1967 Volkswagen Beetle Restoration | From Rust to Icon - Full Rebuild

Kathleen Brooks purchased her very first Volkswagen Beetle in December 1966 in Riverside, California. It was a red 1967 model, and almost immediately she gave it a name — Annie.

From that moment on, Annie became Kathleen’s everyday companion. Over the course of 51 years, the Beetle accumulated more than 350,000 miles — the equivalent of driving around the world 14 times. Today, at 73 years old, Kathleen still drives Annie to work.

After learning about the extraordinary bond between Kathleen and her car last year, Volkswagen’s North American Region launched a unique initiative: restoring Annie at the Beetle’s North American home, the Volkswagen factory in Puebla, Mexico. Over an 11-month period, approximately 60 Volkswagen employees and trainees worked meticulously to return Annie to factory-quality condition, adding a number of custom details that honored Kathleen’s lifelong dedication. This week marked a special moment as Kathleen and Annie were reunited, and Kathleen met the team members who made the restoration possible.

“We hear many stories about devoted Volkswagen owners, but Kathleen and Annie truly stood out,” said Derrick Hatami, Executive Vice President of Sales and Marketing at Volkswagen of America. “The original Beetle helped establish our brand in the United States. This car isn’t just a vehicle — it’s part of Kathleen’s family. After spending so much time with Annie, our employees feel she’s part of ours too.”

Brooks works closely with breast cancer patients and survivors, offering comfort and cosmetic care during treatment and recovery. A three-time breast cancer survivor herself, she says Annie has been more than just a car. For decades, the Beetle sparked conversations with fellow enthusiasts and was always there when she needed it. “I’ve often said Annie and I are a lot alike,” Brooks laughs. “She’s old, faded, scratched, dented, and rusted — but she keeps going. And as long as I take care of her, she’ll keep running.”

Despite Kathleen’s careful maintenance, Annie required extensive work when the restoration began in Puebla earlier this year. Issues ranged from severe floor pan rust to suspension, transmission, and electrical problems. Over the course of 11 months, the team replaced about 40 percent of the car’s components and restored 357 original parts — even recreating the stickers Kathleen had placed on the body and windows throughout the years. To accurately restore the faded red paint, the team matched the original color from inside the glovebox, sandblasted the body, carried out repairs using a blend of period-correct and updated components, and then carefully reassembled the car.

Some upgrades surpassed the original factory specifications, including disc brakes inspired by later Mexican-built Beetles and a modern AM/FM/Bluetooth radio designed to resemble the original unit. The wiring was completely redone, the transmission rebuilt, and the suspension upgraded. The engine was fully disassembled, cleaned, updated, and rebuilt. The seats received a personal touch as well, with “Kathleen” and “Annie” embroidered in a classic Volkswagen font on new leather upholstery. To connect Annie to the modern era, the toolkit and jack were painted in Deep Sea Teal Metallic — the signature color of the 2018 Beetle Coast edition.

According to project manager and mechatronics engineer Augusto Zamudio, the goal was never to create a museum exhibit. “We wanted to return Annie to a condition where Kathleen could continue driving and enjoying her for many years,” he said.

“When Annie arrived, our team immediately understood the deep bond Kathleen had with her car,” added Steffen Reiche, CEO of Volkswagen of Mexico. “The restoration presented many challenges, but it also showcased the passion and care we invest in every Volkswagen we build.”

When Kathleen said goodbye to Annie before the restoration, she left a heartfelt note for the Puebla team, thanking them and asking them to take good care of her beloved car. Zamudio says the sentiment was shared — and the team responded with a letter of their own.

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