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Buggeee Mon Dec 12, 2022 6:57 pm

Meanwhile.... I've got the pedal assembly installed in the rally bug. Here I've staged the parts. As long as I was replacing a worn clutch hook, I opted for the bigfoot style extension for the clutch pedal with a brass bushing for the cable end to roll on. A new brake pedal spring, roller gas pedal and fresh rubbers rounds out the package.




Here in this next picture I've got the clutch cable mounted and am reminding myself that the brake pushrod has to slip on after the cluster is dropped into position.



This time I passed the throttle cable through a plumber's brush full of axle grease as I feed it in. I used to grease the whole cable first, because I am a slow learner.



And ready for action.



Setting the speaker kick panel in place I find there's not a lot of room with the clutch pedal extension kit. I'm not turning back though so will just have to see how it all works in the field. Also - I had to reshape the hard brake line a bit to get it out of the path of the extended clutch pedal so there wont be any rubbing on that.


Buggeee Sun Dec 18, 2022 12:18 pm

Tedium. Inching towards the finish line.

Rear seat rack and panels are in place.




Cleaning and greasing the door mechanisms for the installation. The doors now open and close and lock and unlock. It's the little things that will be taken for granted. That satisfying click as the door latches, attributed to those German engineers. :)








Rayfield Sun Dec 18, 2022 1:11 pm

Nothing to add, just popping in to say that this is a fantastic build. Great work! Enjoying your photos.

vamram Sun Dec 18, 2022 3:29 pm

Yeah, love the progress. Every update is like the next episode of the reboot of Battlestar Galactica, I couldn't wait then boom there it was, yet another crazy twist (that's a good thing).

Buggeee Mon Dec 19, 2022 9:45 am

One of my asshole neighbors shot my cat Marcel with a .22 so I had to put him down. Fuckers.


Cusser Mon Dec 19, 2022 9:50 am

Buggeee wrote: One of my asshole neighbors shot my cat Marcel with a .22 so I had to put him down. Fuckers.
OK with me that you off'd your neighbor for shooting your cat; hope the cat is OK.

vamram Mon Dec 19, 2022 11:00 am

Cusser wrote: Buggeee wrote: One of my asshole neighbors shot my cat Marcel with a .22 so I had to put him down. Fuckers.
OK with me that you off'd your neighbor for shooting your cat; hope the cat is OK.

Dang Cusser...we get it but...wow!

That is so messed up Buggee. Do you have any legal recourse for that???

Buggeee Mon Dec 19, 2022 1:09 pm

I live in farmland and the cat would roam. The sound of rifle practice is commonplace. He was gone for a day so it may have taken him some time to get back from wherever he was. He taught me that eating a mouse sounds like eating a bowl of potato chips. It was love at first sight and I will miss him. When I pulled in returning from the vet the Fed Ex delivery driver handed me the box with his electric warming house. That's the way of things sometimes. Hopefully one of his siblings will adopt us.

Buggeee Mon Dec 19, 2022 1:12 pm

Cusser wrote: Buggeee wrote: One of my asshole neighbors shot my cat Marcel with a .22 so I had to put him down. Fuckers.
OK with me that you off'd your neighbor for shooting your cat; hope the cat is OK.

Well played my good man. I hadn't notice the cards I turned over there. :lol: You laugh or cry. Better to laugh. Thank you.

Busstom Mon Dec 19, 2022 2:23 pm

Buggeee wrote: One of my asshole neighbors shot my cat Marcel with a .22 so I had to put him down. Fuckers.
That there is f***ed up. :x

67rustavenger Mon Dec 19, 2022 7:42 pm

That's fucked up!

Marcel was a great looking cat. And I'm sure a great companion.

I would have been very happy to have him in my home.

I'm really sorry for your loss Buggee.

Like you said. Maybe one of his siblings will adapt you. I hope so!

VW_Jimbo Mon Dec 19, 2022 11:29 pm

That is bullshit, my friend! What the fuck! What kind of person does that sort of thing? Even those around me, would never stoop to a level that low. That includes asshole Dave! Asshole Dave at least waves every other week, when the Mrs is not looking.

Sorry man! I loved painting him green!

Zundfolge1432 Tue Dec 20, 2022 8:15 am

Buggeee wrote: One of my asshole neighbors shot my cat Marcel with a .22 so I had to put him down. Fuckers.



Sorry to hear that we have two cats we like and they earn their keep catching and eating anything smaller than themselves 😀Hardly a day goes by we donít witness or hear about some example of douche baggery . My neighbor had two dogs get out of his back yard and go missing, but they didnít get too far because one of the meth heads living behind us shot them with a crossbow. This would have gone unnoticed if he hadnít been stupid enough to brag about what he did on Facebook.

The dogs owner is an ex Marine ( I know they never really quit being Marines) and I think the meth head has stumbled into one of those
ďFuck around and find out outĒ situations. On the other hand we are outside city limits so can and do shoot guns all the time. No services such as animal control in fact the city tells us to shoot nuisance animals. Catch22

Buggeee Tue Dec 20, 2022 8:39 am

Zundfolge1432 wrote: Sorry to hear that we have two cats we like and they earn their keep catching and eating anything smaller than themselves 😀Hardly a day goes by we donít witness or hear about some example of douche baggery . ...On the other hand we are outside city limits so can and do shoot guns all the time. No services such as animal control in fact the city tells us to shoot nuisance animals. Catch22

Ya thanks Z for the condolence. Thats how it is here too. If you call the Sherrif about an animal they are likely to ask why you are bothering them instead of handling it yourself. Still, the stink of opportunistic overindulgent douche baggery is pungent here as we all readily distinguish a varmint from a bright white pet cat. The scale balancing here will be left to a power greater than I.

It was cool to know a cat that was interested in sorting nuts and bolts while we worked together on the bench.

Buggeee Sun Dec 25, 2022 8:22 am

She does love me!

Merry Christmas Everybody :D



Zundfolge1432 Sun Dec 25, 2022 9:30 am

So much truth in that bumper sticker 😀

Busstom Sun Dec 25, 2022 1:08 pm

Merry Christmas!🎄🎅❄

Buggeee Sun Dec 25, 2022 3:23 pm

One of my kids loves me too! What a great Christmas 🎄 :D

This is a calendar full of Ohio bugs. I recognize some of them from the local shows.



Buggeee Wed Dec 28, 2022 10:53 am

I have found a process that I enjoy less than a headliner. Building the doors! It's like working one of those little wood block puzzles where only one space is missing and you have to slide all the little blocks around, and then slide them back fourteen times to try different maneuvers until you finally stumble on the correct order of things. At least that was my experience. :?

Most importantly, I learned that the little clips that hold all this stuff together, like for example the little clips built into the inner window scrapers, are not designed to come out once they go in. I destroyed some things during some do-overs here, and thankfully my inner window scrapers were in good shape so I re-used those after killing the new ones I bought.

So to start things off, I just followed some Chris Vallone videos I found on YouTube. If I had stuck to his order of things I'd have been fine. I have resisted putting a screen up in the barn to watch videos on so doing it from memory I was at a disadvantage. :lol:

This window regulator has to go in before the vent windows.



I put the vent window in first - and then found the regulator blocked by the spot where the vent window bolts to the inner door. Its got to get above that spot.



As the vent windows went in after the chrome trim with the rubber scrapers were already installed (its own fiasco), I opted to just pull hard on the inner door, distorting it enough to push and squeeze the regulator through the obstacle. Here is a picture of the regulator stuck at the mid-point, peeking at me through the hole in the door while I enjoyed a couple swear words and sucked on the finger I got stuck in there for a moment.



It worked though, eventually popping above the obstacle and all was good again. Of course, I marked that point in my mind as a never-to-be forgotten lesson. I then, of course, promptly forgot the lesson and put the scrapers and vent window in the other door before reaching for the regulator. ](*,)

Before or after the regulator, but definitely after the door latch mechanism, a channel for the felt channel goes in the rear side of the door. A couple of these felt clips are put in it before it goes in the door.



Then, using a little S-shaped clip it pushes up and clips into a slot on the door, then the bottom bolts to the door.



Then the chrome strip with outer scraper pops in the side of the door with these built-in spring clips





And then the clips are added around the outside to hold the chrome in place and provide something to grab the felt channel that gets pushed into it



At the front on the bottom there is a little tab that bends around the door metal to kind of hold it in place until the vent window installs (don't mind the splatter from the polishing compound, it wipes off).






These are the clips for the chrome strip and felt channel. I was missing a couple and broke a couple. The one on the left is broken, and worthless. The one on the right is still good.



Because I did not have enough clips for the second door, I used an adhesive that holds a fiberglass rope seal onto clothes-dryer doors. Its like a fast setting, strong rubber cement from what I can tell, and it is handy for lots of things. Including, in my barn, installing window trim. To be fair to myself, Chris Vallone said the early bugs have little screws for the chrome strip and glue for the felt.





I found some tools to jam in there with c-clamps for a few minutes until it set. the next day a bag of clips arrived in the mail. :shock: Ready for next time I guess. :D



I glued the new felt channel to the vent windows and dropped them in at an angle, rotating up into position and watching the chrome strip ends to help them find home while the vent window went into position.




You can see in this picture that the inner door scraper interferes with the insertion of the vent window so, having learned this, I will forget to do the inner door scraper after the vent window next time as well, I predict.



A single screw at the top holds them in the frame and a single bolt at the bottom holds them to the inner door (after the regulator is in!). You will notice the second picture I am pulling felt channel out of the way to install the forgotten screw. This bends the clip a bit so there is a price to pay every time you back-track in this door-building task.







The long felt channel is the easiest part. I kind of bent it to roughly fit the destination.



The shoved it down into the door.



Then pressed it into the channel starting at the top-front by the vent window and then along towards the rear, then up into the corner, then down the back.




On the passenger side I put a bead of adhesive first, as that side did not have clips.

The glass is the easiest part. I just bent the regulator back enough to slide the glass up into the door, slid it up into the felt channels front and back, and bolted it to the mechanism.




And now the doors not only open and close, lock and unlock, but the windows go up and down as well! \:D/


vamram Wed Dec 28, 2022 11:04 am

Nice work Buggee. I don't know, though, headliner is it for me. Nothing worse, would love a do-over on mine, but I already did it 2x, and the thought of removing windshields and side glass and stretching and gluing and cutting again just don't do it for me. I'd travel to OH to help you do your doors before I'd redo my headliner!!! :shock:



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