Pop-out windows re-sealed

I replaced the rubber seals (glass-to-frame and frame-to-body) this weekend on the pop-out windows.
Here's a 'before' shot of the pop-out window. Note the rotten rubber between the frame and glass. The outer seal was even worse- it chipped off easily with a screwdriver.

The screws holding the frames together were rusted shut and I needed to use ez-outs to remove them. Here is a frame disassembled:
Once the machine screws finally came loose. I polished the frames using aluminum wheel polish and some elbow grease. Some of the film/pitting came off, but not all. Could not find any brasso anywhere to try :(

I ordered replacement screws for about $6 from McMaster-Carr.


New rubber from West Coast Metric is installed, and the window is back in place. Only the driver and passenger doors to go!

VolksWeekend 08 August

It's been a while. With wife and sons out of town this weekend, I had a chance to spend time in the garage and knock out some VW projects. I finished fender beading on the front and rear passenger fenders and installed the gaskets on the rear hatch and forward trunk.


Rear hatch, before new gasket.


Rear hatch, after gasket, passenger fender beading, re-installed tail lights.

Front hatch before new gasket.

Front hatch after new gasket.

Front of the car, new fender beading on pax side. Finally got enough junk out of the trunk to close the lid!

New windshield

I finally got a new windshield installed. Now I can drive around without using ski goggles!





~ $236 from All Star Glass.

Still waiting for gaskets for the side pop-out windows...

Driver's rear fender

Today I re-installed the driver's side rear fender, including replacement engine air intake seal and black fender beading.

The engine intake seal (black rubber gasket beneath window) was $28 per pair from ISP west.

Here's the fender installed, with black fender bead (gasket) along the seam.

Tomorrow should be new windshield time!

Rear Windows, 12/26/08

My dad stopped by today to help re-install some of the glass. Could not do it with just myself and my 9-year-old son... needed some extra oomph! For those who have not tried this before, it takes a lot of silicone spray combined with a ton of pushing and shoving.



The black strips in the photo are electrical tape I used to hold the headliner (interior vinyl) in place. That's 3 windows down, 5 to go!

The Fat Lady Sings!

Ok, I found out that this body style of VW Squareback is called a 'fat chick' due to the larger trunk/'snout'. Could not resist using this in the title. Here are the photos straight out of the Escondido MAACO paint shop (windows still removed).


MAACO said they would re-touch this area on the gas lid for free. Otherwise no complaints for the $1500 they charged me.

10/13 Off to MAACO

I had a local shop quote me over $4k to sand and paint the vehicle. This included $1200 in materials (!).

I want to drive this thing before gas gets to be $10 a gallon and asked them for a referral. They said the local MAACO in Escondido should be able to do a serviceable job for under $2k. They quoted me around $1500 to do some sanding, prep, and re-paint the factory color. We'll see how it goes.

Not having a windshield installed made it a bit challenging to drive 6 miles to the local shop. Ski goggles came in handy!

Here's the 'before' shots of the condition of the squareback before drop-off:




Dig the plate?