Post by Stiffy on Feb 6, 2017 22:10:46 GMT
Removing a Bond Bug Body
If you have had a Bug sitting around for years or perhaps you have found one stored its likely to have a multitude of problems from rusty chassis to star cracking, Maybe a Seized engine and non standard parts fitted. Fortunately all is not lost. There are plenty of folks in the Bug Club, On the Facebook groups and on this forum who are willing to lend a hand and offer there expertise. Over the years I have found the Bug crowd to be a pretty helpful bunch and Joining the Bug club is well worth it.
The following relates to removing the Body of a complete Bug with everything attached.
If your doing a full restoration I would recommend removing the side screens and Windscreen.
Thanks to Dick Bedford and the Bug Club who did the original version.
If you haven't already become a Member I would recommend joining the Bug Club. A joining form is located on the site
1. Disconnect the Battery and remove
2. Disconnect the Horn
3. Disconnect Front indicators and remove them (This gives hand holds for later)
4. Remove interior trim Seats, Engine Cover etc.
5. Remove the Canopy (Optional But makes Restoration easier if work is required on it)
Undo canopy support strut, Disconnect Electrics from Wiper Motor etc, Disconnect Windscreen Washer,Remove 4 hinge nuts and lift of the canopy. Its quite likely if the Bug has never been restored that the bolts on the hinges are going to be rusted in so it maybe wise to soak them in Plus gas or diesel for as long as possible. You will need two pairs of hands to remove the canopy.
6. Remove Air cleaner, Windscreen washer bottle and Distributor.
7. Disconnect Choke Cable and Accelerator. Remove Accelerator Peddle assembly.
8. Undo heater hoses and 2 wires to the heater.
9. Undo Earth strap to chassis and top of gearbox. Disconnect wires to dynamo or alternator plus brake light and oil pressure switch.
10. Remove gear knob
11. Disconnect the handbrake cable - The easiest way is to remove pin under the brake lever and pull out the pulley.
12. Unbolt the Seat Belt Strap from the chassis- 2 Bolts at rear
13. Drain Petrol tank. Disconnect fuel pipe at the sender unit.
14. Unscrew the Brake and Clutch pipes and feed through body.
15. Remove the Steering column - Remove the 3 bolts that hold box to the chassis this is made a lot easier by removing the off side headlight as it allows easy access. Remove the cross member support plate by unscrewing the 2 Bolts and Remove the Drop arm from the box - You may need a puller for this job.
16. Drill out the pop rivets that hold the body to the chassis There is a row in the boot, Some in the foot wells and others under the seats.
Next you will need the help of an assistant to lift the body. Lift at rear and pull gently back. A bit of jiggery is needed to clear the drivers side footwell, As you lift make sure everything is disconnected and free. If the indicators are removed these can be used as hand holds..
Place Body on foam - The seats can be used for this.
Once the body is removed you can really see the state of the chassis and underside.
And now the fun really starts.