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  View original topic: Barn Find THING, Full Restoration, 27,000 Original Miles. Page: Previous  1, 2, 3 ... 9, 10, 11, 12  Next
oasis Fri Sep 11, 2015 5:37 am

I admire write-ups like this but seldom comment because most is beyond my abilities. I like the electrical tape idea. Gonna employ that myself. (I like the Touareg, too.)

randybriscoe Wed Oct 14, 2015 9:50 pm

Certainly NOT beyond anyone's ability, we're just crazy enough to take this on. We don't have any special skills, except for maybe the future owners willingness to invest Porsche money in a VW. A solid car meant no tedious panel replacement. Chemical striping removed all the paint, rust and under coating. That's the hard stuff. A trusted body shop handled the minor body repairs. The rest is just trying to remember what went where.

randybriscoe Fri Oct 16, 2015 8:37 pm



This time we're replacing the rubber steering coupler. We also got a new ground wire. The fancy original nuts/bolts were in great condition, so we re-used those.

randybriscoe Fri Oct 16, 2015 8:44 pm



Time to get the brakes finished. This is the master cylinder reservoir. It fits up under the trunk, in the the passenger compartment. Location was selected to keep it out of harms way. It's made up of three pieces. The reservoir, the filter screen, and the cap. This is the original unit, cleaned up.

randybriscoe Fri Oct 16, 2015 8:49 pm



The reservoir is held in place by this rubber collar device. Its yet another unique Type 181 part, note part number. This is the original and is in excellent condition.

randybriscoe Fri Oct 16, 2015 9:03 pm



The reservoir is inserted into the mounting hole in the body (trunk), from inside the passenger compartment.



The rubber retaining collar is forced down over the neck of the reservoir.



This is all that holds the reservoir in place.




Now the filter and the cap can be applied. The cap is vented.



Here's what it looks like from inside.

randybriscoe Fri Oct 16, 2015 9:10 pm



Rubber seals for the reservoir hoses.



Hoses from reservoir

randybriscoe Sun Oct 18, 2015 11:24 am



The complete master cylinder assembly installed. But I still feel like we're missing somthing?



Of course...we forgot the the brake light switches. These are fun to install if the master cylinder is in the chassis with all it's lines attached! This switch also fits the Gurgel. The first Gurgel I ever saw was in the Virgin Island's in 1980.

randybriscoe Sun Oct 18, 2015 11:31 am



Me re-tapping/cleaning all the body mounting holes. I know...where's the safety glasses.



The threads were in great condition, and we were very fortunate not to strip any when the car was disassembled.



My view as I tap holes, bottom of right side rocker panel.

randybriscoe Sun Oct 18, 2015 11:40 am



Installing the body onto the chassis went so fast, that I didn't even have time to set up for a good picture.



It's like we just climbed Mt Everest or something.



We are just so proud of ourselves...

schwim Sun Oct 18, 2015 11:59 am

An absolutely fantastic transformation from a vehicle that saw maybe the hardest 27k miles on earth to one of the nicest specimens around. I really enjoyed the whole thread. Thanks for sharing!

randybriscoe Thu Nov 26, 2015 11:00 pm




A final check of the brakes. We learned that it's way easier to bleed the brakes if they are adjusted. Now adjusted and bled, we move on.

randybriscoe Thu Nov 26, 2015 11:05 pm



A mix of original and new. The correct 181 snubber installed w/gas shocks.

randybriscoe Thu Nov 26, 2015 11:30 pm




Once the steering wheel is removed, the whole steering column assemble can be slid off the steering shaft. Four screws retain the turn signal / windshield wiper controls. The bright light switch is part of the turn signal assemble, ours was falling apart, so we replaced it.

randybriscoe Thu Nov 26, 2015 11:43 pm





This control housing assemble is pinched onto a tab, that's welded to the steering column. One allen head bolt retains it. the housing slides off (rubber mallet) toward the steering wheel side. We removed the steering shaft bearing retaining snap ring, and gently pushed out the bearing from behind.

randybriscoe Fri Nov 27, 2015 12:06 am



We put the bearing in the parts washer & inspected it. I greased it up and reinstalled it back into the housing. The ignition cyclinder slides in very easily. There is a small spring and a tiny foam pad that goes in before the the retaining plate slips on. I could not position the retaining plate correctly over the spring, until I remove the padding around the key area. It just kinda pulls off with a rolling action.

randybriscoe Fri Nov 27, 2015 12:10 am



With the rubber padding removed from around the key area, the retaining plate lines up easily with the spring, and the two retaining screws drop right in.

randybriscoe Fri Nov 27, 2015 12:30 am




It was at this time we discovered that the Chinese had done it again. It's hard to see in these pictures, but the four holes in the two control modules, need to line up. Four guide tubes slide into the holes. The guide tubes stabilize, join, and prevent the crushing of the two control module assemblies. Anyway...We used one of the guide tubes and a broken 1/8 inch drill bit to grind the holes wider. We'll keep our eyes open for an NOS German replacement unit.

randybriscoe Fri Nov 27, 2015 12:55 am



The wires in the two modules are routed to the back of the assemble by two plastic guides. The guides clip together, then insert into the rear of the wiper control module. Again, the Chinese quality control caused a delay as we had to clean all the flash off the plastic of the new unit. After that the whole assemble slides into the housing. There is a small brass ground contact that could easily lost or forgotten. it's on the top left side. Because of the poor quality control of the turn signal half of the assemble, lining up the screws was a challenge.

randybriscoe Fri Nov 27, 2015 1:10 am



The ignition / turn signal / wiper control assembly slides onto the steering column. It's pinched into place on a tab that's welded to the side of the steering column. Now if we could only find the lost steering wheel!



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