Stefan and his Cal-Look Beetle as a tribute to Ken Block

Introduction

At MechDes, everything revolves around technology. During the day, our engineers work on innovative solutions for clients, but that passion often continues after hours. Many colleagues have hobbies in which the same curiosity, creativity and dedication reappear. That is exactly what makes them not only better engineers, but also people who take pride and joy in building something bigger than themselves.

In our Masters of Engineering series, colleagues share those personal projects. Today: Stefan, who lost his heart to a 1967 Volkswagen Beetle. What started as a rusty classic turned into a multi-year project filled with technical challenges, collaboration, pride and a reflection of his work as an engineer and team leader at MechDes.

The Beetle before the restoration. It was immediately clear that this would be a multi-year project.

A project with character

When Stefan bought his Beetle in 2018, he immediately knew this would not be a job for just a few months. "This is going to be a multi-year project," he thought. And he did not mind at all. On the contrary, the prospect of building something step by step gave him the space and freedom to shape the car entirely according to his own vision.

For a Beetle, many parts and accessories are still available, ranging from replicas to custom parts. That opened up a world of possibilities. Stefan quickly set a clear goal: his car had to become a Cal-Look Beetle. That means a lowered front end, a tough appearance with T-bar bumpers, stylish wheels and, of course, a sporty exhaust. But most importantly, it had to be a car he could truly be proud of.

Stripping and welding together

The project started surprisingly smoothly. Together with his father, Stefan completely stripped the Beetle. Everything came out: seats, upholstery, engine, wiring. Only the bare shell remained. As with almost any classic car, quite a bit of rust appeared. Not pleasant, but not unexpected either.

His father took care of most of the welding work. As a retiree, he not only had the time, but also the experience. For Stefan, this meant more than just practical help. It was a learning process. "I am incredibly grateful to him," he says. "Not only because he did it, but because I learned so much from it. Working together, sharing knowledge and helping each other is something I value greatly, both in my hobby and in my work."

The Beetle was completely stripped back to its bare bones. Everything was restored, welded and painted before being rebuilt with the same precision Stefan applies in his work.

Specialist work and methodical rebuilding

Once the rust was under control, the car went to the paint shop. Straightening the bodywork and applying a flawless paint finish are tasks best left to specialists. In engineering, it is no different. Some steps simply require experts with the right knowledge and experience.

When the freshly painted car returned, Stefan entered what was perhaps the most enjoyable phase: the rebuild. Electrical systems, mechanical components, wiring, everything had to be reinstalled. Thanks to his background as an engineer, he approached this process in a structured and methodical way. Before installing anything, he studied the specifications, created a plan and ensured he had the correct parts. He deliberately chose a ceramic-coated muffler and manifold, a different camshaft and an electronic ignition.

"That is exactly how I approach things at work," Stefan explains. "First investigate, then decide. Not just install something because it happens to fit."

The Cal-Look Beetle in our factory hall, a special parking spot for a unique creation.

The first drive: pure pride

Stefan will never forget the moment the Beetle returned to the road. Together with his father, he drove to a Volkswagen meeting. The drive itself was special, but the real highlight came upon arrival. "The feeling I had when I arrived there was pure pride. This was not just a car. It was the result of years of work, together with my father."

He recognizes that same feeling in his professional life: creating something tangible that you can look back on with a smile. That is what makes technology meaningful.

Engineering skills in practice

What makes this hobby so fascinating is that Stefan can apply his engineering skills to it. A good example is his wish to integrate a third brake light, inspired by the Porsche 911 (992). At first glance, it seemed simple, but in practice it turned out to be quite a challenge.

He grabbed a caliper, designed a bracket in CAD and 3D-printed it himself. He then mounted the assembly in such a way that it looked as if it had always been part of the car. "That entire process of measuring, designing, prototyping and testing is exactly how we work at MechDes."

He uses modern techniques that are also central at MechDes, such as 3D printing. As a result, his 1967 Beetle is not only a classic, but also a personal testing ground where he experiments with new ideas and sharpens his skills. His enthusiasm is contagious. Colleagues became curious, contributed ideas and offered suggestions. A passion for technology spreads easily and often leads to inspiring conversations.

The Beetle with a third brake light inspired by the Porsche 992 and unique American taillights.

A personal tribute

In 2023, Ken Block of Hoonigan, an icon in the automotive world and one of Stefan’s idols, passed away. Stefan decided to honor him in a personal way through his Beetle. It started with a simple sticker on the side window, but became more meaningful when he discovered that Block’s birth year, 1967, was also the production year of his Beetle.

He also designed a unique gear knob inspired by the handbrake lever Block used in his drift videos. It was an intensive process: designing, 3D-printing the parts separately, bonding them and finishing them. "When that gear knob was installed in the car, I felt that same pride again. No one else has this."

Stefan’s Beetle as a tribute to Ken Block: both share 1967 as their birth year, reflected in the unique Hoonigan gear knob and window sticker.

Always evolving

A Beetle is never truly finished. There is always something to improve or refine. For Stefan, that is part of the charm. The project grows along with his own knowledge, experience and ideas. Recently, he focused on the rear lights and pedals. He purchased LED taillights with a polished red polycarbonate plate and a new adjustable pedal set. Two seemingly small details, but for Stefan they symbolize his approach: first thoroughly research what he wants, why these specific parts and which solution best fits his car and driving style.

"It remains a process of improvement and refinement. Just like in engineering: you start with a solid base product, but you keep optimizing wherever possible."

The LED panels are a unique limited edition from the United States, and he found the polished polycarbonate plate particularly elegant. The pedals addressed a practical issue. The brake pedal would occasionally stick, and the pedals were positioned relatively close to him. With the new set from Brazil, he can adjust the position, solving the issue while adding a subtle racing feel that enhances the car’s character.

Teamwork and leadership

Stefan constantly sees parallels with his professional work. Planning and phasing are just as important in a restoration as in a large engineering project. Collaboration is essential. Without his father, and sometimes input from colleagues, the Beetle would never have become what it is today.

In his current role as team leader at MechDes, he recognizes the same dynamics. "My Beetle project sometimes feels like a miniature version of what we do in the professional world. Solving a complex challenge step by step, across different disciplines."

His hobby also supports his leadership. "Now that I am a team leader, I spend more time guiding and coaching than on technical work itself. But through my hobby, I keep that technical feeling alive and continue learning. That makes me a better conversation partner for my team."

He passes that mindset on to his team. "If you keep each other informed, share development goals and stay open to ideas, you create something bigger together than you ever could alone. Just like my father and I do."

When Stefan brings his Cal-Look Beetle to work, his colleagues are immediately curious about the latest additions.

More than a hobby: a living project

What began as an old car that needed saving has grown into a project where passion for technology, family bonds and craftsmanship come together.

Every bolt Stefan tightens, every CAD design he creates and every drive he takes reminds him that technology is not just his profession, but his way of creating.

"The Beetle is more than a car to me. It is a reflection of my work, a learning environment, a family project and, above all, a source of joy." That is what makes this story so recognizable within MechDes. Technology is not just about parts and drawings. It is about joy, curiosity and building something greater than yourself together. Whether in the workshop, behind a screen or on the road in a classic Volkswagen, that shared passion connects us. It makes our work better, our collaboration stronger and our results something to be proud of together.

Our engineers are not only professionals, but makers at heart. And that is precisely why, together and with pride, we can bring our clients’ visions to life.