25/01/2026
BEAN, THE 1977 BAY SINGLE-CAB, MAJOR RUST REPAIRS AND CUSTOM MODIFICATIONS - PART 1.
Welcome to the ongoing rescue mission of a 1977 Volkswagen Bay Window Single Cab, a vehicle that was taken off the road after it became clear it contained more air than metal.
At some point in its life, rust decided it quite liked this truck and moved in permanently. Floors, sills, chassis sections, seams, you name it, nothing was safe. Describing it as “solid” would have been wildly optimistic. “Swiss cheese with headlights” felt more accurate.
Rather than ignore it and try to hide it, weld on some patches or just simply kill the truck off, I decided this restoration is about building something unique, once again, even when that means cutting out large portions of what was technically still a vehicle.
This build involves:
Rust in places rust should never be
Large sections being replaced because they simply stopped existing
Metal fabrication, welding, and structural repairs
Occasional swearing, head-scratching, and tea breaks
Gradual transformation from “terminal” to “roadworthy”
The aim is to put this Single Cab back on the road stronger than it ever was, without hiding the work or pretending it was an easy job. The outside bodywork is going to remain as original where possible, improved where sensible, and always built to last—not just to pass an MOT and cross fingers.
This page follows the full journey: the rot, the repairs, the small wins, and the moments where standing back and saying “that’ll do nicely” actually feels earned.
If you enjoy classic Volkswagens, proper metalwork, or watching something that absolutely should have been broken for parts stubbornly refuse to die, welcome aboard. This 1977 Bay Window Single Cab is coming back, whether rust likes it or not.
Oh and did I mention it's going body dropped? Tubbed, air ride and a pretty tasty motor and box combination?
Thanks for looking, boneshakers 🧡