Removing Doors From Vintage VW Beetle

Got the doors off, now I can clean up rust.

Removing the rusted door hinges from a vintage Beetle is a chore, but well worth it. Whether done all at once or over time, removing the doors will provide a lighter weight body, easier access to hard to get areas, and great opportunities for a better restoration.

I tried to remove the doors a few months back, but it was just too hard. I tried oil, rust remover, impact screw drivers, and brute strength, but nothing worked. I got a few screws out, drilled out a few more, but still was not able to get a single door off.What a chore, but I put it off until I gained more experience. Besides, there was enough other work to do like learning to weld.

So, now after conducting more research, learning patience, and getting some better tools, I started again. This time I conquered the rusted bolts like a champion. I used oil, a blow torch and the impact screwdriver with a determined rhythm. I heated with the torch, banked with the impact driver, applied oil, hit with the impact drive, burned it again...over and over until the screws let loose. There's probably a better way, but I got those doors off.

The Daily Grind-Stripping Paint and Rust From Classic VW

VW Beetle is 3/4 stripped down to metal.

I've been spending a lot of time trying to get the paint off the car. I've tried a few tricks including sanding and chemical stripping. I've even tried getting someone to media blast it, but that also proved daunting. A side job like my Volkswagon is not a major money maker and therefore pretty tough to find commitment. So, that leaves me.

I spoke with a fellow tinkerer, albeit one with a lot of experience. He recommended an industrial grinder and wire brushes. So, that's what I've been working on. It's a lot of work and requires lots of endurance and strength. I've also had to develop a few techniques to both reduce fatigue and keep the work going along. The results are immediate and satisfaction guaranteed.

I've opted for a Chicago Electric angle grinder with wire brushes, both from Harbor Freight. Originally I could only grind for a half hour at a time, but now I can go for an hour or so. I wear safety goggles, gloves, hearing protection and a good respirator.

Happy grinding.