Scrivyscriv's 1967 java green sunroof sedan (stock)

[scrivyscriv]

Ball joint day!
I managed to find time to press in all four ball joints today, after leaving them in the deep freeze for a couple nights. They pressed in really well with this generic kit I found on eBay… the lowers were kind of a pain to get the adapters lined up but all four went in just fine!

Next it’s the beam bearings. They all came in a few days ago. I’ve got to pull the transmission on the family van and rebuild it, so I probably won’t get much done on the bug until that’s all back together.
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[The Pilch]

Excellent work brother!
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'85 Vanagon GL, weekender package, 1.9 wbx named Freddie/ '61 Beetle named Ringo/ '78 Dodge Monaco which is nothing like the Bluesmobile so please don't cast that oily rag upon it.

[richparker]

Are those tires the Nexen SB802?
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’71 Westy build
Adventure thread
’65 Deluxe Build
’71 Double Cab

[scrivyscriv]

Thanks pilch!

And yes those are the SB802s. Hope they are good!
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[67rustavenger]

The radio on the upper left of the stack. Is the closest to the Safire V (5) that was installed in 67. It's not a Safire, but close to the look.

The jack on the left is what I have for my 67. Clean it up and it'll make a nice addition to your car.
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I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!
Don't let your bad ideas remain, ideas!

[richparker]

[scrivyscriv]

[scrivyscriv]

The 4th anniversary of bringing this old tart home is this Sunday. I’ve got lofty goals to celebrate the milestone! I’d like to have her sitting on all fours by Sunday, and I think I can make it happen. The transmission rebuild for the family van is taking priority, but while I’m waiting for a couple Sonnax parts to come in, I’ve knocked out a few key tasks, one at a time, on the front beam.

The old outer trailing arm needle bearings came out without too much complaint using a basic 5lb slide hammer, and the NOS INA bearings went in easily too. They are supposed to be seating right at .20” into the beam, measured from the edge of the tubing. I will admit I did spend an inordinate amount of time measuring the distance on all of them

New beam seals from a guy here on the classifieds, and everything went right together with only the learning curve for a slow down. I was researching the VW 655/3 tool for raising the trailing arms to install the spindles. But as it turns out, it’s not really necessary here. I was able to lift the upper trailing arm with room to spare and get the ball joint stud lined up in the hole.

I’m re-using all the stock beam hardware and it occurred to me that I had not sandblasted and zinc plated the grub screw hardware. At this stage it doesn’t really bother me enough to do anything with it, so I cleaned them up and reinstalled it.
I’m trying the IAP door seals too. I put the drivers side on earlier this week and it seems to be fairly decent
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[scrivyscriv]

First of all the anti-roll bar bushings and hardware I got were the biggest pain in the butt to install! I’m convinced that the larger size clamping pieces are not the right size. The clip on one side is barely hanging on and I think I may have to swap it out with the original clamp

Next, my beam cradle and transmission jack combo was not a real winner. I’d rig up a saddle to drop into my floor jack if I do this again, because I almost couldn’t get the beam in place and then the cradle got stuck - sandwiched between the beam and body!
But it’s in!
I couldn’t find my beam bolt lock tabs I thought I’d ordered a while ago. I’ve just got the beam snugged up in place today and I’ll dig around in my parts stashes some more later!

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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[richparker]

Sweet!!!!!
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__________
’71 Westy build
Adventure thread
’65 Deluxe Build
’71 Double Cab

[The Pilch]

Quality stuff! That beam looks beautiful.
_________________
'85 Vanagon GL, weekender package, 1.9 wbx named Freddie/ '61 Beetle named Ringo/ '78 Dodge Monaco which is nothing like the Bluesmobile so please don't cast that oily rag upon it.

[scrivyscriv]

Thanks y’all.
I’ve installed KYB GR2 shocks on the beam. They’re marketed as vintage-car specific and are supposed to be close to the original ride quality, although they are nitrogen charged, compared to the OG oil-only units. I’m curious how they ride!
The four-year bring-home-aversary was last Sunday; it came and went, I was still wrestling with the family van transmission... It took priority! But it’s been four years since I pulled this old girl home with my two boys. I have to say, time keeps passing and just never stops. This was a quick “put some floor pans in and drive” car for me, and yet here we are four years later just putting the suspension back on!
_________________
Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[scrivyscriv]

Allow me to remind the internet of why you should not throw away old parts before the job is totally done:

New brake shoe pins on the left, old on the right. I don’t know why this is such a common problem but it’s the very first thing I look for when I open a brake hardware kit now.

I’m almost done with the front end assembly, but as usual I’m missing a few small parts and have extras of others I need the bolts lock plates, a few pieces of hardware, and now I know I have three extra tie rod ends! They are “OE brand” made in China - I believe it’s IAP - I’ll mail em to anyone for postage. 113.415.821EC, 131.415.812EC, 131.415.811EC

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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[scrivyscriv]

Some more!
Since this has been such a long reassembly, I thought it would be a good safety net for me to start applying torque stripe on all my front end parts as they're torqued. Everything is going together really well and I haven't run into any fitment or quality issues to speak of so far, other than the brake shoe retainer pins. I've been referencing the Wolfsburg West parts diagrams, Bentley blue book, and the OACDP parts fiches along with photos I took during disassembly, but I'm finding out that none of the above printed sources actually have all the parts listed in their diagrams. A great example is Wolfsburg West - their front axle assy breakdown doesn't illustrate the locking tab under the steering box drop arm bolt. Photos have really helped, even some I thought were kinda dumb to take have ended up helping, like for the spring plates' hardware orientation (bolt heads facing inboard, FWIW).

This is the first time mounting the front drums and seating their bearings, which went ok except for the fact that I misplaced the thrust washers for both sides so I can't set my bearing play!

Very cool to see the front end going back together. I don't know if I'll make my stated goal of driving this to work by the end of the year... less than five weeks to go, and I still have to make time to get the wiring finished, install the z-bar assembly, and re-ring and install the engine.
I've been contemplating the safety upgrade of the collapsible steering shaft. After a bit of research into the upper bearing arrangement, I'm not confident I will be able to pull the retrofit off in a reasonable amount of time at this phase of reassembly. I do think I'll do it in the near future, once I'm driving the car; one of the very few planned deviations from stock.

And last of all, any opinions about the wheel paint now that I've got the wheel and tire on the car? I'm still not sure, but I might do a spray paint job on them with the stock white on black.
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Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[vwuberalles]

I'd leave the wheels as is if it were my car, I've always liked those wheels painted a solid color. (I'm having a set of them powdercoated for my bus!) The scruffiness matches the rest of the car, it might look weird if they were perfectly painted.
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1973 Superbeetle: 1st car, owned since age 12. Update thread --> https://www.thesamba.com/vw/forum/viewtopic.php?p=9919140#9919140
1967 Kombi: Owned since age 17, Dad's retirement project.
1966 Beetle: My new project. (SOLD) Build thread--> https://www.thesamba.com/vw/forum/viewtopic.php?t=678040

[scrivyscriv]

I found my original wheel bearing thrust washers and got both front wheels on! The upper brake shoe retainers were lightly scrubbing against some of the inner drum casting ribs, but I think that will resolve itself once the brake system is filled and properly adjusted.
It’s a big day for the old bag, she hasn’t had weight on all four corners in about four years! The front suspension feels a bit stiff with a good jounce. I’m really looking forward to driving it!!

The front wheel is what I believe the be the original spare wheel, and the paint is original too.
_________________
Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[VW_Jimbo]

Nice job!
_________________
Jimbo

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

[scrivyscriv]

A look at steering shafts
In my previous post, I mentioned not being ready to dive in to the topic of upgrading/modifying the vehicle with a late model collapsible steering shaft. As it turns out, it isn't overly complex; I'll share some of the details here, and I'm considering making a standalone topic with more detailed information.

I will be deviating from stock config here.
I came across a note in the late model Bentley stating that the late model steering wheel may be service installed into earlier cars, but there is no mention of the shaft, so this will be for information only; I am not advocating for nor advising anyone to make this alteration.

Driving or riding in a beetle is inherently less "safe" than a modern vehicle, simply due to a plethora of federally mandated safety rules. Door crash beams for T-bone protection, multiple airbag zones, significantly engineered crumpe zones built into the body, ABS, etc don't exist in the beetle. I am of the opinion that most of us driving a vintage aircooled are aware of these potential risks, and have made a judgement call that we are willing to accept the risks as present. However, there are some very commonly accepted "safety upgrades," as they're presented, that a majority of the community seem to embrace. H4 headlights, retractable three point seatbelts, disc brakes, are all examples. So, there is a bit of internal debate on just how "safe" we'd like to imagine ourselves (or our family!) in the vehicle, and I think it is appropriate.

With that out in the open, let's proceed!

The stock steering shaft on a 1967 U.S. beetle is a solid shaft, meaning it has no crash/impact safety features designed in to it. Starting in 1968, the U.S. beetle was built with what we commonly refer to as a "collapsible" steering shaft. It's made to deform during a head on collision, potentially deflecting the kinetic energy into some other path than straight back into the driver

Side by side, here are the two steering shafts, as removed. They're actually almost the same length, I just didn't have them lined up together.
The solid shaft is from my 1967 beetle, and the collapsible is from an early late-model beetle. I believe it is possibly from a 1968-'70 model, but as of this post I am uncertain the exact year this style of shaft was installed.

After a generous glass bead media blast, here's the tape showing our shaft lengths. The 1967 shaft is approx. 37-1/16" end to end, and the later model shaft is a touch shorter, at about 36-7/8" long. This length difference is insignificant, as the stub shaft couplers at the steering box will slide lengthwise to make up that +-1/4" difference.

If you search for this topic here you'll find an often repeated phrase "don't weld on the steering shaft, they should never be welded" and that may be true to an extent, but that is not a universally applicable statement. Take a look at the collapsable cage.. It is rolled into a cylinder shape and welded shut, and the ends have a disc welded to them to complete the cylinder. It's difficult to determine where exactly other welds are, but it appears both shaft ends at the cage are either swaged in or welded in, or possibly both.

My next discussion on this topic will be the upper column bearing area and what potential differences exist; I may move this to its own topic at that point, it just depends on how much time I have to take photos and go through the installation. I'm open to feedback and corrections if anyone has information to share on this

Edited for late model Bentley information.
_________________
Robert in Memphis
Dünkelgrügen 1967 Java Green bug thread
Engine rebuild thread
If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[richparker]

Cool! Seems like a sensible upgrade.
_________________
__________
’71 Westy build
Adventure thread
’65 Deluxe Build
’71 Double Cab

[VW_Jimbo]

Cut the shaft. Install a sleeve to cover both sides of the joint by a few inches. Bevel the joining ends for of the OG shaft for good penetration. Do a good weld. Then grind the welds in plane to the shaft. Slide the sleeve over the joint. Align the midpoint of the sleeve to the previously welded shaft. Once in place drill out several plug welds and then weld them up. Weld the end of the sleeve around the end to the shaft. Clean up all the welds. You ought to be good to go!

My 2 cents!

My thinking is a collapsible shaft hurts less when you hit it, than a solid shaft. Why would you not?

Got me thinking!
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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!