68 bug sitting in shop for 18yrs

[zodlaw]

Preparing for stub axles and bearings. I'm out of grease so picking that up tomorrow and hopefully get one side done.

All for now..
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[zodlaw]

I forgot how messy this job was.

Done and in.

Brake lines and bags in. Sitting on the ground with all this done makes me feel happy.

On a side note I saw my old ride posted, I still miss it sometimes.

Going to focus on the transmission now. It will probably be a few weeks as I need to spend some time cleaning it.
All for now...
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[VW_Jimbo]

Nice job! That is slammed!

What are your plans for the transmission?
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[zodlaw]

No sure about putting a lot of work into this trans , as I don't really know the condition of it . If it pops out of gear or does any howling I will worry about that later. I might just clean it up and paint it and revisit it when I upgrade to thing axles.
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[zodlaw]

Well that did not take as long as I thought it would. The trans had been sitting out in the weather about 10yrs. The case was pretty hammered, if it was not I would have left it but it needed some sort of coating.

Here is the trans code:

AH 1215426

AH 1500/1600 4.125 IRS from 8/68 – 8/72

I think I will have the same ratio as my swing axle.

Painted, but will prob let it dry a few days as its pretty cold. I did run the heater in the garage for an hour or so. I am thinking that will help a bit.

_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[VW_Jimbo]

Looks good! Did you pull the drain plugs and check them for chunks? Typically the magnets have all sorts of fine metallic particulate on them, so if there are bigger chunks, they stand out. If those are present you might want to dig deeper.
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[zodlaw]

I did pull the plugs and did not see anything you wouldn't see on regular trans. No chunks just fine micro stuff. The oil was drained before I got it, but I stuck my finger in there and still good coating on the gears with no moisture at all. I will probably do a flush and run it for a day or so. I have never really had to do that, so need to look that up.
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[VW_Jimbo]

Just fill it up and try it out. Never heard of flushing a manual transmission. But there is always a first time.

Heck maybe just pour in a 1/2 cup of diesel and slosh it around for a bit. Then drain it and fill it up with gear oil. I have filled crusty old engine cases with diesel to clean everything up before a rebuild. Never did that on a transmission but it ought to work. Maybe someone else will chime in with a pro, con, or a different idea!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[zodlaw]

Well almost had to buy throw out bearing shaft and everything. I tried to free it up but no luck . I ended up taking everything apart and deep cleaning and regressed everything and put it back together. There was not much play and and all the bushings were still good.

I had a small window today and installed the trans and starter. Still need to hook up shifter and starter wires.

After the transmission is finished up , going to probably move on to CV Axles. Need to paint the drums too. That might be a job for tomorrow.
All for now....
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[zodlaw]

That was a lot of fun. I definitely suggest getting the individual packets of cv grease. It worked out well and I was able to manage the damage to a small area. LOL

All done and finished up. Yes one of the cv boots is silver. I am trying not to think about it right now... I hope to install Thing CV down the road anyway so these are just to get me by for now. Hopefully I won't blow them.

All installed... I had to run to ACE and get one allen 8mm bolt. It was missing when I bought the clip. So another anoying thing to forget about.

Not sure what I will tackle next. I need to double check the wires on the starter. There is two tabs not sure which is which, I will figure it out I guess. It might be time to install the motor... Then do brakes or do brakes then motor.
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[zodlaw]

I have been busy....

I have some loose ends to finish up but took it for a drive the other day. It was the only day it was clear..

So to get to this point lots of problems. Mostly with the trans, again I had no clue what condition it was in. I pulled the plugs no water everything looked fine. This trans had been sitting outside for 10 yrs or so.

started a thread not to long thank goodness:

https://docs.google.com/spreadsheets/d/1yLB-Qv_tPJ2r3t1DEaeOkmDOim-0LOUzw-fwOV1orfQ/edit?usp=sharing

Long story short I could not get it into gear etc. even not running. Checked bunch of stuff. reset up the clutch and adjusted the pedal. Clean shift tube reset up the linkage. It ended up being in the same spot. Started slamming it into gear and it started to go in. worked it over few times. It got to the point where I could get it into gear not running. Started the car would not go so started to slam it in to the gears... ground in reverse and slammed it in finally. At this point I though what the hell I take it out. I drove that thing like I stole it slamming through all the gears back and forth and then.... It just worked! Going through all the gears just fine. Took it up let off at high rpm did not pop out of any gears... At this point I am pretty happy drove about 10 miles... rides nice scrubbing little on the rear tires. I get home pull in the garage and it drops like butter into rev. I don't know what happened but its all good now. So they like to get be beat up a bit now and then
I rolled the fenders a little when I got home. The next day drove around town running errands. I miss driving it, but on to the next project... It is supposed to rain the next few weeks and come hell or high water this one is getting done sooner than later. spring is just around the corner.

This link is the next clue to the next project. its a handy tool so anyone can use it if they want.

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

I am sure I am forgetting something.
All for now....
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[zodlaw]

I had some time today and started. Picture heavy!

Got this out with all the brake fluid in it still.

and out

Cleaned up the metal

Cut 3/4 out.

Cut out the steering section.

Body mounts.

Cut body mounts off.

Still need to compress all the way. I have to also clearance for the beam moving back some.

Still not where it needs to be.

Getting closer to where I want it though.

I still had my adjuster stops in but I took them out and it dropped another 1/4 inch or so. There is still something holding it up. So for now its still got another inch or so to go down. I need to pull the pie cut completely together. I will be working on it over the next week and hope to get it done.

I will still have to do the steering,body mounts and fuel tank raise.

All for now..
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[zodlaw]

Finished the welding up, Its not spectacular but it will do. Even with a lot of clean up still bunch of contaminates. In the end I did not need a redo.

For those of you considering doing a pie cut. I would not recommend anything over 3/4 unless you want a can of worms to deal with. At that point it might be worth considering raising the pan head.

This is how much room I have with the master cylinder. Just enough to install it and hook up the wires.

I order my part from Jbugs. I don't usually shop there but getting the part for $35 shipped was pretty good considering I could not even find a used one for that price. I tend to start off with something with an idea of how I want to do it but might change it in the process. This is what I started out with cut down some extra bits I had from an old steering box and the crush zone on the steering I cut out.

I did not want to have too many connections so I ended up welding steering section to the top.

It took most of Saturday to finish up. I had to cut 3/8 or so off the steering shaft connection on the box. I also had to shorten it about 1/2 on the center section of the u-joints. I still might take some more out so I can get little more adjustment.

Right now its stating at about 24 deg angle. Anything under 25deg is not recommended because of the safety issue in a wreak. I still might need to go down a little more. just have to see how it drives after I swap out the casters to the top from the bottom.

If your going to do this you will need some sort of busing here. If you don't have one it will not turn very well at all.

I ended up doing a temporary busing that I picked up at the hardware store. Its a pvc pipe that I had to sand down to make it fit. I put a screw in there to hold it in. I have a pile of surplus bearings at work that I am going to go through to see if I can find something. Maybe a pillow block bearing might work. If I cant find anything I will machine something. The current setup rattles a tinny bit but it will work for now till I find a better solution.

On a side note This is for 71 and up steering so u-joint clamps seem pretty sloppy. I had to really tighten them down to get it to work and it seems solid for now. If any of it gets loose I will definitely know it. I found a few threads about using a Polo golf rac and it doesn't look to bad to make up some brackets. It might be something down the road. I do not know if I will have enough room to get it in there.

Going to get the brakes back together and hopefully that will not take to long. After that will tackle the tanks raise , still not sure how I am going to go about doing that. Maybe I don't need to do it because of the steering setup I did. I will find more about that next week. It was super nice out almost 70 deg and it was painful not to have it finished up. It will be worth it in the long run. All for now....
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[zodlaw]

Oh boy lots has happened. For some reason I could not upload pic to the samba for few months. It looks like it is working now.

So I had to redo the steering because it was not working well and it was loose on the way home from work one day. I had to take it all apart and get it back to stock or something similar.

Prep work:
Made a new flange.

Mostly together







Got it welded together half way.

Using a guide rod to line up the top and bottom.

paint

Finished up

The only small problem is when I turn really hard while I am not moving it grounds the horn out a little. It only happen once in a while but I will figure out what is grounding out. I have been running it for over two months and no problems and my horn works.
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[zodlaw]

So I had a guy from the local club talk me into coming over to his house to cut and wax my bug. He help me understand the process with the stock paint. It turned out great.. I never thought it would look this good. I stripped the bumpers and running boards off just to get all the areas I needed. The other reason was Woodburn Volkswagen show, its the biggest of the year.

At his garage.

At home.

Few days later ready for the show with everything back on.

Here I am at the show and someone else took this picture.

_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[zodlaw]

Few weeks later and it was really nice day at work and I just had to take a picture.

After that nice day the ignition was giving me problems.

It just pulled its self out mostly until I finished it off.

Ordered a new one from Wolfburgwest.

This one is similar to the stock one but it has an extra ground accessories wire. I have not figured out what I am going to use it for yet but its nice to have.

I got it all back through the stock harness and its working well. I am going to add an ignition relay soon so it will last a lot longer as I don't want to replace it again.

more to come....
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[VW_Jimbo]

Looks sick man! Nice work! The car looks really good! Nice job!!!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[zodlaw]

So I ordered this March 16 and after a very long wait it finally came. I was told 4 -6 weeks but showed up June 26th. I wanted to have it in before Woodburn but it did not come in time.

The next day I drove two and half hours north to do the install at my brother in-laws house. No interruptions and full blown two full garage days and that was a stretch. It prob is more like 3 day install.

First layout.

Prep for roof cut out.

We watched an install Utube vid but it was in a different language. Had to watch is several times. Had to closed captions and translate it. It was pretty bad but we got the idea at least.


Bolted the frame to the roof after it was centered and measured multiple time and then multiple times again.

I used a hand jigsaw with a fine blade it worked really well. Started to fit up the hole.

After all that drilled a lot of holes and started on frame install.

That took full day but it was taking it apart refitting and doing it again and again.

The top I think was prob the easier part of the job. I did not get any pictures of that. At the end of the night took it for a drive to get gas for the drive home the next day. It was everything I had hopped for and then some. I had a 61 ragtop a long time ago when I was dating my wife some 30+ yrs ago. Its about a close as you can get without actually grafting one in.

It just looks fantastic!

So your asking would I do it again? Hell yeah brother! I have been driving it since June 28 and it is great just running with the roof open. I would have gone in to more detail but I have been busy driving the Dub to death.

All for now there might be some more updates when I have some time.
_________________
68 build that had been sitting for 18yr in a garage.
https://www.thesamba.com/vw/forum/viewtopic.php?t=657472&start=0

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0

[zodlaw]

[jitbba]

Man, that rag took it to the next level. Looks great!
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My other ride is a Zildjian