Black Fastback Build Thread

[Bobnotch]

[ataraxia]

Small, thick bags (4 mil or thicker) inside of little boxes or taped up with strapping tape (with the fiber in it), use a double wall (or thicker) box, pack the box tight and use strapping tape - it's stronger than duct tape.

Things that are allowed to move around inside of a box (no matter how well the box is taped up) get damaged, break free or disappear. Pack the box tight with the contents not moving around at all. Shake it once it's packed - if you can hear a bunch of shit moving around, it's not tight enough.

[Clatter]

Well, I went ahead and did it today..

All of the stuff was in freezer bags, in little boxes.
Bubble-wrap was packed tight in the spaces the bags didn't fill.
The big outside box was double-wall, and I had a couple more layers in there.
Folded cardboard supported the little boxes from moving around in the big box.
All the tape was that fibery strapping tape..

The big thing that seemed to help was at the shipping place;
The guy who works there said if you insure the box for more than $5K it goes in locked bins,
And rides in a special spot in the truck.
He joked it was in the "Do Not Lose" bin..

It cost an extra $100.
So I bit.

We'll see.
Now to throw an extra $100 at getting it home?
Cheaper than driving there I guess...
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Bus Motor Build

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[Clatter]

Tape off the vitals with duct tape, blast, then mask..
Yep, anal enough to mask inside the CV flanges..

The LAST paint stripping on the whole project!
Good thing, look at that can..

Drug out the motor from the back corner of the shop;
Time to finish shortening heater boxes.

Masterseries (Thanks Brent! ) didn't fish-eye this time.
Fun to watch paint dry sometimes..

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Bus Motor Build

What’s That Noise?!?

[Clatter]

Not much done this weekend..

Drug the motor on the stand outside, and got set up, to start piecing together patches for the heater box mods.

But then the wind came up and the heat from Mom started blowing hot and hard..



Managed to hide in the shop for part of Sunday and assembled axles/CVs.

Was looking for my collection of white-cad CV bolts..
Looking and looking.. Pissed!
But then,
Realized,
That they're on my bus.
And I'll have to clean up another set, and send them off to Oregon..

So my second box of stuff to go to Oregon for cad has officially started,
But,
It's quite likely to be getting bigger.
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Bus Motor Build

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[Clatter]

Package showed up in Oregon!
Just have to get it back..
They said about a month.

Spent about 1/2 a 'day' getting the filler pieces into the passenger's side heater box.
A fun job, actually;
Fitting little fiddly pieces together.
Have to make compound curves,
And the halves have to fit together, and seal to the pipes..
The wind was up,
So all I really did was cut and tack.

The driver's side is easier; They have to be moved less.
All I did was get started, when it was time to go get kids from school..

Valley has the chrome.
Larry The Painter has the shell,
Precision has the bolts.
Steve the upholsterer has the seats.
Ian the polisher has the last wheel.

One day it will all come together!

It will.. it will.. It will..
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Bus Motor Build

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[Clatter]

Look! Everybody!
Look At ME!!

Why _Do we do these things, anyway
Posting up all these pics and words.. Sometimes I wonder..

Anyways... More!

Friday after work I powered through several more hours of heater box mods.

Then my Brother From Another Mother William came by and dropped off his fancy tubing flare tool.
He also has a straightener, and a de-burr tool for brake lines that does OD and ID.
Plus my cutter and benders and.. A fun little play-set!

Thanks to Sambanistas on the Performance/Engines forum,
I got wind of how these metric lines work.
Basically, 4.3mm is our (metric) size, and identifiable at the FLAPS by it's green color.
Bought a couple of big pieces and went to town..

Re-did/moved the bends a bit so I can avoid my fuel fittings (blue),
Tried to get nice large-radius bends..

Saturday I made another mess and tortured those neighbors right good!

Fiddly little patch-pieces all in, welding done,
rough grinding mostly finished.
Just a bunch of finish flap-wheel work, some hammer/dolly, misc. to finish them up.
Thinking I have about a dozen hours in these already at least.
Shortening a set of heater boxes is actually a pretty involved task..
Somebody who had some skills woulda knocked them out a lot more quickly, no doubt..


Look! Look!!!
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Bus Motor Build

What’s That Noise?!?

[Clatter]

Sunday was big stuff.
Put the thicker .030 wire in, and turned up to #2, and even #3, on the big 220 Miller.

Started off making a 12" deep socket for torqueing the mainshaft nut on the trans.
This was a socket cut in half, with some tubing welded in.

Then,
Started in on making a proper engine cart..
I'm sure most of you have seen the cheap China cart most places sell;
Here mine got reinforced with some plate after a heavy type 4 caused the legs to 'splay' out.
Clearancing the sides so it didn't foul cooling tin didn't help, no doubt.
Why they wouldn't make it so you can use it with the tin on your motor is beyond me..
It never really fit a type 1 motor that well, either, especially with a sump.
Type 4s weren't even close.
Plus, the legs were too close together for the jack to fit in there.

So I bought some (hard rubber this time) casters, and some different sizes of angle, and...

Still need a few more bits of big 2 x 4" angle for the legs,
But it fits!

Fun to work on big, heavy parts for a change,
Laying big beads of weld vs. little tacks.

Part of the process..
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Bus Motor Build

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[ataraxia]

[Clatter]

Oh, yeah.. No worries.
thanks for keeping an eye out.
I'm not that far along yet, unfortunately..

That 'long line' is just there temporary-like to make sure the other lines don't mis-locate the 'T"..

The funny angled rubber boot for the long line quest continues..
I have a couple of good used ones, but still wanted to try and find new.

The 'clutch and throttle cable' boot will go on with a bit of trimming.
Because the cables got re-located and much as they did, they also got mis-located in the process.
Hence, the holes are off from where they were originally.
Will be using two of them - cut and glued back together one-inside-the-other,
So they will seal.

You can bet that I will have all of this installed and right up here on the cart first.
None of this stuff would be any fun at all with the body on the pan.
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Bus Motor Build

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[Clatter]

Not much to report..

A box came from some guy - Seems he knows a bit about gas heaters..
These are all(?) of the misc. brackets and ductwork that mount a BN2 into a Type 3.

So one Jason gets me a couple of gas heaters, and another Jason gets me the miscellania to mount one.

Thanks guys!

Also, an odd piece of the puzzle;
A trans jig for Porsche 915.
This supports the two shafts and two shift rods,
So the forks can be set correctly.

All part of the process..
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Bus Motor Build

What’s That Noise?!?

[Jason37]

Holy crap! 😳 that’s more than what can with my car originally. On another note, I for one try to get on here everyday just to see your updates. People are reading, we might just not be the talkative types.

[JeeJeeJason]

A lot of Jason parts are going to be on this car.
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1968 FI Squareback

[Bobnotch]

[Jason37]

[Dfasty]

I read it everyday. Well done
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70 fastback automatic 06 invader

[Clatter]

Aww, Shucks, guys, thanks for checking in.
Feeling the love, no doubt.

After posting five or six times without any response,
I get the feeling everyone has left the room in disgust!

Who would have ever guessed that SO many guys helped me with this project, that there's THREE Jasons even!


Truth be told, I was in Kauai'i for ten days!
Every single morning I got to watch the sun rise from out in the water at Hanalei bay.
I'm feeling quite well-surfed these days.
Three days ago, it was 15-20' outside,
So the inside sandbars were double-overhead, and just about perfect.
Was a really lucky thing to have happen - a rare experience indeed.

Other than having my friend's board he lent me dinged bad by a longboard goon,
it all went well.
Coulda been my ass with another crack in it instead!


Anyways, some goodies waiting for me when I got back:
A really nice SB-12 headlight ring I paid WAY too much for from Chris Morrice,
Some early bus snubbers and mounts to attach to my trailing arms,
A fuel shut-off 'petcock' for when the gas tank gets removed,
A bias valve for front-to-rear brake balance,
Some Dremel burrs for detailing the sliders on my trans.

Funny,
The silicon carbide bits that would appear to be for grinding hard metal, aren't.
And the burrs, that you wouldn't think would be for hardened steel,
Are...

Weird...
Does anyone know where to get the proper tooling for de-burring hardened (like HARD hard) steel?


Still looking high and how for a 5th/R hub ordered, that's to be made into a shaft holder..
The thing done disappeared in shipping or delivery!.

This should all hopefully make some sense, as I soon shall put all of the new, and/or home-made tools to use assembling a trans.
Like, er, the week after next..
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Bus Motor Build

What’s That Noise?!?

[ataraxia]

[Clatter]

[ataraxia]