'Let's Go! Scotland-Croatia and onwards in our Kombi!'

[mcdonaldneal]

I had the exhaust silencer blasted and I painted with high temp paint about four years ago. At the same time I painted the heat exchangers in situ. I wondered about removing them all now to repaint but I think they are so rusty they will need replacement soon, so I’m going to save myself the bother! It wouldn’t have helped very much with exposure for the paint job anyway. I did remove the ducts that lead off up and forward from the HEx’s.
The axles are ready to go away for temporary storage and I cleaned up the starter motor to decide how far to disassemble.

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

The proper work on the Kombi has stalled temporarily, but we are in Covid lockdown again here, so I can do some satisfying, inconsequential things. One of these was sorting out tools and tool rolls.
The Ghia has a gathered together ‘factory’ tool roll, which is not totally correct, but near enough. Also now a retro roll of mostly vintage tools as a broader set for the most basic roadside tasks. These will live in the Ghia, and I made up a similar roll of basic tools for the Kombi. I’ve also made a more comprehensive roll that will move between the Ghia and the Kombi for longer trips, as needed.
I’ll show the Ghia rolls, and a West German foot pump I found in the garage and restored, and then the Kombi tool kit(s).

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

The Kombi basic tool roll, contents left-right:
Pliers
Brake flare wrench
Tyre pressure gauge
Spark plug removal tool
Feeler gauges
Allen key for alternator
Tin of copper grease
14mm spanner for valve adjustment
Fine and reversible screwdriver
Key ring torch
Multi purpose brass grease gun
Hubcap removal tool
Mini vice grip
Circuit tester/test light
(Above) Fuel line spigot
Mini 10/13mm wrench
Mini adjustable spanner

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

Then a general tool set, for longer trips, that will go between the Ghia and the camper as needed. Not as neat, but fills a few gaps and makes a good selection with the other tool roll.
Of course, doesn’t include the various spare parts and some other tools (like a bottle jack and breaker bar) that I might dig out to show if I get the chance.
Contents (L-R):
Leatherman multi tool
Small pry bar
Vintage 3/8” ratchet and extensions
1/4” driver
Rack of bits, hex, flat and Philips screwdriver
Adapter to convert ratchet to 1/4” and 1/2”
Spark plug socket, large flat bit, triple square for CV boots
Key sockets and wobble extension
Zip ties
Bahco fishtail adjustable
Heavy scissors
Wire brush
Picks, mirror, forceps

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[Slip356]

I like the wine bottle opener in the first pic. Could be needed while you wait for the tow truck.

[Abscate]

Forceps for those unscheduled deliveries
_________________
.ssS!

[mcdonaldneal]

As a diversion (again!) today, I dug out the ‘essential’ spare parts I carry in the Kombi. This includes some items that don’t fit our bus, but might be useful for a fellow VW owner. I think all of these could be fitted away from home with the tools I have, and there are a couple of extra useful tools (3’ breaker bar- not shown, and the 46mm rear hub socket). The starter motor is NOT a spare, I’m servicing it!
Clockwise from top right:

LED and conventional bulbs
Voltage regulator
Points set and 2x condensers
WD40 water dispersant (not a lubricant !)
Ethyl chloride spray-can help ID vacuum leaks
Throttle and clutch cables for a manual bus
Fuel filter
46mm socket
2x spare coils-I think one can stay in the garage!
Alternator belt
Fuel cutoff solenoid
Fully refurbished distributor and HT leads
NOS fuel pump and brake cylinder
Oil change gasket set
CV joint boot, bolts and clamps

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

I finished off a ‘proper job’ that I had started too today.
The starter motor had been a bit sticky, so I wanted to lubricate the solenoid plunger. I had stalled because the screws holding on the solenoid were SUPER tight. I had tried my largest screwdriver, a ratchet drive and an impact driver but they wouldn’t budge. I was anxious not to round off the slot, so I left it soaking in penetrating oil for a few days-still no joy!
Almost a last resort, I heated up the screw heads with a small gas torch and they broke free. What a relief!
The solenoid was dirty, but not horrendous, so I have cleaned it up with paraffin (kerosene) and isopropyl alcohol and I will lube with something suitable and seal the joint when I reassemble.

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

I thought I should document what the underside looks like before I start work on it. It’s surprisingly difficult getting clear pictures of the state of the underseal and bodywork, but first set of pics is the left side channel and rear wheel arch. I know from doing the front quarter that it looks much better that expected at this point!:

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

Then, mostly, the central section. One of the cross members has been squashed by either an impact or an ill advised jacking attempt. It must have been many years ago, and so structurally has held up ok, but I might try and bend things into a better looking shape:

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

Lastly, the right hand channel. There is a gaping hole here where the water tank pipe work used to enter the cabin. I think I will just seal this up fairly simply with an aluminium plate and sealant or rivets (or possibly a vent, as a gas safety measure?)
There is definitely rusty metal creeping under where the underseal has dried and lifted, especially at the wheel arch.

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[RalphWiggam]

I don't know man. I don't really see much to mess with in those pics, but you have a better idea looking at it in person.

Most of what I see looks to be in very good shape. That's a tremendous amount of work to undertake if it doesn't really need it.

Can you take pictures of where you say it is crusty?

[deepcflea]

Just jumped on to the end of this thread so I haven't read from the beginning, but I plan on it.

Not sure how far you plan on taking your work on the undercarriage, looks pretty to be in pretty good shape, but if you plan on removing all the rubber undercoating, be prepared for frustration and a long monotonous process. I removed all the undercoating on my double cab and painted it. What a pain in the arse... but I'm glad I did it and it's over with!
_________________
1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd

Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy

[mcdonaldneal]

[mcdonaldneal]

So, I’ve finally started!
Phase one is to use the needle descaler to broadly remove the underseal and the worst rust. It’s an awesome tool!
Each of the small panels in the pics took about ten minutes to do to the state you see. It’s a first pass, and awkward work. Also, the garage is below freezing just now and the tool vibrates a lot, even with gloves on, so I’m limiting it to an hour at a time. On the plus side, the underseal is so cold it’s quite brittle and comes off easily!
I’m encouraged by the results so far. I will go over it again from another direction, and then there will be various stages of wire brushing and sanding before I can even think about treatment and paint before the new underseal.

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[MorkC68]

Thats tidy underneath matey, lots of superficial corrosion, that will clean up nicely.

Gonna be good when you finish it
_________________
Major; 1977 Westfalia Campmobile
- Subaru EJ20
- Koni Classic adjustable dampers & Empi Heavy Duty Anti Roll Bar
- 180W Solar System

My blog: https://twolatebays.wordpress.com/

[mcdonaldneal]

[MorkC68]

[mcdonaldneal]

Another spell, freezing on the garage floor and I’ve reached the rear wheel arch.
As before, largely solid, but you can see a big streak of deeper rust which could really do with treatment.

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!

[mcdonaldneal]

It’s a dirty job for sure. Eye protection and earplugs are obvious, the descaler is very noisy, especially on a hollow panel. I added a face mask today, as yesterday my airways were full of rust and underseal for about 24hrs. The flat cap is optional!
I’m not taking pictures as I go, but the area I’ve shown is hard to access, it’s above the starter motor, which is out. Probably worth treating the surface rust where I can though.

_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper

Stop dead photo links! Post photos to The Samba Gallery!