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1968 Deluxe resurrection
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TDCTDI
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PostPosted: Sat Aug 05, 2017 11:40 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Thanks busdaddy!

Today I revisited the parts donor bus, I'll have to remember to take a machete with next time.
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I already grabbed the windshield & some of the stainless window vent visors. While scavenging parts, I was excited to find an original Z bed (I guess it's actually a rock n roll bed.).
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The brackets are definitely rough but I can at least repair or recreate them.
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TDCTDI
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PostPosted: Thu Aug 10, 2017 6:38 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

So... while the sliding door track cover was off, I thought I'd see if I could align the door a bit as the gap was tight at the trailing edge but quite excessive at the leading edge.
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Upon closer inspection, it looks like I'll need some guides & rollers.
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I removed the door.
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And found the lower vertical roller nonexistent.
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Spike0180
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PostPosted: Thu Aug 10, 2017 6:52 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Wow, I'm surprised that door was shutting at all. Good luck with recovering those parts and adjusting the door.
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TDCTDI
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PostPosted: Fri Aug 11, 2017 3:50 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Thanks Spike0180, hopefully I can find the lower roller, I tried a couple of hardware stores but they didn't have anything close to correct. I thought I might have found a comparable bearing from a slider off a Honda Oddity but the OD was too small.

Im going back to the parts bus tomorrow & hopefully it has something salvageable.


Today all I accomplished on the Crusty Pig was removing a bit more paint.
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TDCTDI
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PostPosted: Sat Aug 12, 2017 12:53 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Woohoo! The donor bus has the parts I need for the Crusty Pig.
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Spike0180
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PostPosted: Sat Aug 12, 2017 5:14 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

WOOHoo!!! Party rockin in the house tonight!
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TDCTDI
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PostPosted: Mon Aug 14, 2017 8:16 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

After removing the lower roller bracket from the donor door, I removed the dust covers dipped it in some used engine oil overnight to see if I could get the rollers to free up some.
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This works incredibly well but I wanted to make sure that the rollers had a bit better lubricant so I cut the top off a can, filled the bottom 1.5" with Liquid Wrench Chain lube & set the rollers in it over night.
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Satisfied with the results, I went out to install the bracket on the Crusty Pig & found this little guy hiding out.
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I'm still trying to figure out how he got up there as the only thing touching the ground is the ratchet strap but it's on the other side.

While I had the slider off, I thought it would be a great time to remove the paint on it.
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I found that if I set the saturated rag on the paint, I can save time by scraping the paint off, the plastic safety cap for the acetone works well.
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I got as much as I could in the time that I had & went to reinstall the door only to have issues with the lower rollers not wanting to move, upon closer inspection, I discovered that someone had welded in a section of 3/16" stock to compensate for the lack of the lower roller Evil or Very Mad
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1961bluebug
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PostPosted: Tue Aug 15, 2017 1:06 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

amazing effort! keep it up!
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Spike0180
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PostPosted: Tue Aug 15, 2017 7:44 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

TDCTDI wrote:

I got as much as I could in the time that I had & went to reinstall the door only to have issues with the lower rollers not wanting to move, upon closer inspection, I discovered that someone had welded in a section of 3/16" stock to compensate for the lack of the lower roller Evil or Very Mad


Oh I'd be soo pissed. I don't know of any way to get that off... a grinder I guess? Hope you have a big enough disk to get in the slot. And hope you don't run into the original issue being the track and not the roller.
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Dkwautounion
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PostPosted: Tue Aug 15, 2017 10:12 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

If it's welded , grind it. If it's brazed , then heat it and wire brush the braze off.
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PostPosted: Tue Aug 15, 2017 10:14 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I've read your whole thread today and really enjoyed it. Thanks.

I can't believe the paint situation. That dark stuff is horrible. I'm going to try some of mine this week. It's originally pastel white and still is inside but the exterior is covered with a pure white powdery paint. I hope it comes off like your's has been.
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TDCTDI
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PostPosted: Wed Aug 16, 2017 11:17 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

1961bluebug wrote:
amazing effort! keep it up!

Thanks!

ajplmama wrote:
I've read your whole thread today and really enjoyed it. Thanks.

I can't believe the paint situation. That dark stuff is horrible.

& Thanks to you too.

As bad as the repaint was, in a way it has preserved the original for all these years. Good luck with removing your repaint!

Dkw & Spike0180, yes, I was definitely torqued!

After carefully assessing what was going on, I determined that as rusty as the rockers were, the track was still intact so I gingerly started to cut the welds away.
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And then carefully chiseled the bar stock free.
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And removed it.
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After replacing the lower roller assembly, fitting the slider & and rear guide, I adjusted the door & it now rolls & closes easily.
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I think this color makes the Bus look longer. "does this color make my bus look fat?"
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PostPosted: Wed Aug 16, 2017 7:47 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

WOW! lucky stuff! Your PO was a terrible mechanic. lol And those welds didnt even looks too bad to get off either, just spot welds.

"Does this color make my bus look fat?"

this killed me. Laughing Laughing Laughing
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TDCTDI
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PostPosted: Wed Aug 23, 2017 4:06 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Thanks Spike0180, yes, I was fortunate in how easily it came apart.

Last weekend I revisited the parts pig & snagged the steering box, front bumper and the spare tire well.
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The one in the Crusty Pig had been getting wet for quite some time due to bad window gaskets.
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PostPosted: Thu Aug 24, 2017 8:18 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

So I pulled the engine back out of the Crusty Pig to sort out a few issues.
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The first thing to remedy was the clutch, I had replaced the disc with one that I had laying around that apparently had an incompatibility with the pressure plate so I replaced the whole kit.

The next thing to deal with was the sparkler wheel of a generator, I ordered new bearings & brushes for it since I the old ones were pretty nasty.
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I thought it needed bearings when in actuality it just needed brushes & a good cleaning of the armature & commutator.
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Believe it or not, this thing was actually charging.

I blew all the dust out of the armature & carefully cleaned up the commutator & pulled the old bearings off.
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Then reassembled the generator
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And then, to keep from chewing up the belt, I cleaned the rust pitting off the pulley.

Before
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And after.
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Once it was all back together, I used this cool little VW tool to lift the brush springs out of the way to install the brushes.
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And then secure the pigtails.
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PostPosted: Fri Aug 25, 2017 10:41 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I want one of the tools! I've got brushes up for replacement soon on mine.
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TDCTDI
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PostPosted: Fri Aug 25, 2017 11:07 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Canadian VW wrote:
I want one of the tools! I've got brushes up for replacement soon on mine.

I was wondering if someone would bite Laughing , They can be found in the tire tool kits of most any 1999 & newer VW Golf, Jetta, Beetle , & Passat. It's for removing the PITA little lug nut covers & center caps. Maybe even available at the dealer still.
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PostPosted: Sun Aug 27, 2017 8:28 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Since the carb was leaking fuel out of the throttle shaft I replaced the carb & stuffed the engine back into the Crusty Pig. After tuning it & timing it, I started to install the rear apron & realized how much abuse the Crusty Pig saw dragging tobacco out of the fields.
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The hitch was mostly mounted to the rear apron mounting points & used the bumper as a stop. Here's where it elongated the other holes.
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So I hammer & dollied them flat again.
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And got the apron in again.
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I have to order new throttle & clutch cables, the ones in the Crusty Pig are too long, they must be for a different year.
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PostPosted: Tue Aug 29, 2017 1:15 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I took the Crusty Pig out for it's first drive around the block today, I even recorded it to share with y'all.

Link

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PostPosted: Tue Aug 29, 2017 1:31 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Awesome!
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