Thank you for purchasing 1998-2005 New Beetle Door Panel Insert Kit.
*** PLEASE READ INSTRUCTIONS BEFORE YOU BEGIN ***
 
TOOLS NEEDED
- Basic handtools
- Soldering iron
- 3M Super 77 spray glue
- Loctite Professional Super Glue
- Heat Gun or Hair Dryer (not necessary but it will help make material more pliable during installation producing a better fit)
 
DOOR PANEL REMOVAL

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Remove door pull insert by prying it out and remove the two screws

 

 

 

 

 

 

 

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Roll window down. Carefully pull or pry up the power window switch (under the switch mount there are three screws which need to be removed) 

 

 

  

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Remove screws on bottom of panel, pull panel out, slide it up and off vehicle

 

 

 

 

DOOR PANEL INSERT PREP AND REMOVAL

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 Using soldering iron and a flat head screwdriver, heat plastic tab and lift up while heating to remove the insert.
 
 Note: Some of the platic tabs could be broken but will not affect the final installation becuse reinforcement strips are included in the kit which will be used to re-attach the the panels.
 
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Slide the black locking strip out and remove it. Now, the insert panel is ready to be removed from the door panel.

 
With insert panel removed, clean old material and foam from the panel. Best way to clean the old foam is using a damped cloth and 409 cleaner rub the foam off. Allow to dry 
Note: Since old foam is water based, DO NOT use thinners or petroleoum based cleaners

 

 

 

 

  

INSERT INSTALLATION  

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 These are the pieces included in the kit which are to be installed

 

 

 

 

 

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 Test fit the arm piece onto the panel. Mark center or make a reference mark. spray glue on both panel and insert allow to tack up ,line center mark up and install piece on panel.use heat gun to help soften material to stretch easiser

 

 

  

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 rolling material on panel

 

 

 

 

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 Glue the front part down next  

 

 

 

 

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 Glue and wrap rear edge around panel trim edges of vinyl flush on the other three edges

 

 

 

 

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 fit top piece ,spray glue on insert and panel

 

 

 

 

 

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using  super glue apply bead around edge of top insert
 
 
 
 
 
 
 
 
 
 
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REASSEMBLY OF PANEL

Trim edges ,cut notches for plastic tabs 

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Next install insert panel back in panel

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NEXT STEP IS USING SOLDERING IRON TO MELT THE PLASTIC TABS IN PLACE ,NOW THE REINFORCEMENT STRIPS CAN BE APPLIED USING SPRAY GLUE APPLY TO BOTH PIECES ALLOW TO TACK AND PUT ON EDGE CONNECTING INSERT PANEL TO DOOR PANEL

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 NOW YOU ARE FINISHED ,QUESTION PLEASE CALL ED 540-320-9978 THANKS