Phoenix - A 1971 VW Westie returns from the Ashes

peteandvanessa · Posted: Thu Nov 27, 2014 2:43 pm Post subject:

Dan sourced an original air filter stand/bracket. The P/O at some point, cut the old stand/bracket to fit dual carbs. We managed to find an original one from thesamba Classifieds.

I just painted it almond white and then Dan refitted it today:

The stand/bracket from a donor Bus:

Image may have been reduced in size. Click image to view fullscreen.

Fitted the oil bath filter to the bracket:

Still need to refit some of the pipes to the oil filler and pre-heat tube:

_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

peteandvanessa · Posted: Sat Dec 06, 2014 7:50 pm Post subject:

Today we went and picked up the dismantled interior parts. We hadn't seen these since the fire in August. Last time I remember them they were just fit for making patterns and then scrap heap.
But today, they didn't look too bad, we came to the conclusion that most of the panels could be rescued, just sand it down, then stain and where needed we could apply some new wood veneers.

So here's the pile of parts we pulled back from Kim and Bob's today:

I decided to start with the pull out bed. Here's the front part of the support for the bed (yep the veneer is burn't and crispy):

but underneath the wood veneer it looked pretty good:

These got sanded and then stained. We plan on buying some new wood veneer. Also stripped the z bed brackets and got them primered. Will finish painting them tomorrow ready for re-assembly.
_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

Tcash · Posted: Sat Dec 06, 2014 8:30 pm Post subject:

Hi
You can shellac over the burned pieces that are still good.

peteandvanessa · Posted: Sun Dec 07, 2014 4:53 pm Post subject:

Continued to work on the interior today, didn't get a huge amount of time since we went on a charity toys for kids run this morning. Dan took his Bus and I took his '58 Bug, lots of fun.

I pulled the Z Bed cabinet door apart today. The door was looking pretty sad from the fire. I pulled off the door handle (which looks salvageable), hinges and hardware.

The other side was toasted pretty good:

So I cleaned both sides and the side that was badly burned I used an electric planer and stripped 1/16th inch off the surface, effectively stripping off the charred wood. Then a good old sanding with 80 grit.

Here's the charred side after the clean up:

Looking very useable now. Also went to lowes to look at laminates, here's two in the Pic that are very close to the original Westy laminate, so Dan might go with one of these.

Also resealed the front windshield. We had a lot of rain last week, and a lot of it got into the front of the Bus, even though the seal is new.
We think it's getting into the top of the seal on the left and right hand sides then it runs down to the lowest point and drips into the cab.

I peeled back the windshield seal a little, and poked a caulking gun tip in and squirted a good amount of black silicone caulking in there. I cleaned up the excess. I hope it now doesn't leak. We shall see next time it rains!!!
_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

peteandvanessa · Posted: Tue Dec 09, 2014 6:00 pm Post subject:

After sanding and cleaning the wood this is what I was left with, assembly time.

Used all the original hardware to bolt the parts back together. Still need to do the passenger side support for the bed (that was too burned to save), and then I need to copy the burned seat back to replace it, then finally build the bed.
Not too shabby for a burned Bus:

_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

peteandvanessa · Posted: Sun Dec 14, 2014 3:58 pm Post subject:

Spent a good six hours installing the rear seat/bed.

Here's the initial test fit:

Then I added the bottom of the seat/bed:

I had to copy the burnt part of the rear seat back, it was too far gone to save. This was made with 3/4 inch thick ply, here's it installed:

Just put on a throw over the seat for now:

_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

peteandvanessa · Posted: Wed Dec 17, 2014 5:50 pm Post subject:

Pulled the jump seat wood today and started cleaning. The jump seat was pretty badly burned in the fire, especially at the front.

Here's the loose jump seat panels after I knocked off most of the burned wood:

Some of the wood had started to split from the water hoses when the firefighters put out the fire in the Bus.

I had to do a lot of pinning and gluing to repair some of the jump seat panels. I had to remake the front part of the seat since it was too far gone to save:

Here's the seat after all the sanding, gluing and repairs. Feels good that I managed to save the majority of the wood from the jump seat. Now I need to get the new wood veneers and cut them out with a router and glue onto the key seat panels. That will be a task for the weekend:

_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

peteandvanessa · Posted: Thu Dec 18, 2014 5:25 pm Post subject:

The new wood veneer arrived yesterday, so today I left work early and started work on the rock and roll bed.

I user a router to route out the wood veneer, I used the veneer router bit with the bearing on the BOTTOM, to cut the veneer out. Here's the veneer clamped to the cabinet door and partially routed out:

Here's the door routed out completely:

I did the same to the bottom of the bed unit then glued the veneer on.

It came out pretty good:

Cleaned it all up and got some new coach bolts and hardware. Got a new throw for the bed (well it needed sprucing up after I did the veneers)

_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

Tcash · Posted: Thu Dec 18, 2014 5:39 pm Post subject:

It is easier if you glue the plastic veneer on first and then router the edges

Looking great
Tcash

peteandvanessa · Posted: Thu Dec 18, 2014 6:10 pm Post subject:

wcfvw69 · Posted: Thu Dec 18, 2014 6:50 pm Post subject:

Wow.. that wood veneer looks fantastic! You did a great job.

Is the veneer pricey or?
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc

Decades of VW and VW parts restoration experience.
The Samba member since 2004.

**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours**

peteandvanessa · Posted: Thu Dec 18, 2014 7:54 pm Post subject:

peteandvanessa · Posted: Fri Dec 19, 2014 2:10 pm Post subject:

Similar to the Rock and Roll bed, I rebuilt the wood veneers on the jump seat. Still need to source some new foam and the seat cushions, but the jump seat is now looking good:

_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

wcfvw69 · Posted: Fri Dec 19, 2014 4:16 pm Post subject:

That looks REALLY good. I like that veneer. Would you happen to know the color of it or part number?

Thanks
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc

Decades of VW and VW parts restoration experience.
The Samba member since 2004.

**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours**

peteandvanessa · Posted: Fri Dec 19, 2014 5:24 pm Post subject:

peteandvanessa · Posted: Fri Dec 19, 2014 5:28 pm Post subject:

Took the jump seat and installed it in the Bus.

Still need to source some new foam for the seat bottom and back as well as some seat covers, but the jump seat is now up and running:

_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

peteandvanessa · Posted: Sat Dec 27, 2014 5:16 pm Post subject:

We have been having the "brake pedal engages and applies the brakes" when first starting the Bus. The brake pedal was also very slow to return after applying the brakes.

We have cleaned everything up, greased everything, checked free play, but the brake issue wouldn't go away. So we decided to replace the master cylinder and the brake booster all in one go.

Here's the new and old brake booster, the new one is on the right:

To get the brake booster out, you have to remove the master cylinder anyway, and I'm pretty sure it was the original, so it was showing signs of wear after all the years of service.

Here's the old and new master cylinder (new one on the right):

The new master cylinder doesn't come with brake switches, or the reservoir seals or reservoir itself, so you have to carefully remove those off the old master cylinder and transfer them to the new one. Pretty straight forward though.

It was pretty straight forward, took about 4 hours to complete.

After installing, we bled the brakes front and back and adjusted the free play as per spec. We also replaced all the vacuum lines, there are a number to replace. The one's we pulled off were in a very sorry state (most likely original too).

After getting everything bled and adjusted we went for a test drive. Sweet, no diving brakes on start up and the brake pedal returns to it's starting position immediately after applying the brakes.

The brakes are now super positive with plenty of stopping power.
_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

peteandvanessa · Posted: Fri Jan 02, 2015 4:45 pm Post subject:

So Dan is running a rebuilt 34PICT3 in his Bus, which is coupled with the notorious 009 distributor, a really bad combination by all accounts.

Before the fire, the Bus had the exact same set up, with no issues at all with hesitation when transitioning from idle to half then to full throttle.

But when we threw the rebuilt carb on the engine and ran the Bus, we had the hesitation off idle.

We checked the timing by confirming TDC on cylinder 1 (a short wood dowl down plug 1 one), then marked that on the pulley, then we used an angle finder to mark the 30 degrees advanced mark. The timing was advancing correctly about 30-32 degrees at 3500rpm, so that was normal.

Also set the mixture and idle screws as per the manual, so that was correct as well. Check the points gap, that was correct at around 18 thou as well as adjusting the valves.

Still couldn't get the hesitation to go away when transitioning off idle. Scratched my head a bit and then re-read this thread here:

http://www.thesamba.com/vw/forum/viewtopic.php?t=56411&highlight=idle+timing

The idle was fine, but as I re-read the thread, I picked up on this text here:

"With air bypass idle circuits, the mains pick up much later in the velocity curve. If you slow the air bypass velocity by opening the throttle plate, the fuel level drops in the emulsion tube and flat spot here we come.
If you shut the throttle, jack up the bypass air volume screw, retard the timing a smidge to keep your idle speed correct, or better yet, ensure that if you are supposed to have a vacuum retard with your set-up then make sure it is working, then your transition is fuelishly smooth."

So I tried adjusting the throttle plate by richening it by closing the throttle plate slightly, all I did was to loosen the screws to the automatic choke assemble and rotate the plate ANTI CLOCKWISE a little. This is like adjusting the automatic choke from summer to winter settings, but I had to go a little further than the markings on the body of the carb.

Test drove the Bus again and Bingo, no more hesitation from idle to half or full throttle. Strangely, there's nothing in the manuals to really tell you to check the adjustment of the throttle plate / automatic choke settings, it only talks about the Bypass screw and Volume control screws.

So if you have hesitation when transitioning from idle, take a look at your throttle / automatic choke settings.
_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

peteandvanessa · Posted: Tue Jan 13, 2015 7:37 am Post subject:

Hectic few days to get Dan's Bus ready for a run to Buses By The Bridge in Lake Havasu.

We had an oil leak on the Bus and the Clutch was slipping badly.

We had no choice but to pull the Engine last Sunday:

We pulled the motor, removed the clutch, pressure plate and fly wheel. Replaced the main oil seal, cleaned up the clutch and put the motor back in:

Then "Sparks" (The new name for the Bus), taunted us and puked oil all over the engine bay, had to arrange a tow back to our friends shop late Sunday night:

We traced the oil leak down to the passenger side valve cover, so we replaced the valve cover and gasket, cleaned up the engine bay.

Drove the Bus home late last night and packed it ready for the trip.

He should be leaving Sacramento around 3pm today on his way to Bakersfield. He's travelling with a Friend who is also driving his Bay Window Bus. If you see them give them a wave.
_________________
My 1974 Standard Build Thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=568220&postdays=0&postorder=asc&start=0

My Son's 1971 Bay Window Westie Build Thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7295189#7295189

RixiesRide · Posted: Tue Jan 13, 2015 10:40 am Post subject:

Great job!

If he's taking 99 south let him know that they've been doing road work between Stockton and Manteca, and the freeway is jacked-up. I have to drive to Modesto once a week and it just pisses me off how horrible that stretch of the freeway is. There's no shoulder because they have those temporary walls up, you can't tell the difference between the old lines and the new lines so you have the person in the lane next to you driving half way in your lane. And there are so many ruts in the road that it pulls you from side to side.
_________________
1973 Wild Westerner "Mr. Peabody"
1967 Beetle "Sherman"

http://s13.photobucket.com/albums/a269/RixiesRide/WW/


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Phoenix - A 1971 VW Westie returns from the Ashes
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