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Fri May 16, 2025 1:14 pm

If you're replacing the front beam because of the rust on the bearing surfaces, I wouldn't get too carried away fixing it. Most beams I've bought used, didn't come with spindles, so that would be the thing you'd need to fix. If anything, you'll want to remove the bearings and bushings out of the beam before they get damaged, as those are the hardest parts to find. They're not quite NLA, but they're very close to it. Enough so that some are making brass/bronze bearing inserts, and or using Delrin for replacements. Just something to think about. At this point, I'd probably just use a new ball joint to replace the one that was cut off. This would allow you to assemble the front beam enough to install some tires on it to roll the car around. I'd polish the trailing arms with some crocus cloth, to knock most of the rust off, and get it smooth again, so it doesn't damage the trailing arm bushings. Just some random thoughts.

Sat May 17, 2025 9:31 am

Thanks Bob. I am installing all new ball joints and have wire wheeled the bearing surfaces so they don't damage the bearings which I'm guessing are toast anyways. Right now I am just assembling things so I can roll the car out of the way to work on the beetle.

Meanwhile....

We went from this:

to this:

In three days

And just a couple of weeks ago...

You want weather? Come to Manitoba, we got weather!

Don

Sat May 17, 2025 10:30 am

Thanks, but no thanks. I/we get enough here (I'm south and east of you). We had the warm weather this past week, just not as warm as you, then the thunderstorms rolled in with the cold front (it's currently 58*F with the wind out of the north, blowing in from the lake). I'm hoping the wind will dry out the water in the swamp, so I can cut the grass. :roll:

Sat May 17, 2025 3:18 pm

Its called variable weather! Keep the weather proof boots, the shorts and the beers handy.

Sun May 18, 2025 3:33 pm

Anyways...

I just love the finish I get with POR15. Super hard, just the right gloss and easy to apply.

I bought a heli-coil repair kit and repaired the threads on the bolt I had to drill out.

And now unexpected difficulties installing the steering knuckles. It turns out to be not easy like king and link pin.

I will invite one of my girlfriends over to lean on the pry bar while I bolt things together. Hopefully she can do this without killing herself.

Don

Mon May 19, 2025 9:45 am

sunroof wrote: Anyways...

I just love the finish I get with POR15. Super hard, just the right gloss and easy to apply.

I bought a heli-coil repair kit and repaired the threads on the bolt I had to drill out.

And now unexpected difficulties installing the steering knuckles. It turns out to be not easy like king and link pin.

I will invite one of my girlfriends over to lean on the pry bar while I bolt things together. Hopefully she can do this without killing herself.

Don

Just wait until you get one side assembled, then start on the other. That's where the real fight begins (the 2 sides begin to fight each other). I normally use one of those small ratchet straps for binding things for shipping. In this case, wrap it between the two trailing arms to squeeze them together, so you can start the ball joint nuts (do the top last).
Note this is a lot easier done with the body on, as then you'll have some weight working for you, versus nothing to help you. I suppose you could always work a ratchet strap between the lower trailing arm and the top of the shock tower.

Mon May 19, 2025 9:29 pm

Quote: I suppose you could always work a ratchet strap between the lower trailing arm and the top of the shock tower.

Hmmm, I'll have to dig up a ratchet strap and give that a try.

Meanwhile...

I'll start digging into this:

DPO strikes again

So now I have to buy new tie rod ends.

All dismantled waiting to go into the solvent bath.

Then media blasting and POR 15 to make it pretty

Don

Mon May 19, 2025 9:45 pm

I think I'll invite Jennie over,

She could do this easily

She works for a company that sets up and loads out arena shows like 21 semis and like that. She is strong like bull and knows how to work safely. Ya I think I'll give Jennie a call.

Don

Tue May 20, 2025 9:19 pm

Jennie to the rescue

Surprisingly it took a full Jennie to do the job. It was much more difficult than I was expecting but done.

Now I need to dig into the tie rods

Don

Wed May 21, 2025 2:00 pm

That's the special 9* bent left inner tie rod end. I can't remember if it's left hand thread into the rod or not, as it's been a while since I've done tie rod ends on my own cars. That one can be hard to find sometimes. The rest are the same as a bug.

Wed May 21, 2025 9:03 pm

Quote: That's the special 9* bent left inner tie rod end. I can't remember if it's left hand thread into the rod or not, as it's been a while since I've done tie rod ends on my own cars. That one can be hard to find sometimes. The rest are the same as a bug.

The one I took out was right hand thread. I ordered 2 rights and 2 lefts. This better work.

Don

Fri May 23, 2025 7:51 am

Wow, that turned out nice

Now just have to wait for the tie rod ends

Don

Fri May 23, 2025 11:04 am

sunroof wrote: Quote: That's the special 9* bent left inner tie rod end. I can't remember if it's left hand thread into the rod or not, as it's been a while since I've done tie rod ends on my own cars. That one can be hard to find sometimes. The rest are the same as a bug.

The one I took out was right hand thread. I ordered 2 rights and 2 lefts. This better work.

Don

If you're keeping the car stock height, you'll want to find the 9* one, as it helps control the bump stop motion of the front end (why VW put it in). Here in the states we can order them from Autozone, NAPA, and a couple of other places.
If you're going to lower the front end 2 or more splines, then you can get away with the straight bug tie rod ends, as the angle of the left tie rod will be more in line with it lowered.

Fri May 23, 2025 3:52 pm

I bought tie rod ends from CIP1 and they don't even nearly fit

Of course now that I have the wrong ones I look more closely at their website and the ones I ordered don't even mention type 3 even though they are in the type 3 front suspension section. If I go over to the beetle from suspension there are the correct tie rod ends for my car listed under beetle front suspension. I've run into this sort of thing with CIP1 before, they are sloppy in their descriptions and website in general. I spoke to Chris at CIP1 and he agreed the website was confusing and misleading. They will get back to me on Monday with a plan. I actually have confidence it will work out, they have been very accommodating in the past when there have been problems.

Don

Sat May 24, 2025 11:54 am

Part of your problem is VW changed the size of the ball joint studs in 1966, and you have an early 66, versus the later 66, which uses the later stud size (mid 66-on).

Sat May 24, 2025 12:13 pm

Quote: Part of your problem is VW changed the size of the ball joint studs in 1966, and you have an early 66, versus the later 66, which uses the later stud size (mid 66-on).

I'm finding that out!

I spend a lot of time working on British cars and I expect this sort of thing from the British but Volkswagen?! OY

Don

Sat May 24, 2025 3:05 pm

sunroof wrote: Quote: Part of your problem is VW changed the size of the ball joint studs in 1966, and you have an early 66, versus the later 66, which uses the later stud size (mid 66-on).

I'm finding that out!

I spend a lot of time working on British cars and I expect this sort of thing from the British but Volkswagen?! OY

Don

Part of that 3 bolt door weirdness. 62-65 tie rod ends should fit.

Sun May 25, 2025 11:50 am

sunroof wrote: Quote: Part of your problem is VW changed the size of the ball joint studs in 1966, and you have an early 66, versus the later 66, which uses the later stud size (mid 66-on).

I'm finding that out!

I spend a lot of time working on British cars and I expect this sort of thing from the British but Volkswagen?! OY

Don

Yup, it's a "mid year update". VW did the tie rod ends in 66, then the inner bearing size in 68, then in 71.5 rotor and caliper size enlarged (used parts from the early 411-412).
Like Jason said, the 3 bolt door hinges (used from 61-65) are part of the clue, in that it's an early 66 (left over parts from the previous year).

Sun May 25, 2025 6:09 pm

Quote: Yup, it's a "mid year update". VW did the tie rod ends in 66, then the inner bearing size in 68, then in 71.5 rotor and caliper size enlarged (used parts from the early 411-412).
Like Jason said, the 3 bolt door hinges (used from 61-65) are part of the clue, in that it's an early 66 (left over parts from the previous year).

Dammit Volkswagen you are making my life very complicated over here.

Here's something I know: I had a 1971 Notchback in L91 Kansas beige. A friend had the exact same car *except* mine had retractable seat belts and his did not. Another mid year change.

Don

Mon May 26, 2025 12:02 pm

Maybe, but it could also be the parts supplier to the dealership, since they usually install items like that. Same applies with hub caps, and other items.