My New 66! Getting Back into Bugs!!

[justcruzin]

[pOrk]

The painted intake looks a bit weird to me, but I LOVE how the generator fan shroud is black and the piece behind it is purple, looks rad.

Thanks for the tour of the shop, very jealous! My 1 car garage is the reason I got into vw's, but holy hell would I love that much space.

[justcruzin]

[BUGTHUG]

Hey whats the wood looking thing above the car seats on the shelf? It looks like a car or something kinda neat.
They had a show on storage lockers and a guy found about 5 or 6 slot cars he sold to a collector, man I had'nt thought about slot cars in 40 years. Thats some good fun there
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I know you would understand what I'm saying if you could just see my HANDS
Even the middle of the week says W T F

1963 15 window bus
1964 split window bus
1966 VW bug
1969 Dune Buggy
1971 Westfallia camper bus
1972 Kelmark, VW drive line
1948 Chevrolet Hearse

[justcruzin]

That is a fiberglass mold for making a VW Bug go cart. If I remember right hubby stretched it a bit, so it isn't the exact shape as a bug. He did it so one could fit in it better.
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Kim
Sacramento, CA

1964 Split Window Bus
1966 Beetle Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=472933
1970 Westy Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=479538
1971 Squareback Build Thread = http://www.thesamba.com/vw/forum/viewtopic.php?p=6652459#6652459

[justcruzin]

Got a little more done today!

I discovered that the final front portion of the tin I had was the wrong one for what tin was on the motor. Figured that out yesterday so I went up to the left over VW parts hubby had and lucked out and found the correct tin!! Today I got that cleaned up and painted. So now all I need it to get the muffler. I will hopefully get that tomorrow.

I also cleaned the passenger side pan and got that painted with flat black Rustoleom. Once that was done I went to work on the firwall matting. With some help from hubby we got that in. Then it was time for the tranny mounts. That was a job and a half! LOL Got them out and then took everything out to get painted. Once dried I got the fun job of putting it all back together with good mounts! Now the back is ready for the motor!!

Tomorrow I am hoping to tackle the 67 only brake reservoir and tie rod ends!

Here are some before and after pics!
Before,


After,


before,


after,



Do they make tar mat for the passenger area? I would like to get some before I put in carpeting!

And finally a boring picture of the new tranny mounts! LOL One is grey and one is black. Don't ask me why, all I know is one hubby got a long time ago, and one we just bought yesterday!



Oh, I also got some more stuff on the motor, but I won't bore you with more pics of it, least not till I get it in the car! LOL
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Kim
Sacramento, CA

1964 Split Window Bus
1966 Beetle Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=472933
1970 Westy Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=479538
1971 Squareback Build Thread = http://www.thesamba.com/vw/forum/viewtopic.php?p=6652459#6652459

[justcruzin]

Progress as slowed down a bit lately! I am to the point I have to wait for hubby to help me. Sometimes that takes a while. LOL I have the motor ready to go back in now. All it needs is the gas line, fresh air ducting, and the zoom tube. All that can be added after it's in the car though.

Sure wish they made a black distributor cap for the 009! LOL


Today I went out and tried to find some things I could do to the car with out having the motor and all in it. I decided to look at the electrical. I wanted to see if all my lights and switches and all worked. I hooked a jumper box to the cables and tried to turn on the lights, nothing! I then realized that the cables are backwards as far as color goes. The red one is hooked to the body of the car and the black on goes to the starter. Hooked it up the right way and still nothing. I got a test light and the only wire that had power was the one that looked like it came from the starter and went into the engine bay. So I am guessing that the motor has to be in and all wires connected to it for all of the electrical to work? I decided to see what would happen if I hooked up the jumper to the other wire in the engine bay. The one that has 2 other wires in with it. I got headlights!! Well, actually I got headlights and tail lights and also found out that the push switch on the turn signal is the high/low beam button! I didn't have anything else though. No turn lights or 4 way flashers. Actually when I pushed the 4 way flasher button back in, a light came on for a split second. I got it to do it one other time, but that was all.

My turn signal switch was loose so I took the steering wheel off, only to discover that the screw was accessible with it on! LOL I wanted to check on the horn wire too though, so it wasn't a total waste! LOL Speaking of horn wire, where is it at? Is it supposed to be visible, or hidden in the switch? I took a pic of my switch, maybe someone can school me on what these copper looking tabs are and if they are the right size and shape. I am guessing that they help make the horn work?



I also found out that my rear heater wires need some help. One just needs to be hooked up but the other is broken off and gone. Is there a way to replace them? For now I don't think I would use them anyway, but I would like to have them be correct, eventually. I can just use my finger to open and close the flaps for now though. For the most part they would be closed to get the air to the defrost and front vents anyway!



Well, hopefully I can come back on tonight and give an update about the motor being in! Hubby say's he wants to at least get it in the car tonight. I figure if he gets it in, I can finish hooking the other stuff up and hopefully start it!! Can't go anywhere yet because the brake reservoir still needs to be installed, but it will be nice to at least hear it run and move it under it's own power!! Will make it easier to check electrical too! LOL
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Kim
Sacramento, CA

1964 Split Window Bus
1966 Beetle Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=472933
1970 Westy Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=479538
1971 Squareback Build Thread = http://www.thesamba.com/vw/forum/viewtopic.php?p=6652459#6652459

[lovethatconvertible]

While your engine is out, you should rotate your axle boots to the 9 or 3 o'clock position. right now its in the 12 O'clock and will fatigue quicker because of the bulky seam. Keep em coming.

[justcruzin]

[Aynthm]

uh oh
_________________
'66 Beetle
Keep it simple, keep it stock.
Mantra..Tantra...Yantra

FACEBOOK PHOTO ALBUM:
http://www.facebook.com/john.marr.9237/photos_albums

[lovethatconvertible]

OK your gonna make me think are ya? Page 5 section H-4 In the Bentley
Replacing Rear Axle Dust Sleeve #1 Slightly coat jointing faces of the split dust sleeve with plastic sealing compound (VW sealing compound D 1a)# 2 The flange of the split dust sleeve should point horizontally towards the rear. Tighten screws. #3 tighten retaining clips (9 mm/0.35') So they do go to the rear of the car. But at the 3 o'clock Position. Hey we learned something today.

[justcruzin]

Didn't get much done today. Hubby wanted to work on stipping his old truck so he was in my way. We did get the underneath washed better though!



I did do most of the pressure washing but hubby wanted to make sure I got everything. LOL

I also went to the parts store and bought a new steering tie rod thingy, and also another axle boot. Yah, hubby decided we could still change the boots after the motor was in. He was in to big of a hurry to get the motor out of the way. I figure he can change the boots now! LOL

I did get the hood hinges installed. This was as close as I could come to the paint color. Luckily one won't see it to often.



The bug is back in the garage and ready to put back on the lift, so hopefully the motor, master cylinder, and tie rods will be done tomorrow! I really want to see how she runs!!
_________________
Kim
Sacramento, CA

1964 Split Window Bus
1966 Beetle Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=472933
1970 Westy Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=479538
1971 Squareback Build Thread = http://www.thesamba.com/vw/forum/viewtopic.php?p=6652459#6652459

[lovethatconvertible]

That is one Hell of a car lift you have there girl. So portable too.

[justcruzin]

[justcruzin]

Today I got a little done. Not as much as I wanted but we got the things done that I needed the car on the lift for. Well almost. Tomorrow I need to change the steering tie rod thing, but then I can do everything else on the ground. I still need to do the axle boots and hook up the heater tube things that are under the car. I can do that later though, main thing is, I can now get the things done so I can actually do a test drive!!! The axle boots will have to wait till at least next weekend. Tomorrow night the lift is needed for actual paying jobs.

So, today we got the 67 only brake reservoir installed. Yah, had to drill holes to fit it.



I still need to pull it back out before I hook the lines up. Need to take care of that surface rust.

Also got the zoom tube and regulator installed.



Hubby put a dent in the zoom tube , but we only paid 10 bucks for it, so it wasn't like we had a lot of money into it. I guess it matches the car now. It has a lot of dings and dents in it too! LOL

Tomorrow I plan on getting some new wire to fix some of the bad wires that go to the regulator. Once that is spliced in and covered I will hook all the wiring up in the engine. Next will be the gas line! Once that is done I can hopefully do a test start of the motor!

Once the brake lines are done, I can hopefully install the gas tank and then do a real test start and maybe drive!!!
_________________
Kim
Sacramento, CA

1964 Split Window Bus
1966 Beetle Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=472933
1970 Westy Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=479538
1971 Squareback Build Thread = http://www.thesamba.com/vw/forum/viewtopic.php?p=6652459#6652459

[justcruzin]

Today I got the steering tie rod bar in!!!



Also got the motor all wired and ran the missing wire for the license plate light ran!! Also got the fresh air tubing installed. Hubby had this plastic stuff so I thought I would try it. Never seen this stuff before. Always used that aluminum black stuff before.



I have a newer model oil bath cleaner I will run with for now, till I find the correct one for a 66. I will put it back on once we get the bug running!

With all the wires connected I was able to test my lights. I have running lights, head lights and brake lights. I don't have any blinkers what so ever. Even tried the 4 way flasher. I could get it to make a flash and then it would do nothing.

The PO had one of these clamped under the hood. I forgot to take a pic of that one, but they had 2 more ( ones in the pics) in the glove box. I'm wondering if there might be an issue with these?





They are both blue, even the one in the first pic. It just came out darker do to the camera's angle and lighting.

I have a 66 bug which has been converted to 12 volt. Is this the right flasher unit for this type of a conversion for this year?
_________________
Kim
Sacramento, CA

1964 Split Window Bus
1966 Beetle Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=472933
1970 Westy Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=479538
1971 Squareback Build Thread = http://www.thesamba.com/vw/forum/viewtopic.php?p=6652459#6652459

[gerg]

There is a template in the Bentley for making the piece that is missing . . I made mine, works great.


_________________
Gerg

. . . I got 99 problems and my bus ain't one . . .

'65 Sunroof Beetle
'65 Vert
'60 Singlecab

*SBS 75*, LVVWC, SV2

www.my65bug.com
www.her65vert.my65bug.com

[Rome]

Kim, this is an enjoyable thread, to see you delving into your solid Beetle! Great that you and your family have the ability and space to tackle a long-lost hobby interest of yours.

Some observations:

Your safety belts are OEM VW for a '68 thru approx. early '72 Beetle, or even type 3. These are excellent belts even though they need to be adjusted manually for the first time you wear them. Make certain the belts are in good condition by examining the edges of the belt webbing carefully for signs of fraying. They should also have a white-plastic spool on them, which rolls the belt out of the way when it';s not worn. I have such a spool on my '70 Fastback's original belts (39,000 miles on the car when I bought it) and they work well. If the driver's belt shows signs of wear, see if the passenger belt is better, then switch them and try to find a good one as a spare at a VW meet. This is a part you must check in person, rather than relying on a description by a VW part seller via internet. Once you have the belt adjusted for your body and driving position, you don;t need to change it.

Your chassis/body tag has numerous words in German, partly abbreviated.

Zul Gesamtgew is short for zulaessiges Gesamtgewicht, the GVWR (gross vehicle weight rating). This consists of the vehicle's empty weight, with the allowable maximum passenger and cargo weight added. 1kg is 2.2 lbs.

Zul Achsl vorn is short for zulaessige Achslast Vorne, or maximum front axle load. hinten means rear (axle load).

Your purple paint on the intake manifold heat risers (the small tubes going out to the top of the muffler) are subject to the direct heat of the exhaust gases which go into the muffler. Unless you used specific exhaust-heat resistant paint (like up to 1300F) chances are the color will melt off after its first highway drive.

I may have missed it, but did you install a dual-circuit new master cylinder together with the '67 only fluid reservoir? If so, that's a wise upgrade, though you'll need a new front brake line for the left front wheel, since the original one is slightly shorter when using the single-circuit M/C.

In case you cannot loosen the tiny set screws in the black wire junction for the rear seat heater outlet wire, RadioShack has similar ones in white, in 2 sizes. Then you can cut off the original unit, paint a new white one black with vinyl spraypaint to make it look close to stock, and use a slightly longer wire to compensate for the small piece still sticking inside the piece when you cut off the wire.

We'll share your enthusiasm when you get the engine running and the car driveable!

[justcruzin]

/\ /\ Wow thanks! That was an informative reply! I didn't realize those German words were for GVWR!! Now I know! Also thanks to both you and Gerg for the tip on the heater wire holder and such. I thought I was just sol.

Sounds like I will have to clean up my engine compartment after the first highway drive! LOL I didn't know those tubes got that hot and I just used Rustoleom paint on them. Oh well, live and learn.

I will have to take a better look, but I don't think that white thing you speak of is on my belts. They are just thrown where ever and don't roll up into anything. I am guessing they are broken.

The PO put the dual master cylinder in so the brake lines to the wheels have all ready been done!! I just put the 67 only reservoir because he had an even later model one ( kind that mount by the fender under the hood) just tied to the spare. We lucked out and found this 67 one at PnP!!

As far as getting the car running, that kind of depends on hubby. LOL I would like to try to start it by pouring gas into the carb just to here it run. But, it depends on if hubby wants to help me do it. To get it actually ready to run on it's own, I still need to get the brake lines hooked up to the reservoir. Ran into a snag there. The lines comeing out of the reservoir are pretty small, about the same size as the metal gas line. The hoses that the PO have on the master cylinder, are bigger. I'm not sure if it is because the mc has bigger inlets, or if it is just what the PO had. I haven't pulled the hoses off yet to look. Maybe that is a good project for me to work on tonight. If I have to use the bigger hose for the mc, hubby wants me to go buy smaller hose for the reservoir then go to Emiegh hardware and find some sort of metal step down tubing. I plan on getting all that tomorrow after work, if I need it!

Of course, I will update as soon as I can!! I love project threads! Also love to share pics, as you guys can tell!
_________________
Kim
Sacramento, CA

1964 Split Window Bus
1966 Beetle Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=472933
1970 Westy Build Thread= http://www.thesamba.com/vw/forum/viewtopic.php?t=479538
1971 Squareback Build Thread = http://www.thesamba.com/vw/forum/viewtopic.php?p=6652459#6652459

[Rome]

Here is the belt retractor:

http://www2.cip1.com/ProductDetails.asp?ProductCode=C16-111-704A

VW provided small plastic hooks to hang the belt tongues on. The hook was mounted with 2 screws to the top of the B-pillar (door post) behind the grab handle loop. This keeps the belt out of the way and off the floor, though I'd suggest buying a few spares since they can easily break if the belt tongue is pulled off crooked or if a person getting into the back seat snags the belt. Your car might not yet have the original mounting holes for the hooks but you can drill them carefully thru the side pillar vinyl.

http://www2.cip1.com/ProductDetails.asp?ProductCode=C16%2D111%2D723A%2DWH

Since your new engine has a doghouse fan and shroud, that fan takes more cooling air than the original 1300's engine. You should prop the bottom of the engine lid open a bit to allow more air in while driving, especially when on the highway. This has been covered alot here on theSamba, with a simple method to use a half of a tennis ball shoved onto the decklid's latch. After your drive you can then simply pull the ball off to latch the decklid.

Make sure you use the "blue" original style brake hose to feed the M/C. This is a special rubber composition which does not dissolve when in contact with brake fluid the way conventional rubber (like for fuel lines) will. Or ask for hose at a FLAPS specifically rated for brake fluid.