Even with Brooks’ best previous efforts, Annie required substantial work as the renovation started. The floorpan had rusted through while the suspension, transmission and electrical components provided cause for serious migraines.
Over 11 months, the Puebla team replaced roughly 40 percent of Annie’s parts and restored 357 original pieces, right down to recreating all the stickers that Brooks had slapped onto the body and windows over the last five decades.
To properly restore the Bug’s faded red paint – well beyond a patina state –, the renovation experts matched an original shade from the inside of the glovebox, sandblasted the body, repaired with a mix of period-correct and updated parts, and then reassembled.
To ensure Annie sees another 50 years, several vehicle components were restored to better-than-new condition, including disc brakes that were a upgrade found on later Beetles produced in Mexico and an AM/FM/Bluetooth stereo designed to mimic the look and feel of original Bug radios.
The wiring was completely redone; the transmission rebuilt and suspension upgraded. The engine was completely disassembled, cleaned, updated and rebuilt. Even the seats received a special touch, with 'Kathleen' and 'Annie' embroidered in a classic VW font over new leather.
The project goal, explained project manager and mechatronics engineer Augusto Zamudio, was not to ‘create a museum quality Beetle’, but to bring Annie back to a state where Kathleen could drive and enjoy her for many more years to come.
"When Annie arrived, our team members quickly understood the connection Kathleen had with her car and embraced this project wholeheartedly," said Steffen Reiche, CEO of Volkswagen of Mexico. 'Restoring this car posed a number of challenges, but also provided a demonstration of the dedication we put into every Volkswagen we build.'
When Brooks parted with Annie, she wrote a heartfelt note to the Puebla team members thanking them for their efforts and asking them to take care of her special car. Zamudio says the feeling is mutual – and the team wrote Brooks back a note of their own.
'This was a labor of love for all of us. It was emotional to see Annie go after all the time we have spent working on her, but we are happy Kathleen and her can be reunited.'