JBugs Video Series

1971 VW Super Beetle - Clutch Cable Access Plate Modification:

Body Chassis

Video Overview:

Replacing a clutch cable in a VW Beetle, Karmann Ghia, Thing or Type 3 requires removing the pedal assembly which in our opinion is a poor design. Wouldn’t it be so much easier if there was a hole on the other side of the tunnel? We think so, we’ve done it before and we do it again. Our tech performs a quick but simple modification to the chassis of our 1971 Super Beetle which allows quick and easy access for the future with a clutch cable access hole.

Vehicle prep: 0:54
Tunnel modification: 1:25
Cover plate modification: 2:03
Cover plate installation: 2:19


Video Tips:

Tools used in this video:

Drill
3" Hole Saw
Angle Grinder
Cut Off Disc
Flap Wheel Disc
Band Saw
Chisel
Impact Driver
Phillips Bit
Hammer
Wood Vice

Video Transcript:

Hi! I'm Sam here with JBugs.com
While we're working on the chassis of our 1971 Super Beetle, 
we added something that VW should have done from the factory. 
Some of you may have noticed it in our floor pan video 
but what we did is add a clutch cable access port on the tunnel. 
Granted, it isn't very often that the clutch cable has to be replaced 
but every time we have to pull out the pedal assembly to replace a clutch cable, we have to shake our heads at the design.
Before we start, we'll make sure to say, wear appropriate protective gear. 
Work in a safe and well-ventilated environment and only perform work that is well within your capabilities. 
Cutting, grinding, and welding can all be dangerous so make sure to use all the necessary precautions.
While we're on the subject of the clutch cable, we verify that the clutch cable tube in the tunnel is secure. 
We can see at some point that the tunnel had been opened up for a repair 
and we want to make sure that we don't have to fix or repair the tube again. 
We'll start our access hole by looking through the driver's side of the pan 
so we can locate the cable brace inside the tunnel and make sure that we don't cut through it on the opposite side. Looking closely on the passenger's side of the tunnel, we can see the spot welds for the brace.
We'll use a drill and a three-inch hole saw to drill a hole in front of the brace, into the side of the tunnel. 
With the first hole drilled, we move forward on the tunnel a bit 
and drill out one more hole so that we end up with a figure eight cutout of sorts. We use a cut-off wheel on an angle grinder to open up the hole into an oval. 
Then, we grab a sheet of aluminum to use as a cover plate. 
We mark and cut out the aluminum to shape.
Then, back at the chassis, 
we smooth out the edges of the cutout and the cover plate. 
Since we don't have the floor pans in place at the moment, 
we'll make sure to position the cover-up high enough on the tunnel so the new pan will fit below it. Then, we use some self-tapping screws to drill into the tunnel through the plate. A hammer and large vice are used to shape the cover plate while we install the screws. With that, we have a simple but very useful access point for the future.
Thanks for watching! 
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