
(https://i.postimg.cc/KzCw2Ht5/6.jpg) (https://postimg.cc/5Yqn5p7H)
(https://i.postimg.cc/4xZCyqqB/7.jpg) (https://postimg.cc/Vd7ZHGYC)
(https://i.postimg.cc/bwqMpbS4/8.jpg) (https://postimg.cc/XpDxgr8g)
And then like magic, the gearbox was in. another job done or so it seemed as I'm sure most of you will realise my rookie mistake, I had the bloody axel tubes on the wrong side.
(https://i.postimg.cc/vTLzNqhf/13.jpg) (https://postimg.cc/D40LWctw)
Good news from down there then, gearboxes with oil in and boots in good condition to stop water and dirt ingress are generally fine
Quote from: snoopy on June 17, 2026, 03:41:46 PMGood news from down there then, gearboxes with oil in and boots in good condition to stop water and dirt ingress are generally fine
Yep, I must admit, I was very surprised. I really thought it would look like my steering box. It was also 3-400 kms inland so a bit dryer than on the coast.
Ill hold judgement until I actually get it running but so far so good.
"DUMB WAYS TO DIE"
I am slowly figuring out that working on Volkswagens requires a small amount of ingenuity and thinking outside of the box. I nearly learned this the hard way with the spring plates and a much to close call with stored kinetic energy.
(https://i.postimg.cc/wv5kP9Ty/20251227-120244.jpg) (https://postimg.cc/1nt6VhFs)
I had no sooner finished congratulating myself on how smart I was when the ratchet strap snapped, sending a spinning propellor of sprung doom my way, narrowly missing my knee then my face.
Not being a quitter and not being willing to
A. spend the money on the correct tool
and
B. waiting for said tool to arrive,
it was off to my local hardware store (Bunnings) for the Aussies out there where I came up with this contraption.
(https://i.postimg.cc/4dnJ2x1p/20260101-154708.jpg) (https://postimg.cc/Fd557m8K)
(https://i.postimg.cc/mZz9tLG7/20260101-154712.jpg) (https://postimg.cc/QVDCzrCM)
Very crude yet very effective, safer, and cheap at about $8 bucks.
And while I was there I thought "why not buy a new ball joint splitter" as I also put one to many ugga duggas into the rattle gun that morning also just missing my face and risking my rugged good looks. No one said you needed to be smart to build a car. ;-)up
(https://i.postimg.cc/nrbhstvk/20250914-194635.jpg) (https://postimg.cc/mzjsqJpz)
With the rear end sorted, it was onto the front Beam assembly and mounting the shocks and Disc Brakes.
(https://i.postimg.cc/R0hQM2Q6/20250926-121030.jpg) (https://postimg.cc/zLmR7tQ8)
The original plan was to go with the Red beam and components but Black looked so much cleaner.
(https://i.postimg.cc/8cS6rYWY/20251007-180458.jpg) (https://postimg.cc/sQTXkwTP)
I now know the purpose of the holes in the rear support arms, Thanks Volkswagen - you really thought of everything.
(https://i.postimg.cc/9FX45ZBr/20251007-180454.jpg) (https://postimg.cc/qgYB2tST)
Yep..... There have been a lot of serious injuries when folk have been too close to spring plates when trying to get them off. I was lucky back in 1970 on my first try. Just by chance my body wasn`t in the way of a spring plate that came off it`s stop like a rocket.
It's not just VW springs.
Always wondered why spring compressors are sold in pairs so the spring can ping out when a set of three makes it safer
And the Stoltswagen has an Engine. Now for the tear down and rebuild. It is running so wont be doing a great deal to it, just a freshen up, clean oil, new gasket set and push rod rod tubes. May go for dual port heads down the track but will get registration done first.
(https://i.postimg.cc/c4KsrGMf/Buggy-Motor.jpg) (https://postimg.cc/BX0WVyzv)
Disc brakes have been the topic of discussion in my household, do I stick with the drums all round, go with a combination disc front drum rear or just go all out and put discs on each corner. After doing the numbers as everything needed to be replaced any way, the Disc brakes are now on all-round. I'm just hoping my fasteners holding the fiberglass body are also good enough to stop the body with the brakes applied.
(https://i.postimg.cc/dVD335xG/18.jpg) (https://postimg.cc/zyZ8PF5f)
(https://i.postimg.cc/76rZBwYt/19.jpg) (https://postimg.cc/kVwCGrSW)
With the disc callipers installed, my attention shifted to the installation of new brake lines. The rear callipers needed a much longer brake hose than the drums had so I ended up fabricating and welding on a new rear mount to keep the flexible brake lines to a reasonable length.
(https://i.postimg.cc/sgSFTSB0/20260613-180956.jpg) (https://postimg.cc/5Xxk0XSw)
(https://i.postimg.cc/Jnz2CBh2/20260613-181057.jpg) (https://postimg.cc/06hfpjDY)
I'm not sure how everyone else manages this but I work away from home and fly out for 8 days home for 6. While I'm away, if I haven't times it correctly I get a notification that my shiny things I have bought are about to be delivered while I'm away. Now this is very exciting for me but also brings a shred of terror because I am not home to be able to take delivery of said shiny items and hide them in the shed before Mrs Stoltswagen finds them. All I can hope is that they arrive early in my swing and she has to calm down before I get home. ;D
(https://i.postimg.cc/ZnksBsHR/20260420-122041.jpg) (https://postimg.cc/mzwyKw0f)
Coming together nicely
(https://i.postimg.cc/kg5s4dCs/20260613-181006.jpg) (https://postimg.cc/Vd3nGpd0)
(https://i.postimg.cc/90pPmLnH/20.jpg) (https://postimg.cc/Mfnftmw9)
I couldn't help myself I had to pop the body on and see how it looked. I just need to start some fiberglass work and lengthen the body to fit the full length pan.
(https://i.postimg.cc/Nfn96hTS/20260326-164907.jpg) (https://postimg.cc/VdjkwVKW)
The stance with the body on looks really good and should incentivise you even more.
Could you get some of your shiny bits delivered to a friendly discrete neighbour. Or think of something fairly big (a BBQ, say) that you can suddenly produce to your dear wife saying you have been buying this large item in many small parts over recent months and have now assembled it ?
Good to see progress being made, you may find the coil overs make it too hard so it bumps and bangs when driving.
Quote from: Hugh on July 29, 2026, 07:04:22 AMThe stance with the body on looks really good and should incentivise you even more.
Could you get some of your shiny bits delivered to a friendly discrete neighbour. Or think of something fairly big (a BBQ, say) that you can suddenly produce to your dear wife saying you have been buying this large item in many small parts over recent months and have now assembled it ?
You may well be onto something there. we certainly are a devious bunch are'nt we ha ha.
Quote from: snoopy on July 29, 2026, 07:27:47 AMGood to see progress being made, you may find the coil overs make it too hard so it bumps and bangs when driving.
Yea I think I got caught up in looks and being a two wheel fan as well I love the look of coil overs. After reading a lot of info in here, I have now also bought a set of normal ones just in case.
The springs are easily removed from the shocks then they are fine but here in the UK water and road salt means the piston chrome rusts and peels as there are no dust covers.