Sept '67 (1968 MY) deluxe, another Blakes Bus

[sparkywig]

I'm not happy with the Dodomat on the cab floor, but the mice like it apparently.
So it's coming off and I'm sound deadening the complete cab floor.

[sparkywig]

Back to rewiring

I've converted the wiper/washer switch to run the electric washer pump.
Details on this link here
https://earlybay.com/threads/how-2-convert-your-stock-washer-air-switch-to-electric.18970/page-2

Washer tank

Headlights are in, I'm using Mk I Golf/Rabbit units.

And Euro tail lights

Indicator/turn signal unit

Reversing lights and rear registration plate light wiring

[sparkywig]

The reverse light switch terminals on the gearbox are a bit close to the trailing arm mount.

[sparkywig]

Electric fuel pump, cut off solenoid and pipework.
I'm running AN-6 PTFE/teflon hose to reduce the risk of modern fuel issues.

During this job I noticed that I was missing a section of the clutch cable conduit that runs under the torsion tube.
It looked as if it was cut deliberately, but anyway, I replaced the short section and installed a new flexible conduit onto the gearbox as I was fitting the electric fuel pump mount.

Back to the plumbing, cut off solenoid under tank to fuel pump

[sparkywig]

Remember that engine mock up with the later support bar?
Well, that didn't work.
The later support bar and mounts are way too wide to fit an early rear chassis, so back to an early set up.
I cut the support bar brackets off another early shell, drilled the spot welds out and shortened them until they bottomed up against the chassis leg.

So that gives me about 75mm/3" of engine raise. I've already raised the front of the gearbox about 20mm/3/4". I didn't want to start cutting into the floor to get any more room, and the gearshift still works.
The only downside is that the rear bumper brackets will have to be modified, as they slide through the support bar mounts.

[sparkywig]

May 2024
The Fuchs are being sent for detailing, so I'm stripping the existing paint from them.

And the front discs have turned up, so they can be fitted.
The calipers and then the hubs have to be removed as the discs are bolted to the hubs from the rear.

And calipers refitted.

The more eagle-eyed amongst you may have spotted the front calipers are different. That's because the early 996 calipers have a slightly different casting and interfere with the wheels.
Good job I checked.
Any way, a gratuitous shot of a bare Fuch on the hubs.

Can't wait to get the bus back on all 4 wheels.

[sparkywig]

Interior again.
Mocked up a piece of 18mm ply and installed the full width Westy bed hinges.
Trimmed and glued the carpet.

Cab floor carpet fitted.

Stripped the steering column out again as the lower mount was bent, replaced it with a decent one from storage and refitted the column with the wheel on temporarily.

[sparkywig]

Engine bay seal panels have been trimmed to fit.

welded in and primed

[sparkywig]

It's engine time.
Do you remember that 80x92 stroker long block that was going into my squareback?
Well, the square sold without the engine so it's being converted from a Type 3 to Type 1 and going into the deluxe.

First job is to fit an oil cooler, but as Type 3 oil coolers are laid flat on the case I'll have to cut down the mounting stud, retap and fit an adaptor to mount the cooler.

All the oil cooler seals are stuck into the adaptor using Wellseal

[sparkywig]

The Fuchs are back from detailing, so straight to the tyre fitters and get them on to see what they look like.

Rears - Deep 6 with Continental Vanco 195/70/15

Plenty of room

Fronts - 4.5" with Continental 165/50/15 XL

[sparkywig]

June 2024
Another job jobbed, belt trim clips and trim refitted.

Back onto the engine, here's the spec if you're interested.

Carbs out of the box

[sparkywig]

Managed to get an 1960's Veglia Borletti electronic 4 cylinder rev counter and pod.

And decided to run with black wheel nuts and bolts.
Have you seen how much Porsche lightweight wheel nuts are!!
Should've gone with chrome instead.

[sparkywig]

As Type 3 engines have a different dipstick set up I had to use one of these dipstick adaptors that don't fit properly.
So I modified it.

I bought a big bore (42mm/1 5/8") exhaust and heat exchangers for the squareback

But unfortunately they clash with the engine support bar, so J tubes it is for a while.

All ready to go in.

[sparkywig]

July 2024
Engine bay ready for engine

[sparkywig]

Engine install
Run into a couple of unseen issues due to the engine raise, firstly I've had to drill a hole higher up for the throttle cable tube,

and secondly I installed the engine seal panels in stock positions rather than 3" higher.
They're clashing with the valve covers and stopping the engine fully mating with the gearbox.

So the recip saw has come out to trim the metalwork, and then temporarily pop-riveted back to get the engine in. So unhappy with myself about this.

But the engine is now in place.

Fuel lines and wiring connected.

[sparkywig]

Engine oil remote filter, cooler and lines.
These are done in stainless braided AN-8 lines.
Remote filter and sandwich plate under N/S battery tray, lines forward over torsion tube to cooler and fan mounted under LHS of cargo floor.

Oil lines that run from the case to the filter have heat proof sleeving to protect them from the exhaust.

For the first engine start and cam burn I'm going to leave the sandwich plate and oil cooler disconnected. Less oil to throw away after the cam burn.
And as there is a deep sump fitted I can run the oil level lower on the dipstick.

[sparkywig]

August 2024
Dashpod and gauges installed and connected.

And we have power

I've sent my radio off to be bluetooth converted, seems reasonable at £150.

[sparkywig]

Another issue before I can try to start the engine, the repro ignition switch has failed already.
Column apart again.

And we're back

[sparkywig]

So first start went well.
Left the coil lead off of the distributer cap to get oil pressure and check fuel delivery when cranking, reconnected coil lead and it started on the second attempt.
Timing set, cam burn done, no leaks and oil drained.

Unfortunately I hadn't any spare oil filters that I normally use, so a replacement was sourced and on the next start blew apart.
I've now got stock of my usual filters.

[sparkywig]

Rear valance fitted off my old bus, and engine lid.

First time outside and running.

First drive around the yard, and parked next to a couple more buses from Blakes Yard.