2/61 15 window restoration

[acrosier]

Hey there everyone. I'm finishing up the dash wiring and cable routing for Elsa, my '61 15 window with a '59 nose. I need to install the parcel tray underneath, but can't seem to find a photo or at least a discussion of the wire or cable routing. The weldor had pulled the wiring, fuse box, and speedo cable. I just want to get this all back in place correctly, and only have one bus these days, so I haven't a reference sitting next to me. Anyone familiar with a photo link on TS or willing to snap a picture or two to help me get this back together?

Thanks!
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2/61 15-window walk-through "Elsa"

http://www.thesamba.com/vw/forum/viewtopic.php?t=428802

[acrosier]

This is Elsa when I bought her. After selling her to another buyer, the owner hit a deer at 55 mph. The impact had an auto-stop response: it applied the emergency brake. He and his passenger kicked the nose out to drive home.

I picked up this nose to have installed, but no parcel tray. The nose is perfected clean with no bondo. It came off a rolled panel, so no deluxe dash stuff like the grab handle and clock.

Unfortunately, it’s a ’59 nose, so the fuse box support is this:

So I kept the original damaged frame piece so I could use the original box:

The nose is on now. Yes, my little metal shop VW emblem hangs by a nail until I pick up an actual one. The original emblem and deluxe trim still had deer hair in them when I bought it.

I picked up another parcel tray which I have painted to as closely match the Geo turquoise that the body is painted, for now. The inside of the nose is still Dove Blue, obviously. I’ve already painted the dash.

So here is my dilemma:

I need this parcel tray in, but where do the cluster wires go? And how does everything route to the fuse box?
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2/61 15-window walk-through "Elsa"

http://www.thesamba.com/vw/forum/viewtopic.php?t=428802

[jeremyrockjock]

Looks like a great repair job.
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Why buy what you can build.
Step away from the fiberglass and no one gets hurt!!

[EmpiGT]

All the wires go over and behind the shelf. The only thing that gets routed through the shelf is the speedometer cable.

[acrosier]

[Clara]

58 :

This next pic is of a 66, but has the same fuse box as a 61.
It is held in by a clip at the left, just visible in the pic.
The 61 would not have the 9 pin relay box at the lower left:

hope that helps.
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The Obsolete Air-Cooled Documentation Project http://oacdp.org/

[acrosier]

[Clara]

[acrosier]

[Rain's Westy]

[Eric&Barb]

At very least you need to take each brake cylinder apart for a good cleaning out and inspection. Doing so will also drain out all the old brake fluid, which is going to have lots of water in it.
We have been leaving brake systems apart for about three weeks to let air dry completely. Then changing to the silicon brake fluid which is not hydroscopic like the usual brake fluid is. You still need to bleed the brakes every year or two with silicon brake fluid to get rid of any water in the lowest part of the brake system.

Sounds like the muffler you have is for a 1200 cc, not the later 1500/1600.

BTW is you old bus nose already gone to the scrapper? We could use some parts off it for a project we have.
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In Stereo, Where Available!

[acrosier]

Hey Rain! Are you still in NY?

Oh there's plenty to do. I got sidetracked with a motorhome and a boat and buying a house, but I'm finally back to it. Poor Elsa always takes the back burner.

Really good to hear from you. I appreciate the offer very much! Metal work will likely be my winter project so expect to hear from me!

Everyone else, credit where credit is due: this is the weldor who blessed Elsa with her new nose and helped me get underway on this project.
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2/61 15-window walk-through "Elsa"

http://www.thesamba.com/vw/forum/viewtopic.php?t=428802

[acrosier]

[Eric&Barb]

Well the early 40 HP (1200 cc) muffler has a rubber bracket that bolts to the dampener, that bolts to a welded on bracket on the left rear bumper bracket.

1500/1600 muffler has metal bracket that bolted to the left of muffler and to the dampener.

Got images of your muffler?

Lots of good info in the parts manuals:

http://www.oacdp.org/aboutdoc.html

See the links at the bottom of that webpage.
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In Stereo, Where Available!

[acrosier]

[Eric&Barb]

If you look at the parts manual you can see in the parts listing that some parts were used up to a certain chassi #, and other were used on from that number.

If you use the later steel bracket on the left of the muffler, then you do not use the smaller bracket welded to the muffler.

If you use the earlier bracket welded to the muffler, then you use the early rubber support to bolt the outer end of the dampener to the early LR bumper bracket.

Found it is best to just use the later steel bracket bolted to the left of the muffler. Then weld the dampener into the muffler opening. Unfortunately the dampeners when bent loose the round shape and become more oval. So the dampener does not seal properly in the exhaust gasket there. This in turn if leaking exhaust can get into the engine compartment and to the interior. Monoxide in exhaust getting to you or your passengers is not nice, can cause brain damage with long time low exposure, and even death at higher levels.
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In Stereo, Where Available!

[acrosier]

Got the '61 fuse box surround tacked in. Grinding, painting and wiring tomorrow!

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2/61 15-window walk-through "Elsa"

http://www.thesamba.com/vw/forum/viewtopic.php?t=428802

[Z]

[acrosier]

[Z]

Mine is currently disassembled, and its been awhile, so that may well be correct.