Scrivyscriv's 1967 java green sunroof sedan (stock)

[scrivyscriv]

Took a couple of days to get everything squared away but I think I’m about done with the wipers! I may have to swap over a motor drive link, so I’ve got a 6V SWF motor core on the way in case surgery is needed. I’m really thinking about using the tig function on my multi-process welder if I need to swap the link. This wiper assembly is very different from what was in the car originally and is even in better shape! the shafts are way better and the linkage is all very tight.

I snapped a couple e-clips reassembling the linkage. I’m glad I had replacements!! They flew across the room when they broke…

Since I was mixing up epoxy and paint anyway I prepped the new pushrod tubes and front brake drums to go along with my pan washers and the wiper parts. I’m still really struggling with gettin a good consistent glossy finish from the paint gun.. I think it’s my settings.
That bottom photo is before I swapped the motor over to the new frame. My center defrost vent tube had holes punched in it right where the old wiper assy went, and it looks like the incorrect assy was the reason for it.

If anyone’s interested, I’m painting with summit racing 2k flat grey epoxy, and their 2k single stage gloss black. No filler primer on these parts since I wasn’t going to do any more prep to them. I repacked the wiper pivot shafts with redline cv grease.. I’m not sure if that’s the best grease, but it seemed like a fairly decent lube for the situation.
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[msot99]

Just stumbled across your thread and noticed you were local. I love all the pictures and the attention to detail! I don't have nearly the discipline.

[scrivyscriv]

[scrivyscriv]

1967-only wiper conversion!

The donor 6V single speed wiper motor came in! It's a SWF and is not interchangeable with the Bosch motor I presently have in any meaningful way. My first plan was to swap the wiper motor linkage on the end of the motor shaft. I found the SWF motor output shaft is retained on its gear by a press fit and small pin through the shaft to index it on the gear. Well, truthfully, I found the pin AFTER I pressed the shaft out. It's very small.

I thought maybe the entire output shaft would interchange, but they do not. The shaft on the Bosch motor is much larger diameter and is not pinned on the same way as the SWF motor. You can see here the difference in shaft diameters and also the small hole drilled in the SWF for a pin.

That's fine.. I thought it would be simper to swap the entire shaft over, just pressing the SWF shaft into the Bosch gear, but that will not work. So I decided to proceed with my original plan, TIG welding just the drive link on the shaft.

The drive links are peened in place, very easy to remove with some surgical grinding. I used my 1/4" angle die grinder with a zizz wheel for intial metal removal and it was pretty good. Much more control than the electric 4-1/2" angle grinder.

The Bosch link was peened differently with much less material in the joint. I would call it more "swaged" than "peened," but tomato tomato. It took a bit more work to remove and because the motor cover plate was still in place, I was concerned I'd bend and warp the plate if I put too much pressure on the assembly.. I used two pieces of 1/8" angle iron to support the shaft while I knocked it out with a punch.

Finally, got the link swapped in, and with a little cleanup it was ready for a fusion weld with my TIG machine. I usually MIG weld and am a real beginner at TIG. I recently bought a new multi-process welder from Eastwood based on the experience I had with their 135 MIG, and it's lived right up to expectations! The TIG function does not have a foot pedal option so the tungsten is hot anytime the welder is switched on. After a few practice scratches, I put my Bosch motor in the vise and did a few swirl passes with the torch. I only wanted to melt the edges in, not add extra material or make a deep honkin weld, in case it ever needed to come back apart.

And that's about it for the wiper conversion. It is now essentially a 1967 only motor.. 12 volts, two speed, and smaller diameter linkage. I have a Wolfsburg West order coming next week with the final pieces.. a bushing kit for the the drive linkage, wiper shaft caps, a rubber insulator for the middle support, etc you know just misc small nickel and dime pieces that eat up a budget and slow a project down.



I also did get my sunroof stuff in and began the initial fit check of the sliding panel.. it is so far out of rig I don't even know where to start!!

That's about it for now.. I only have a few major tasks left before the car will be ready to drive. The front beam is one of them.. I plan on getting it in paint and reassembled in the next two weeks. Electrical needs a few things to be finished, and the engine is waiting for rings and seals and reassembly. After that it's just bolting parts on and adjusting stuff!
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[scrivyscriv]

I thought I’d be done with the wipers already!!
The Wolfsburg west parts came in today and after installing, removing, and installing the assembly again, I can finally say that my wiper assembly is now complete and installed.
However, I broke the little microswitch I had just finished soldering up for the electric washer motor relay; one of maybe less than 5 non-stock modifications I’m planning to make the car a more reliable and enjoyable daily driver!!
Anyway, the wiper linkage hit the back of the switch during removal, so I’ll have to pull the stock switch out and replace the microswitch, which is just screwed in where the washer pneumatic valve was.
I dug around in my stash of acquired hardware and found a suitable Kamax bolt for the center rubber isolator mount.. a bit of scrubbing and some solvent, and I’ve got somewhat of a reasonable approximation to stock! I’m not sure if it originally had a large washer there but it looked like a good idea so I reinstalled the one that came on the car. The brass tab was already on the replacement early wiper frame, I just buffed it both sides with a maroon scotchbrite roloc on the die grinder.

Oh, yeah, this brings me to the wiper arms! I searched my stash and couldn’t find them, and had to scroll back through my as-purchased photos to remind myself that, yes, it did have wiper arms when I bought it!

I’d glass beaded them some time ago and stored them in my pile of bare metal parts. They could use another light glass bead touch up so I’ll take care of that this week Yah willing. I’m in a small dilemma; the wiper arm pivots have a lot of wear at the rivet hinge point, and I don’t know where to find a suitable rivet to replace it if I disassemble the arms and weld up the wallowed hole. Plus, I think the arms were originally a flat black or possibly a grey colour, neither of which I have on hand. Decisions, decisions. How much do I really care??


Lastly I started looking over the head I’d removed from the donor dual port powerplant, and I decided, in my typical fashion, they were not going to be reliable enough for a daily without some repairs. They have spark plug-to-seat cracks, which I understand are not a death sentence, but no seat-to-seat cracks. The things that bothered me were how rusty the valve springs were, because a failed valve spring is a really big deal on the road, and the age and heat cycles on the exhaust valves.

Don’t get me wrong, I’m not trying to spend a ton of money on this essentially temporary engine, but I take I-240 around Memphis four nights a week, and if one of those nights is in the beetle and involves a roadside emergency, there is a very real danger of being hit by traffic. We are the FBI’s top most dangerous city this year for murders as well, and a dark roadside breakdown just isn’t favorable, no matter how well armed and prepared one may be, and I’ll leave it at that.
So, with that understanding, I ordered a handful or replacements from CB Performance. Hi-rev single valve springs, keepers and retainers, and a full set of chrome 32mm exhaust valves. I’d like to have them on hand so the transition to engine reassembly will be smooth - I’m forcing myself to stick with the existing in-work items, before getting into the engine again.
This may be it for a bit.. we have a lot going on with some home upgrades and baby Scrivy #6 due in August. I see this topic has had over 18k views since inception, I’d like to thank everyone who has been keeping up with this little car I call Dünkelgrügen (a corruption of the German word for the paint color, dunkel grun). I enjoy this kind of work and I hope I’m able to help someone else out down the road, whether it’s photos, a repair idea, or just simply motivation to keep moving on one’s own projects.

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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[NachoCar]

Congrats on the new family member on the way! Family is the spice of life!

As always, incredibly detailed work!

[scrivyscriv]

Thanks George! I've been watching your topic, it's great to see you're at the finish line!!!! Perseverance!
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[mukluk]

[scrivyscriv]

[scrivyscriv]

Stuff and things

I broke the replacement brake adjuster spring trying to install it on one of my front backing plates and just to make sure I didn’t have to make another Wolfsburg West order, I added two more to my order. Lo and behold, after the order shipped last week, I realized I selected the wrong color pinch welt for the pop out windows, and the wrong brake switch boots! Then when the order arrived, it turns out that their ‘67+ windshield visor clips aren’t suitable for a 1967, which seems to use the older style clip. Which means I’m going to have to make yet another order

This order was for a bunch of miscellaneous parts, including the rubber pop out seals and body trim clips. I’m missing the front quarter trim on both sides and hopefully some will come up locally instead of ordering new stainless trim. The left seal went on with no trouble so I’ll do the right side next, and get the white pinch welt.

Back to the brake adjuster - I have never been super impressed with their method of staking the adjuster springs in; it must have saved a small amount instead of using hardware to secure it, but it’s certainly not that rugged. I dug around in my stash and realized the 4mm distributor screws were the perfect size for this! The brake adjuster casting is solid in the middle and has plenty of room for the 4mm x 0.7mm screw and washer. I liked it so much I drilled and tapped the other side, which of course came out cleaner since it wasn’t the Guinea pig. 😆

I also got the rest of the axle beam parts - all Meyle tie rod ends, and a cofap steering damper. I’m still looking at the beam trying to make myself finish stripping it so I can get it put back together!
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[ot1138]

I just found this thread. Nice work so far! I'm looking forward to following your progress.

[scrivyscriv]

[scrivyscriv]

I'm still here y'all! This summer I've pioritized a large house project over all the other stuff I've got going on, so the VW is in a holding pattern. Feels crazy to look back at photos and realize I've had the donor motor apart and new rings for it for over a year!!

I'll be turning 39 in October. As I get older, I realize there is value in having less.. I've been slowly selling, thowing away, or giving away tools and parts and junk that I don't need or want. It makes room for other things I DO want, such as this $65 marketplace find! A 3x6 solid 3/8" thick steel work table. I even found a decent 6" Larin bench vise to replace the 3-1/2" Craftsman, so the Craftsman found a new home and my new Larin vise only ended up costing me $25.

If someone could bring me some motivation to strip the paint and clean up my front beam, I'd really appreciate it. I might even throw in a pound or two of freshly roasted coffee too.
_________________
Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[scrivyscriv]

Taking my own advice that even small tasks help get a car back together, I pulled the passenger side (I’ve been in aviation too long, when I was thinking this sentence in my head to type I mentally said “first officer’s side!”😂) pop out window to reseal it

It’s a stock OG glass. I believe this sunroof car also came with pop outs from the factory. I don’t get why they are so desirable beyond the cool factor, I guess once I start driving the car in a few weeks it might make sense. The pinch welt needs replacing and I haven’t tried to re-order the white pinch welt from Wolfsburg west yet. Hopefully it will go on with the window installed!🫣

I’ve been saying for months and months now that I L O A T H E using paint stripper on the front beam. I was trying to avoid media blasting it due to potential needle bearing contamination; however, the beam is my one holdup that’s preventing me from moving forward with reassembly. Ive got it on the copycat beam holder i welded up.. side note, the dimensions of the beam holder need to be very accurate when making it. There are a lot of parts to the beam and you can’t just hang it anywhere on the tool.

I’m planning on running it down to Rick’s powdercoating tomorrow to get them to glass bead the beam. I’ve been waiting long enough and now I’m probably going to miss the nice fall driving weather!!

_________________
Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[scrivyscriv]

Game over, front beam!!🤠

I did the deed.. dropped the old bag off at Rick’s. Y’all, those needle bearings are HIGH! I priced out a set of four bearings in case they get messed up during glass beading. Rick is a great dude, his dad is the local VW engine and transmission builder and I think they still race VWs. He told me he’d make sure the beam ends got rubber capped before blasting. But, on the chance they needed to be replaced, I looked at Wolfsburg West and a set of four is almost $200!

Of course, on of my helpers came with me. It’s been almost four years since I first dragged this car home from a field November 2019, so the photos here are nice memory lane reminder of how the time flies
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[scrivyscriv]

Clutch shaft & stuff

I boogered up the new clutch cross shaft bushing while installing it a while ago and today I’m going to show a method for fine tuning the fit of a shaft into a bushing or bearing or other hole!
I learned this early on in my aviation career but it never occurred to me until someone showed me on the job one night. Full disclosure this method is not exactly kosher with many due to the fact that it does have the potential to embed abrasive particles in the base material, so use at your own risk! This is just another tool for the toolbox.

Problem: the new bushing is too tight on the cross shaft.
Solution: file any high spots on the shaft, and clearance the bushing out.

Strip of maroon scotchbrite, a large cotter pin, and a drill:

It’s not a fast process but is fairly accurate. You can remove just enough material to get a good fit, checking every so often. This works on a variety of problems.

I started on the clutch shaft because I had just finished my VEWIB axle boots and noticed the clutch still needed attention.. the boots went on great, the best out of all of ‘em.

I still have to install the clutch cable Bowden tube and all that. I just wanted to make sure the bushing wasn’t too tight as felt at the pedal, and it was a good feel. I think it will work out just fine!
Although I’m too late for fall driving, I do think I’ll get the car running and driving before the end of the year - about 3 months from now.
_________________
Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[scrivyscriv]

I try not to spam with updates, but I ran into an issue I remember also having when I tore down my '72 bus transmission for repair over a decade ago: All the usual parts places only illustrate a portion of the parts that are really on the clutch cross shaft! Bentley shows a plastic-looking spring seat for the clutch lever return spring, and potentially some kind of rubber seal on the cross shaft at the bushing inside the bellhousing.

I'd like to replace everything that's supposed to be there, not just the parts that are "available." I tried getting the spring seat off a donor transmission but it's too brittle to re-use.

Anyone got any links to those parts??
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[diablosandwich]

Not spam to me, I enjoy the updates. That is quick turnaround on the bead blasting of the beam!
I have an original parts book from VW and looked up the rubber bushing and the spring seat. see if these are what you need....

spring seat. https://weddleindustries.com/products/111-141-727/111-141-727

rubber bushing. https://weddleindustries.com/products/113-141-721/113-141-721

If these are not what you are looking for I can take a pic of the diagram so you can figure out what you need.

Casey
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1966 Java Greens

[scrivyscriv]

Of course Weddle has them! I forgot about them when I was looking around. Those two are what I need, and I also noticed p/n 113-141-717 "16mm cross shaft washer" that I'm not sure about. Just looking at it, is it correct to assume the washer goes between the inboard snap ring and the shaft rubber seal?
https://weddleindustries.com/products/113-141-717/113-141-717
_________________
Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[The Pilch]

Bro, this is an EPIC thread! It's amazing to see the attention to detail and the technicalities you are encountering and conquering as you go - despite being held back by time constraints. Consider me inspired! Keep up the amazing work!
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'85 Vanagon GL, weekender package, 1.9 wbx named Freddie/ '61 Beetle named Ringo/ '78 Dodge Monaco which is nothing like the Bluesmobile so please don't cast that oily rag upon it.