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Assembly required - '63 Vert Bug - Buildup.
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cjargo
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PostPosted: Sun Jan 31, 2016 1:46 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
ORIGINAL STEERING WHEEL RESTO

Wood filler was used to fill the cracks & shallow dents, then sanded, primered, more sanding, and followed up with three coats of silver beige from Wolfsburg West. It was color sanded with 600 and 1000 then hand buffed with chrome polish. The original horn ring was rechromed and the misc. hardware was cleaned up with 4 ot steel wool. The horn button is aftermarket. Since I've decided to go with the FIV wheel this one will eventually be sold.

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ASHTRAY

The finger pull was painted black last night and put together today. Black and chrome compliment each other brilliantly as compared to ivory and chrome.
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_________________
'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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cjargo
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PostPosted: Wed Feb 03, 2016 2:09 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
SEE NEXT.....
_________________
'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia

Last edited by cjargo on Wed Feb 03, 2016 11:09 am; edited 4 times in total
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cjargo
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PostPosted: Wed Feb 03, 2016 2:17 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
I BEAM REMOVAL FROM DRUM TO 2 IN. NARROWED I BEAM, 2 1/2 IN. DROP SPINDLES & DISC BRAKES

A stout motor calls for CB performance disc brakes and their 2 inch narrowed I Beam for safety. Hopefully this won't be a "How not to do it" version. This will be more like a picture book.

NOTE:
If the body was on the car, I'd have to remove the gas tank, disconnect the steering coupler, jack the front up and remove the wheels then the cool part begins.





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REMOVE TIE RODS

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REMOVE STEERING BOX NUTS

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MOVE STEERING ARM OVER TO CLEAR I-BEAM

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REMOVE BRAKE LINE CLIP AND HARD LINE FROM SOFT LINE

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REMOVE NUTS THAT HOLD BRAKE DRUM

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REMOVE BRAKE DRUM

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REMOVE BACKING PLATE

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REMOVE NUT & BOLT FROM UPPER AND LOWER TORSION ARMS

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HAMMER UPPER ANND LOWER KING PINS LOOSE

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REMOVE SPINDLE WITH UPPER AND LOWER KING PINS

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LOOSEN UPPER AND LOWER LOCK NUTS ON TORSION ARMS

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LOOSEN UPPER AND LOWER ALLEN BOLTS

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HAMMER UPPER AND LOWER TORSION ARMS LOOSE

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REMOVE UPPER AND LOWER TORSION ARMS

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DO OTHER SIDE THEN BOX UP AND TAKE TO MACHINE SHOP AND INSTALL NEW KING PINS INTO NEW SPINDLES. TURN AROUND TIME 24 HOURS.

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I BEAM INSTALL

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_________________
'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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cjargo
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PostPosted: Sat Feb 06, 2016 2:26 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
LINK PINS ASSEMBLY & FINAL FRONT END ASSEMBLY

The only curve ball was the CB brakes that were completely disassemble for QC reasons. Some of the bolts that people usually don't check were finger tight. I also zinc plated all the hardware that came with the brakes. They always rust. Bear with me, I'm still cutting my teeth.

SHIM ADJUSTMENT & LINK PIN ADJUSTMENT

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THIS IS THE DRIVERS SIDE.

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CONTINUE FRONT CLEAN UP & END ASSEMBLY


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THE SPINDLE CARRIAGES ARE PAINTED IN HIGH HEAT CLEAR.

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_________________
'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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hitest
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PostPosted: Sat Feb 06, 2016 8:44 pm    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
Bravo sir! This is becoming more like the Bentley manual of my dreams! Full color, HD clarity, simple, detailed descriptions... Fantastic job!

Looking forward to a sneak peek at your FV wheel too, I've got on old NOS one going in my '62 convertible.
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EverettB wrote:

I wonder what the nut looks like.



'62 L390 151, '62 L469 117, '63 L380 113, '64 L87 311, '65 L512 265, '65 L31 SO-42, '66 L360 251, '68 L30k 141, '71 L12 113, '74 ORG 181

FU#5
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far rider Premium Member
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PostPosted: Sun Feb 07, 2016 6:21 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
Wow! Doesn't get any better than that. Thanks for laying out the procedure with step by step clarity. The picture detail is so helpful. Much appreciated.
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cjargo
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PostPosted: Sun Feb 07, 2016 9:13 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
hitest wrote:
Bravo sir! This is becoming more like the Bentley manual of my dreams! Full color, HD clarity, simple, detailed descriptions... Fantastic job!

Looking forward to a sneak peek at your FV wheel too, I've got on old NOS one going in my '62 convertible.


Thanks for following the thread and the kind words. Actually most of the info comes from the Bentley manual plus a little experience.

Today the FIV steering wheel gets a 3rd coat of varnish. I may strip it and star over because I'm not 100% on the color. I looked at your FIV and it's stunning, and the way the spokes flair out to meet the wood is stylish. Great find on the wheel.
I'll post the progress on my wheel later tonight.
_________________
'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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cjargo
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PostPosted: Sun Feb 07, 2016 9:46 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
far rider wrote:
Wow! Doesn't get any better than that. Thanks for laying out the procedure with step by step clarity. The picture detail is so helpful. Much appreciated.


Knowing that someone critical is pay attention keeps my discipline steady and makes for a better build. So thank you for paying attention and helping with the build.

Since the I-beam, spindles and brakes was pre-sold to a gentleman who had never R&R'd them before, it seemed right to make his job easier by thoroughly documenting the info and pass it on.
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'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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grandpa pete
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PostPosted: Sun Feb 07, 2016 3:21 pm    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
Excellent photos ; you will help many in the future with your documentation !

Now for a little smart assed Bostonian sarcasm ; Twisted Evil

Question Very Happy Do your brakes use gasoline or are you running special carbs that run on brake fluid ? Twisted Evil

How many miles do you plan on getting with 5 ounces of brake fluid . Razz
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vwnut1
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PostPosted: Sun Feb 07, 2016 4:54 pm    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
Superb build and documentation. Q. Is the drivers side stainless brake line under stress when the wheel is at full left?
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cjargo
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PostPosted: Mon Feb 08, 2016 10:54 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
grandpa pete wrote:
Now for a little smart assed Bostonian sarcasm ; Twisted Evil

Question Very Happy Do your brakes use gasoline or are you running special carbs that run on brake fluid ? Twisted Evil

How many miles do you plan on getting with 5 ounces of brake fluid . Razz


Good eye. The windshield washer bottle will be the gas tank, and then the brake reservoir as a reserve.
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'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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cjargo
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PostPosted: Mon Feb 08, 2016 11:43 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
vwnut1 wrote:
Superb build and documentation. Q. Is the drivers side stainless brake line under stress when the wheel is at full left?


Thank you vwnut1. Good catch. Initially the tie rod was binding on the gas line so the gas line was altered and now it clears by 1/4 inch. It will be QCd again one everything else is stitched in.
_________________
'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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cjargo
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PostPosted: Tue Feb 09, 2016 1:57 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
LOCKING GEAR SHIFT LEVER ASSEMBLY

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NICE HANDLING UP GRADE.

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CLUTCH PEDAL ALIGNMENT.

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HAND BRAKE RESTO PREP.

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'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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Airride66
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PostPosted: Tue Feb 09, 2016 11:06 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
Great work. Your doing a pretty thorough job trying to use most of the original parts!
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cjargo
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PostPosted: Wed Feb 10, 2016 12:58 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
Airride66 wrote:
Great work. Your doing a pretty thorough job trying to use most of the original parts!


Thanks Airride66. I think we all enjoy the challenge of restoring the seemingly impossible. With every passing day we have fewer and fewer original parts. And for the aftermarket stuff, well.... it cheapens what VW stands for.... A quality built car. So that's why I go the extra mile. Again thanks for noticing and reading the thread.
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'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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cjargo
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PostPosted: Wed Feb 10, 2016 1:16 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
Single to duel circuit master cylinder conversion.


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Before disconnecting bleeder kit....


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Place plastic then a rag to catch any spilled brake fluid. It will damage the paint.

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_________________
'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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Bala
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PostPosted: Wed Feb 10, 2016 9:02 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
What a great project! It's coming along nicely.
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pwomble
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PostPosted: Wed Feb 10, 2016 5:02 pm    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
Time to raid the secret stash of metal clothes hangers to install my stainless brake lines! Great idea.
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grandpa pete
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PostPosted: Thu Feb 11, 2016 11:51 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
Excellent tutorial on master cylinder upgrade .
I added it as additional info on my " Upgrade to dual master cylinder " thread .

The coat hanger idea is genius !!
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http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery
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cjargo
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PostPosted: Fri Feb 12, 2016 12:11 am    Post subject: Re: Assembly required - '63 Vert Bug - Buildup. Reply with quote
grandpa pete wrote:
Excellent tutorial on master cylinder upgrade .
I added it as additional info on my " Upgrade to dual master cylinder " thread .

The coat hanger idea is genius !!


Very cool. Glad it could be of help GP. Today I purchased a brake line bender from Eastwood that is fast, makes tight bends, easy to use and priced well. They have a video of it in action which sold me. Check it out:

http://www.eastwood.com/ew-brake-forming-tool-pliers.html
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'63 Vert. Bug - '58 Bug Ragtop RHD - '63 Vert. Bug -
'78 911 SC Targa - '69 911 E - '57 Vert. Porsche - '84 GTI - '69 Bus - '57 Bug - '68 Bug / Sunroof -
'65 Bug - '63 Bug - '74 Bus - '72 Karmann Ghia
'67 Bus / Sundial - '59 Karmann Ghia
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