TheSamba.com :: View topic - Great Grandpa’s 1964 Sunroof Bug Full Stock Restoration

Tue Nov 21, 2023 10:35 pm

Any updates on it yet, how’s the project been?

Mon Nov 27, 2023 5:33 pm

No update. I just got back from a month in Asia for work. I still have the same electrical issue but also a serious case of "I don't want to work on that right now-itis"

:)

Tue Apr 29, 2025 1:25 pm

Quote:

In April 2002 i had my deluxe also features. Good times. I still have this bus.

Quote:

It does not seem that long ago I watched you paint the SWR on that bus @ your Dad's shop. Wow time flys! Oh, BTW my SO42 purchased a bit before you bought this bus still sits in my garage unfinished. You "completers" are to be admired. Just a different breed than us "attempters" ;-) Hope you are well sir. Great work on the sunroof as usual.

Wed Apr 30, 2025 7:00 am

Thank you Steve. I can always count on you go present the bright side.

Look how young that kid was. Man we were young.

Wed Apr 30, 2025 7:10 am

And for an update.

Is any work being done? Nope.

But as Sheriff Doc said to Lightning. "Get a good look son" Why yes, i now can get a good look with my new lift. The idea is that when i get back to this project i can more easily work on it. It is 3rd in line right now...

Now to clone a few more of me or find a good local mechanic.

Wed Aug 13, 2025 7:53 am

Actually did some work on the 64. I have been messing around with my 65 bus trying to get the engine correct. (Thread below. I did not start it but probably kick-started it)

https://www.thesamba.com/vw/forum/viewtopic.php?t=395732

This in combination of the already mentioned Black beauty 22 mile 64 bug i have been in pursuit of blue ignition wires and white wire clips.

This is the 22 mile bug.

My focus has been reproducing the color, length and ends of the ignition wires to the best that can be done. Also making the white clip.

You can read about it in the 1200 Bentley manual. (Forgot to grab a image) If i recall it was 1962-ish. Ill have to find that. I also learned that prior to 61 they were orange red and dark red. Things you learn...

I made a set for my 65 1500 bus and my 64 1200 bug. (Lengths are different. It is nice to get rid of the "one size fits all" black wires)

Anyways... My results.

The bug.

And in my bus.

Wed Aug 13, 2025 8:55 am

Per usual Matt, your attention to detail is next level. Nice. Did you make those “VW” stamp safety wire seals or were they always on that governer?

Wed Aug 13, 2025 9:27 am

swharris wrote: Per usual Matt, your attention to detail is next level. Nice. Did you make those “VW” stamp safety wire seals or were they always on that governer?

Thanks Steve. I found another enthusiast who had the VW stamp.

Mon Sep 15, 2025 9:52 am

Motivation building...

Saturday i got her out trying to find my mo-jo.

Some time ago I lost my to-do list for the bug. Part of my motivation problem. Re-wrote that list. Everything from basic fuel check-out from sitting for so long to finishing touches like interior hand straps and sunroof headliner.

No pictures but I figured i would fix one thing while out there so i put in a new red battery cable to the starter. It was suspect last year. I also removed the hard start kit to get back to basics. Measured my "New", year old 6V battery at 6.09V and gave the starter a go.

Nothing... Well just a slight "click" and nothing. Reminds me of this adventure...

https://www.thesamba.com/vw/forum/viewtopic.php?t=792826&highlight=no+start

Will follow my own thread and see what i can learn.

My bet is the starter because i did not know what i was doing back in 2021.

I also found a few bummers.

First, my plating on the generator was not so great. Rusty. Will have to re-do.

Second is damage from something that dropped against the car cover. Easy to fix.

Third was me being stupid with my floor jack... This one hurts as it means paint...

Oh well... It happens.

Come on motivation. Don't fail me now...

Fri Sep 19, 2025 8:29 am

Starter troubleshooting... Pulled starter out expecting it to be a used one. It was not. hmm... OK. Unit on bottom came out of the car. Unit on top was another i had on the shelf. Both tested the same. I was looking for the solenoid to pull. Tested by shorting direct from battery to solenoid. Not alot happening... OK. Lets start with the battery. 6.09 is a bit low. Lets put it on the charger and try again later.

In the meantime took a look around. Cobwebs galore

Master cylinder leaking. Lost all the fluid and my nice pan is not so nice. Uggg...

Engine. here is the rust i shared about. My options are to strip the parts back down and try to plate them again or find suitable replacements. Any opinions?

This weekend i hope to work through the starting issues by bypassing parts to figure out where my voltage drop is coming from.

Pull spark plugs and ignition for easy crank
Check ground straps
Hard short starter at solenoid
Bypass entire harness and run direct wire from ignition to solenoid
Bypass light switch and run direct...
Bypass fuse box and run direct...
Bang head against wall.

Fri Sep 19, 2025 10:08 am

matthew henricks wrote:

My focus has been reproducing the color, length and ends of the ignition wires to the best that can be done. Also making the white clip.

Did you 3D print the white clips? Or do you have another source? Thanks

Nick

BTW, on my 63 6v bug, I added another ground wire from the starter body to the pan, and it spins over way faster now. Something to consider

Fri Sep 19, 2025 11:39 am

Mooosman wrote: matthew henricks wrote:

My focus has been reproducing the color, length and ends of the ignition wires to the best that can be done. Also making the white clip.

Did you 3D print the white clips? Or do you have another source? Thanks

I did. I am working out some bugs with them right now. When done i plan to make them available.

Mon Nov 24, 2025 10:09 am

No pictures...

Found a little motivation this weekend. I am trying to figure out why i cannot start the motor. I get nothing. Not a click or anything when turning the key.

First step was to remove the hard start kit. I find it hard to believe my wiring and fuse block are bad. I want to go back to basics first.

- I already soldered up the fuse block.
- Wiring while not new, was replaced in the 90's with a wiring works loom and worked fine when the car was taken apart.

Things i looked at and prepped for.

- Battery charged to 6.4V
- Starter in good shape AFAIK.
- It is a AC Delco rebuild of a bosch unit. 6V Has maybe 20 starts on it.
- All grounds installed and of course clean.
- I pulled the spark plugs to make turn over easier.

Nothing. Still no click or any sign of life.

I then checked continuity from:

- Batter to starter. Check
- Starter to Generator. Check.
- Generator to Light switch. Check
- Light Switch to Fuse Block. Check
- Fuse Block to Ignition switch. Check
- Ignition to solenoid. Check

I then checked the ignition switch for continuity. All OK.

Next i am going to chase voltage drop. I do not have a spare 6V headlight handy and every time i read how to do this i come away flustered. Anyways... here we go again...

How come i already think this is a solenoid problem...