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Project: I just wanna drive my 66 beetle
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Gnarlyleech
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Location: Southwest Louisiana
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PostPosted: Fri Jul 13, 2012 7:53 pm    Post subject: Project: I just wanna drive my 66 beetle Reply with quote

Back story on this Bug.

I am hanging out with the brother in law at his buddy's house. We are picking up a 68 4door Dart that he just bought from him, real nice car. His buddy has a big shop and fixes up old cars, not just any old cars though, he can take a rusty holed piece of shit and turn it into something really nice. So I ask him if he ever comes across any beetles to call me. I have always wanted one and with my new job, I happen to have some extra cash flow burning a hole in my britches. He said he would be on the look out.

Back at home, I tell the wife about what I asked him to do, which was "find me a bug". The wife looks me in the eye gives me a little smerk, and says "No". No, as in, yeah right hell no. So as a husband does with his childhood dreams, I through that idea out the window. A few weeks later she spills the beans that she had a surprise for me and that I looked so upset lately that she would tell me what it was. For the past few months or so she already had her brother trying to find me a beetle to restore. She had found one on ebay classifieds and was going to check it out and get it for me.

She bought it for me and it broke down on the way home. This is where the journey begins....

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I have done a lot so far and I will be posting all the pictures and updates in the next few days hopefully.
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Gnarlyleech
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PostPosted: Fri Jul 13, 2012 8:09 pm    Post subject: Reply with quote

The first thing I gotta do is figure out why the engine died. She gets it home and parks it. At the time, I am in the GOM working on an oil production platform. I get home and fire that bug up. It doesn't sound good.

About me, I went to UTI after high school and got a degree in Auto and diesel mechanics. I worked for chevrolet for 2 years, and then I worked for Ford for 8 years. Now I am Offshore working as a Lead mechanic for an oil company. I tinker with everything from weed eaters to classic cars to modern high tech diesels and gas engines.

Anyways, I here the VW engine running and my mechanic ears can hear something like top end knock. I adjusted the valves, made a quick check on a few things, everything looks good, which isn't a good sign. oil level is okay, but it is black, I mean black black. Drained oil, and found this
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Looks like it is time for a tear down.
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TequilaSunSet
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PostPosted: Fri Jul 13, 2012 8:10 pm    Post subject: Reply with quote

NICE! Now go take the wifey shopping... you will be needing more stuff Very Happy
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Gnarlyleech
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PostPosted: Fri Jul 13, 2012 8:21 pm    Post subject: Reply with quote

Lol. I owe her big time. She takes care of me. Razz
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Gnarlyleech
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PostPosted: Fri Jul 13, 2012 8:30 pm    Post subject: Reply with quote

Here is the original 1300 engine. green allow pointing to egr valve. this beetle came from califormia.
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dirting heads. burnt up oil and lack of maintenance from PO
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Morning time and starting to pull the engine in my yard. i'm country.
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What I found? #2 rod bearing spun on the shaft. Crank is toast. Metal everywhere. Sad
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#3 Main bearing seat in the case is not looking healthy. Fretting is common I am told. This is going to the Machine Shop.
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I packed up the case and sent it to BrothersVW in california to get align bored.
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Gnarlyleech
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PostPosted: Fri Jul 13, 2012 8:34 pm    Post subject: Reply with quote

I decided I wanted to try and keep this car as stock as possible. Atleast until I drive it for a while. I found some NOS 1300 piston and cylinders on ebay. Snatched them for $125. Not that many broken fins. still usable.
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Mostly original engine parts on this thing.
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I will post more tomorrow.
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Gnarlyleech
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PostPosted: Sat Jul 14, 2012 8:01 pm    Post subject: Reply with quote

I removed the seat and I am getting ready to paint the floors. I am using a grinder with a wire wheel to knock the rust off and clean the floors up a little.

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Wire wheeled and ready for Phosphoric acid. This is the worst part of the floor board. The battery acid has eaten the floor board out a little. I don't have a welding machine so I will have to resort to plan B.
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I let the Phospho sit overnight and washed it out with the water hose the next day. After it dried I applied Master series silver primer to the surface. My next layer included a few sheets of fiberglass. the Mastercoat will sandwich the fiberglass and give the floor more strength.

After the primer, I applied master series AG black paint. It turned out really good.
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I may decide to paint this part at a later date. it is not in bad shape.
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bladerunner80
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PostPosted: Wed Jul 18, 2012 4:39 pm    Post subject: Reply with quote

Looks good! I'm about 75% done with my body off resto of a 66. Keep the pics coming!
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Gnarlyleech
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PostPosted: Wed Jul 18, 2012 5:42 pm    Post subject: Reply with quote

Surprise. Nice bondo job I just peeled off. I guess I get to look forward to fixing this.
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It looks normal from the outside.
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Gnarlyleech
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PostPosted: Wed Jul 18, 2012 5:48 pm    Post subject: Reply with quote

Replacing the rear seals. If I had an air compressor, sand blaster, and a nice shop to work in I would powdercoat all of this stuff and make it look nice. But a las, I do not. I just want to get this thing drivable and on the road.
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Backing plate. Note how the paper gasket is smaller. I am told this is how it is suppose to be but I didn't like it. I used a razor blade to cut it down the same size as the backing plate opening. It will still seal okay.
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Gnarlyleech
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PostPosted: Wed Jul 18, 2012 5:58 pm    Post subject: Reply with quote

Taking the original 66 distributor apart I broke one of the fiber washers. A samba member mailed me some new ones. Thanks again Glenn.
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Also broke this.but I just soldered it back on
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Parts are clean and ready for assembly.
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Gnarlyleech
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PostPosted: Wed Aug 01, 2012 8:36 pm    Post subject: Reply with quote

Random piles of parts. Hoping to get this stuff back together soon.

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Gnarlyleech
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PostPosted: Wed Aug 01, 2012 8:41 pm    Post subject: Reply with quote

Building the engine. Never thought it would take so long to put a crankshaft into the case. I went with a 74mm crankshaft and it required a little grinding because the connecting rods were hitting the case. I cleaned the case and put the crankshaft in and out 4 times. Finally got it right.
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Heating up crank gears in the oven.
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My 1966 Beetle Project Thread http://www.thesamba.com/vw/forum/viewtopic.php?t=520182


Last edited by Gnarlyleech on Wed Aug 01, 2012 8:49 pm; edited 2 times in total
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Gnarlyleech
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PostPosted: Wed Aug 01, 2012 8:45 pm    Post subject: Reply with quote

One the the heads is missing this little piece of sheet metal. I will have to make one I guess. I can't find it anywhere.
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Gnarlyleech
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PostPosted: Wed Aug 01, 2012 8:47 pm    Post subject: Reply with quote

Piston is hitting the crankshaft. So I have to grind it down to the area marked with a black marker. This 74mm crankshaft is starting to be a pain. It will be worth it in the end.
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Looks good.
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Gnarlyleech
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PostPosted: Wed Aug 01, 2012 8:52 pm    Post subject: Reply with quote

Checking the deck height, it looks like The piston is coming out of the cylinder .060". I am gonna need .100" to get my deck height right.
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These are the cylinders I am using. Found them on ebay.
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Gnarlyleech
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PostPosted: Wed Aug 01, 2012 8:54 pm    Post subject: Reply with quote

Lapping the valves and checking head cc's. I got 48 cc's. These are the factory 1300's.
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My 1966 Beetle Project Thread http://www.thesamba.com/vw/forum/viewtopic.php?t=520182


Last edited by Gnarlyleech on Wed Aug 01, 2012 9:06 pm; edited 1 time in total
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Gnarlyleech
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PostPosted: Wed Aug 01, 2012 8:56 pm    Post subject: Reply with quote

How things are looking. This is my engine rebuilding area/storage room. It is hot as hell in here.
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Gnarlyleech
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PostPosted: Wed Aug 01, 2012 8:57 pm    Post subject: Reply with quote

cleaning up stuff.
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Gnarlyleech
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PostPosted: Wed Aug 01, 2012 9:06 pm    Post subject: Reply with quote

I finally got caught up with the pictures on this thread. Right now I am at a stand still with the engine. I need a new 8 dowel flywheel, clutch, pressure plate, and cylinder spacers. This will cost around $350. I will have to wait for a while. I still have a lot of new parts for the car so I decided to do that stuff instead.

So the past 3 days I have gotten a lot of work done. I have replaced the left rear axle wheel seal, both axle shaft boots, cleaned up and installed the brakes, replaced the shifter shaft bushing, shift coupling, and installed the quick shifter kit. I will have some pictures of this soon.
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