Install Guides
Technical Reference
Install Guides
Notes from the bench. The procedures, tips, and torque specs we use in our own shop — written for people doing the work themselves. These aren't replacements for a Bentley manual, but they cover the parts we sell most and the questions we get most often.
01
Body & Sheet Metal
Beetle · All Years
Heater Channel Replacement
Cutting out and welding in a full heater channel without warping the body. Bracing, sequence, and the order to weld in to keep the door gaps where they need to be.
Difficulty AdvancedTime 2–3 days
Not written up yet. Call the shop and we'll walk you through it.
Beetle · 1968+
Frame Head Repair
Identifying frame head cracks versus surface rust, when to repair versus replace, and how to fit the repro frame head pieces we carry to the early or late-style tunnel.
Difficulty AdvancedTime 1 day
Not written up yet. Call the shop and we'll walk you through it.
Bus · All Years
Rocker Panel Replacement
Full-length rocker replacement on Type 2s. Cuts, fits, sequence, and the trick to getting the inner-to-outer rocker spot welds right.
Difficulty AdvancedTime 1–2 days per side
Not written up yet. Call the shop and we'll walk you through it.
02
Chassis & Pan Work
Beetle · All Years
Tunnel Access Plate Installation
Cutting and welding in our access plates to get at the shift coupler and clutch tube without dropping the pan. The covered approach in our blog post, written up step-by-step.
Difficulty IntermediateTime 2–4 hours
Read the blog post →
Beetle · All Years
Floor Pan Replacement
Pan-half replacement with the body on versus off, when each makes sense, and the bracing you need before cutting if you're doing it body-on.
Difficulty AdvancedTime 1 day per side
Not written up yet. Call the shop and we'll walk you through it.
Buggy · Custom
Pan Shortening Basics
What to cut, what to preserve, where the structural points are, and how to set up the jig so the rear end comes back square. Not a project for a first build.
Difficulty ExpertTime Plan for a week
Not written up yet. See how we shorten chassis in-house, or call the shop.
03
Engine, Fuel & Ignition
Type 1 · 1600
Engine Tin Installation Order
Which pieces go in first, why the upper cylinder tin always seems to fight the lower, and the three bolts everyone over-torques.
Difficulty IntermediateTime 2–3 hours
Not written up yet. Call the shop and we'll walk you through it.
All Carbed · Dual
Dual Carb Synchronization
Using a synchrometer to balance dual Webers, Dellortos, or EMPI HPMX kits. The mistake that wastes the most time: not setting the throttle linkage zero first.
Difficulty IntermediateTime 1 hour
Not written up yet. Call the shop and we'll walk you through it.
All · Distributor
PerTronix Ignitor Install
Swapping points for a Pertronix module on a stock 009 or SVDA distributor. Wiring, gap-setting, and what to do about the ballast resistor if you have one.
Difficulty BeginnerTime 30 minutes
Not written up yet. Call the shop and we'll walk you through it.
04
Suspension, Brakes & Steering
Beetle / Buggy
King & Link Pin Rebuild
Pressing out the old, reaming the new, and the torque sequence that keeps the beam from binding on the road. Skip the reaming step at your own risk.
Difficulty AdvancedTime Full day
Not written up yet. Call the shop and we'll walk you through it.
All · Front Disc Swap
Wilwood Front Disc Conversion
Drum-to-disc conversion using the Wilwood kit we carry. Master cylinder considerations, proportioning, and the line you'll need to re-route.
Difficulty IntermediateTime Full day
Not written up yet. Call the shop and we'll walk you through it.
Beetle · 1968+
Steering Box Adjustment
Getting the play out of a tired steering box without making it tight. The two adjustment points, what they actually do, and how to test the result on the ground.
Difficulty IntermediateTime 1 hour
Not written up yet. Call the shop and we'll walk you through it.
Working in your own garage?Pair these with the original Bentley or factory shop manual for your year. If something doesn't match what you're seeing on the car, stop and call us before forcing it — an undocumented previous modification is the most common reason an install doesn't go to plan. (657) 438-7002, Mon–Fri 8am–5pm Pacific.
05
Drivetrain & Shifting
Watch & Learn
Video Walkthroughs
Several of these guides have matching video walkthroughs on our YouTube. The tunnel access plate install is the most-watched — we'll be adding more over the coming months. Check the blog for new posts as they go up.
Can't Find a Guidefor what you're doing?
This list grows as we add more in-house documentation. If you're working on something that isn't covered, send us a note — if it's a question we get often, it'll probably get written up next. If it's specific to your build, we'd rather just talk it through with you.