Dean Kirsten’s new cal-look bug (eng. ver.)

Here’s Dean Kirsten’s of Der Kleiner Panzers freshly debuted cal-looker. Most of cal-look fans know who Dean Kirsten is, but those not really familliar with the subject should be informed, that he is the editor of HotVWs magazine, a california based title which focuses on air cooled VWs for over 45 years. Below you can read Dean’s own words about his fabulous ride. This car sets a new meaning of the term: High Standard…. Translation to Polish will follow soon.

Dean Kisten's new cal-look bug

I purchased it back in 1999, as a worn out stocker 1967. By the time I took it apart, I soon realized it was not in good condition, so it was going to take a lot longer to build that I figured. It ended up taking me 12 years to build, and five times more money than
originally thought it would!

BODY: All of the front sheet metal had to be replaced. I found another front clip off a clean ’67, and replaced the everything from the front cowl forward. Each panel was removed and replaced drilling out the factory spot-welds and seams. New German fenders were
located, the fronts were modified by TIG welding up the stock turn signals and horn grilles, and mounting Lucas 488 turn signals down below. The rears were NOS German, so they came without over-rider holes. The rear apron was metal-finished without the exhaust
holes, and the inner heat shield was removed, and a new one-piece lower lip added. All trim holes were filled with TIG, along with removal of the antenna hole and the passenger side wiper boss. We found a ’67 convertible deck lid and removed the emblem holes. All
lower heater vents removed sand filled in, front and back. Replaced rear parcel tray. Installed carbon fiber reverse NACA ducts to allow engine compartment heat to exit. Cut access panels in both sides of the engine compartment, covers were made out of K&N
motorcycle filter covers. Taillight wiring relocated, holes filled. Danny Gabbard, Long Haired John, and Buddy Hale metal work.

Dean Kirsten's new cal-look bug

DASH: we metal finished the corner vents, and removed them all together. We also filled in the glove box trim holes. We then created a new dash panel out of steel, and mounted two Auto Meter carbon Fiber gauges (Speedometer and tach), along with three smaller
gauges (oil temp, pressure and fuel). This panel slightly tilts the gauges to the driver. Metal-finished the panels on the back side was well! Filled in the ash tray, removed the stock fuse panel. Danny Gabbard metal work.

PAINT: walnut blasted body inside and out. Body work done on a rotating stand. Painted using a 3-stage urethane, bright orange, GM Tangier Orange, clear. Color sanded and buffed top and bottom, inside wheel wells and inside fenders and hood. Buddy Hale paint
and body.

FUEL SYSTEM: all hard lines from front to rear bulkhead. 3/8 or -6 lines, with Mallory 60 GPH fuel pump with Holley regulator, rubber-mounted.

Dean Kirsten's new cal-look bug - trunk

TRUNK: covered with aluminum panels with Dzus fasteners, painted to match body color. Fuel tank fitted with -6 AN bottom line, with -6 breather fitting on filler neck. Smoothed and painted black with clear coat. Auto Meter electric sender with OEM top cover.

FLOORPAN: media blasted, new pan halves installed (Wolfsburg West). All TIG welded, then sanded smooth. 3/8-inch hard line installed in tunnel with two access panels installed. Rear torsion ground and sanded smooth. All factory welds redone and ground smooth.
Pan sanded smooth both top and bottom. We removed the heater cables and old fuel line. Triple black and clear powdercoated, sanded between coats.

FRONT BEAM: German, narrowed 1-1/2-inches per side. Completely metal finished, all welded and radius re-welded and ground smooth. Shock towers modified and smoothed. Triple black and clear powdercoated. CSP disc brakes, Koni adjustable shocks. Brad PurserQ beam.

Dean Kirsten's new cal-look bug engine

ENGINE: 2275cc, new mag case, 82mm Bugpack forged crank, 5.4 Bugpack H-beam rods with Carrillo bushings and bolts. 94mm Mahle pistons with Total Seal rings. Honed cylinders, Rimco machined and decked case. 10mm Raceware studs, KS bearings, Engle K-8 cam and Scat lifters, Magnum straight cut gears, wedgemated crank and 12-lb flywheel, KEP Stage 2 clutch with ACE Copper disc. Jeff Denham heads, welded, ported, flowed. 44mm x 37.5mm Manley valves, Berg seats, Kawell combustion chambers, 9.0:1
compression, CE .060 copper head gaskets, Berg wide sump, Berg 28mm pump, CE pulley, MSD distributor with 6AL box. Thing fan housing, modified cylinder tin, Scat Trak manifolds, match-ported, polished, dual 48 IDAs with 40mm venturis, Berg blue-printed
shafts and butterflies. 1-5/8 x 1-3/4 step header by A-1 Muffler. 4-inch stainless muffler by A-1. Made 196hp @6700 rpm on Heads Up dyno. Dean Kirsten built engine.

COOLING: Thing fan housing, Type 4 cooler, remote Setrab cooler with hardlines. Full-flow oil system with Geers billet filter, hardlines by CE.

TRANSAXLE: Swingaxle, short-short SAW axles, 3.88 ring and pinion, Weddle one-piece mainshaft, Berg 5-speed conversion, Quaife Locking differential, GEM gears, side cover, chromed axle tubes, Type 3 drum brakes, detailed case with polished ribs. Dual breathers
for 5-speed. Koni adjustable shocks, Berg mid-mount. Harold Carter Transaxles

WHEELS: U.S. Wheels 4 x 15-inch fronts, polished inside and out. 135 Michelin ZX tires. 6×15 rears, custom made by OMF, polished inside and out. Modified lips.  215x65x15 M&H DOTs.

INTERIOR: JCL roll bar with two down tubes to rear torsion tubes. Powercoated black. Rear aluminum panels, Dzus fastened together, painted to match the leather using dull clear. Tan headliner, tan German squareweave carepting with herringbone cloth binding. Front seats are ’65, covered with tan leather, double-stitched biscuits. Powerecoated frame (black and silver), aluminum side panels to match rears. Simpson belts, dual dome lights, custom Motolita steering wheel with shortened polished hub. Custom Berg shifter with Hurst line-loc. Blueprinted pedals with heim-joint clutch cable, and beefed clutch pedal, early pedal pads. Collins Upholstery

WIRING: custom made, street rod fuse box in rear seat area. All hand-wrapped, zip tied and heat shrunk. Hidden wires throughout. Wayne Elam wiring.

RUBBER: VW of Mexico window rubber. WCM, Wolfsburg West.

DETAILS: Landproducts ’67 billet door pulls and breather box, Super Beetle rear license plate hood, Haneline engine-turned stainless thresholds, kick panels and rear license plate frame. Welded and smoothed (backside), polished ’67 door and hood handles. One-piece
windows, custom billet and leather arm rests by Gary Economy. Talbot exterior mirror painted body color. Hella SB12 painted headlight rings. Black interior mirror. NOS inside window handles and pulls. NOTE: All hardware is either APR 12-point race hardware, or
stainless, with custom CNC aluminum washers. Over $1400 worth of hardware went into this car. All oil and fuel lines are hand-bent hard lines by CE or Kris Lauffer.

Now you know why it took me 12 years to build this car!

Hope this helps,  Dean Kirsten