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Bobnotch
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PostPosted: Mon Nov 27, 2017 8:48 am    Post subject: Re: Back At It Reply with quote

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


I read the updates but only comment when I've something useful to say - part of my slow crawl into 'older and wiser'... Laughing


And we do appreciate your input, sir.
Wiser is most welcome.

Sometimes,
I feel like this build should be called "Newbie Mistakes Listed; What NOT To Do".


I'm one of those people who have to make the same mistake in a few different ways before I really learn anything. It's no fun if it works the first time.


I prefer to let others make the mistakes first, then I can see for myself why it happened. Wink But then I've made plenty of mistakes on my own over the years. Embarassed
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71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120
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oxsign
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PostPosted: Mon Nov 27, 2017 10:18 am    Post subject: Re: Back At It Reply with quote

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


I read the updates but only comment when I've something useful to say - part of my slow crawl into 'older and wiser'... Laughing


And we do appreciate your input, sir.
Wiser is most welcome.

Sometimes,
I feel like this build should be called "Newbie Mistakes Listed; What NOT To Do".
Sometimes it's the only way to learn. But keep at it, I learn from these threads too. Like ataraxia though, I do read but only post when I'm useful, lol.
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Xevin Premium Member
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PostPosted: Wed Nov 29, 2017 12:07 am    Post subject: Re: Back At It Reply with quote

Clatter wrote:
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.


Oh, I’ve been lurking. But mostly to make sure you’re not eating “Little Xevin”
I see you got him a new outfit. It’s very festive. Well done. Laughing


Link


And your build is still amazing. Nice work. Glad you got some surf time in last week.
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GFY's Xevin and VW_Jimbo! Very Happy

Clatter wrote:
Damn that Xevin... Very Happy Very Happy Very Happy

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I respect Xevin and he's a turd Razz

SGKent wrote:
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Clatter
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PostPosted: Sun Dec 03, 2017 8:42 pm    Post subject: Re: Black Fastback Build Thread Reply with quote

Well, had some stuff cooking off and on all week and some of this weekend.
The surf was good, so it wasn't much.. Wink

First off,
One of the least-known VW master machinists in America is here in Santa Cruz.
He's not going to be doing this for too much longer, folks,
But he's going strong as of today!

Funny how places like Rimco and Northwest Connecting Rod and Painters Grinding become well known on these forums,
But a guy like Jim here just doesn't advertise himself.
Jim Musich, Napa Carr Parts in Santa Cruz, CA.
He has built thousands of these motors.
This, people, is one of those guys whose kind will be gone forever.
There will never be another time when so many of these motors were done every day,
And the machinist got a chance to develop tooling and skills to do work of this quality.

This is opening up a Type 1 case to 90.5 for my Oval..

Once you have inspected a few different open-ups by different builders,
You can tell the masters from the newbs.
There are bunch of subtleties to this job for sure.
I was a machinist for about five years,
And have a bit of eye for these things..
Shore is purdy!

Much Respect to Jim..

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

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Clatter
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PostPosted: Sun Dec 03, 2017 8:54 pm    Post subject: Re: Black Fastback Build Thread Reply with quote

Brooke blasted those bus rear snubber mounts for me.
Good thing..
Check out how far gone they are.
(And her nice work chasing those crevices).

Some weld will fill those in..

Image may have been reduced in size. Click image to view fullscreen.



Narrowed a bunch of hardware for the rear spring plates..
The rear sway mounts, and some other bolt heads need narrowed to clear the sub.
Image may have been reduced in size. Click image to view fullscreen.



Darren at Arc-Tec let me use his lathe to shorten my Lanner e-brake extension tubes.
(Sorry, no pic) Embarassed
Went in and drilled a hole to start running the cables thru the arms,
And,
They were supposedly just hollow,
But,
They're not..

See the inner reinforcement plate at the back edge of the hole in there?
Sucks.
Image may have been reduced in size. Click image to view fullscreen.


Went and chucked up a rotary bit in the straight die-grinder,
To hog that sucker open,
And it died.
25 years is pretty good for a China die-grinder.
Image may have been reduced in size. Click image to view fullscreen.

Anyone recognize that name?
They make machine tools like lathes and band-saws.
I got that one off of the tool truck when I worked as a machinist so many years ago.
It ported a lot of heads.

Anyhow,
The e-brake-cable-through-trailing-arm project came to a screeching halt today.
Going to take those back in to Darren and see if he has any ideas.


And buy another China die-grinder... Wink
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Jason37
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PostPosted: Sun Dec 03, 2017 9:21 pm    Post subject: Re: Black Fastback Build Thread Reply with quote

The pic of the trailing arm...I saw it before I read the caption and thought, Damn that Steve went and got himself a tig machine and look at those welds. Then I read the text and saw you’re still fighting. Just out of curiosity, could you weld a tube to the outside of the torsions for the e-brake cable?
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Clatter
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PostPosted: Sun Dec 03, 2017 10:12 pm    Post subject: Re: Black Fastback Build Thread Reply with quote

That's actually a really good idea, Jason.

Maybe I'll just flip the backing plates,
Make up a piece of conduit,
And weld it to the top of the arms.
That might be just the trick for keeping them from getting pinched.

Will have to mock that one up;
Already got a piece of the perfect size tube that was supposed to go inside.
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Clatter
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PostPosted: Sun Dec 03, 2017 10:50 pm    Post subject: The Battle of the Detents! Reply with quote

Whenever you try new things,
There's bound to be some pain.

A lot of times, when people are old,
They lose their taste for struggling, having pain, and feeling stupid.

Not Me! Very Happy Very Happy

Here's a (long) example - if you are in a hurry go see the next thread.
(This likely won't make much sense anyways). Confused


Detents - the little bullet-shaped things that keep a trans from being in two gears at once;
I have other names for them now.

Here's one - if it's pushed by the shaft in one hole, it moves to the other.
Image may have been reduced in size. Click image to view fullscreen.


These got masked off with some tape before blasting.
It didn't work very well. Should have been disassembled first! Embarassed
Notice that I'm struggling with a pick to get it free.
The glass bead, and wet, had wedged it into place pretty good.
It was kind of crusty-corroded in place.
Have to get it completely free, to pull it out with gravity and a magnet;
Can't push it out, the hole it travels thru is blind at one end.

Blow with air, and brake cleaner, and push/wiggle it until it comes loose.
Image may have been reduced in size. Click image to view fullscreen.

This above one was the easy one - it gave no trouble at all.

Here's the one that almost beat me.
Image may have been reduced in size. Click image to view fullscreen.


The thing is, I have never found the manual for this trans on line.
If anyone has a link to one, man, I would be SO grateful.
No luck for me there after way too much searching.

I didn't know how this goes together,
But,
After driving out the two roll pins, a detent, spacer, spring , and rod came out.
Easy enough, right?
Image may have been reduced in size. Click image to view fullscreen.


Got this end free by jamming a long rod thru there..
Image may have been reduced in size. Click image to view fullscreen.


Cleaned it up..
Image may have been reduced in size. Click image to view fullscreen.


Used my gun brushes to clean the passages..
Image may have been reduced in size. Click image to view fullscreen.


Got it all cleaned up,
Put a spatch of grease on things,
And started assembly.
What could possibly go wrong?
Question

The problem showed up when I started pounding in that 2nd roll pin..
As I was driving the pin in, the drift started resisting, and I hit it a few times harder with the hammer..
The drift was cocked sideways, and stuck in the hole.
I had forgotten to press the sleeve thingie far enough into the hole! Shocked
Was gouging the side of it with the pin, and hammering more! d'oh! d'oh!

Now, the spacer thing was burred, and the inside of the bore where it all goes was chewed up.
So the whole thing was seized in the bore, stuck tight into a blind hole..
You can't pull a stuck object with gravity and a magnet!
Brick wall Brick wall Brick wall Brick wall Brick wall Brick wall Brick wall

It looked like, for a while there, that I ruined the main gear case.
Unless those detent parts slide smoothly in that bore,
There ain't gonna be no shifting happening in this trans.

Had me a real piss fest there for a while.
I'm not one to keep a cool head.

After a beer (or two) I came up with a game plan.
Luckily, I had a file with a square handle shank that fit inside the spacer dealie.
Was able to jam it into there, tight enough that it could be hammered through the burrs I made.
After several desperate tries, and just dumb luck, got it free.

Here it is, with scars from my brilliant hammering.
Image may have been reduced in size. Click image to view fullscreen.


I had a couple of different long, small, round files to smooth the burrs from inside the bore,
Cleaned it all up again,
Greased it up.
Compressed the spring this time Exclamation
And drove the 2nd roll pin straight home..

Here they are - the plugs are off at cad plating -
With tape over their plug holes,
Cleaned, greased, and ready for assembly.

That one on the left was almost a casualty today..

Image may have been reduced in size. Click image to view fullscreen.


*Whew* Exclamation

There were SO many times when I was younger and did something like this.
Couldn't count them all; so many failures.
Get in a hurry and ruin something...

This time, experience and patience (And a big dose of luck) saved me.
I keep trying to look for the benefits of being old,
And there aren't many,
But here's one! Very Happy
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Clatter
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PostPosted: Sun Dec 03, 2017 11:58 pm    Post subject: Heater Boxes Part 4 Reply with quote

Did a bunch of finish grinding to the heater boxes;
Almost there..

Why do I even bother grinding the inside of these? Rolling Eyes
Image may have been reduced in size. Click image to view fullscreen.


The outside, though, gotta smooth those out.. Cool
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


Just some finish hammer/dolly and fitment to the piping..

Now,
What coating for these..?

Ceramic sure is nice,
But I'm getting quotes for like $600+ for that from a couple of places.
That's most of the way to a nice stainless 1 5/8 from Tiger at A1..

Rustoleum BBQ Black has worked well for me.
Far better than that VHT bake-on nonsense.. Rolling Eyes

Really want to put something on the insides of them,
To keep them from rusting from the inside out..
Maybe they don't do that, because of the heat?

Anything inside there would likely burn and stink and fill the compartment with fumes.

Anyone have any ideas?

Ceramic likely won't burn off, but, dag that's pricey...
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Jason37
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PostPosted: Mon Dec 04, 2017 6:54 am    Post subject: Re: Black Fastback Build Thread Reply with quote

I have had good luck with using a no-bake cylinder paint on all the motorcycles. When I get home tonight I will snap a picture of it.
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Boogievan
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PostPosted: Mon Dec 04, 2017 7:20 am    Post subject: Re: Black Fastback Build Thread Reply with quote

I like using Stove Bright. For a bomb can paint job it has always worked great for me, and you can get it in some pretty cool flat metallic colors.

I've painted a lot of headers and manifolds with it, and it's never burned off. Some of them were bolted to motors that were treated very badly too...
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Jason37
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PostPosted: Mon Dec 04, 2017 9:29 pm    Post subject: Re: Black Fastback Build Thread Reply with quote

Image may have been reduced in size. Click image to view fullscreen.


Really missed my calling as a hand model...this is the stuff I have used on countless bikes and the only one wear it is showing some wear is on an old Iron head pre unit, which I used the silver. The black has held up well on all the other bikes.
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Clatter
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PostPosted: Wed Dec 06, 2017 8:32 am    Post subject: Re: Black Fastback Build Thread Reply with quote

Thanks for the tips.

Have you tried it on the inside of heater boxes?

I'm hoping to find something that won't stink when the heat is turned on.

Maybe "Stove Paint' is designed that way?
It's used indoors, around food..

Spent my "day off" finishing up the engine cart.

Here's a tip I learned from an old master:
When drilling a lot of deep holes,
It helps bits last if you keep them lubed up.

Slather the bit with oil, so it runs down the sides onto the tip.

Then, start the hole and get it going a bit,
Then fill the hole up with a pool of oil.

Image may have been reduced in size. Click image to view fullscreen.


It took a few hours, because this thick angle needed trimmed so much,
Plus all of the (stainless) bolts had to be shortened and chased,
But I got the welding and grinding done.

Got the welder up to #3! Very Happy
Image may have been reduced in size. Click image to view fullscreen.



So, something.. I guess.
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Jason37
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PostPosted: Wed Dec 06, 2017 8:00 pm    Post subject: Re: Black Fastback Build Thread Reply with quote

Never tried it on the inside of a heater box. Do you have a run stand? If you do, paint them, clamp the halves together and try it. If it works, weld em and call it done, if not, onto better coatings.
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Clatter
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PostPosted: Mon Dec 11, 2017 12:02 pm    Post subject: Grinding Along Reply with quote

It was a pretty good weekend.. Only a few hours, but stuff got done.


Friday, Brooke got my cart coated for me.
Picked up the fasteners, and threw it together. Dancing
Added this rubber padding stuff along the 'bed' area to protect a case.
Image may have been reduced in size. Click image to view fullscreen.


Because, she's a princess, and needs a nice, soft bed.. Cool
Image may have been reduced in size. Click image to view fullscreen.



Saturday was MORE welding/grinding/flapwheel-ing of heater box pinholes, plus,
Several hours of hammer/dolly and test-fits.
I'm getting REAL sick of these heater boxes at this point.. Evil or Very Mad
Image may have been reduced in size. Click image to view fullscreen.


Too bad my phone camera sucks so bad,
Otherwise, you would be able to tell that these are smoother than they were.
Image may have been reduced in size. Click image to view fullscreen.


Looks like I'm just going to have to bend over, take it like a man, and get them ceramic-coated at Jeremy's.
Hopefully, I'll at least get a kiss and some lube..


Thankfully, there are some things to do on the car that aren't trailing arms or heater boxes..
Actual forward progress here on the trans! Very Happy

The great Paul Guard schooled me on smoother shifting for Porsche transmissions; Using a diamond burr to detail the edges of slider sleeve engagement teeth.
What's not shown here is a big magnifying glass..
Image may have been reduced in size. Click image to view fullscreen.


The edges of the teeth tips get little nicks in them with use.
The burr smooths these out and puts a little bevel on the edges.
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.



This should be the last tool to make for this job;
A reverse hub adapted to make a shaft holder.
Will probably have to weld a couple of 'ears' onto that hub, as it doesn't look like the splines will hold 180 ft.lbs in the vice by itself..
Image may have been reduced in size. Click image to view fullscreen.


The motor got the heads and shrouding pulled off (need to use 2 liter heads with my linkage because the spark plugs foul the linkage),
And put on the new engine cart.
This set up for some operations with the trans..
Image may have been reduced in size. Click image to view fullscreen.

Once my fasteners all come back from Oregon, the trans should be ready to go back together. Pray Pray Pray


So:
Heater boxes are ready to go to have the insides ceramic coated (finally Rolling Eyes ).
Exhaust manifold inner header pipes are going to Jim for a surface, then they will get coated too.
Coating will get ground away at weld points, and welded backed together.
Plus the seams will get folded over and all - hope it looks OK.
Then it will get a final outside coating, along with the header.

The trailing arms should hopefully be dispatched on a mill.
Will keep everyone posted on that..

Ugh. Trailing arms. They're like this bad dream that keeps coming back after you fall asleep again..


On and on and on and on...
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Jason37
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PostPosted: Mon Dec 11, 2017 9:01 pm    Post subject: Re: Black Fastback Build Thread Reply with quote

I always love how clean the background is in the pics. Makes me think that there is a huge pile waiting to topple down upon you just lurking out of frame.
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eyetzr Premium Member
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PostPosted: Tue Dec 12, 2017 5:00 am    Post subject: Re: Black Fastback Build Thread Reply with quote

Nice cart/bed. I see we have upped the beer quality. My favorite. So no body updates?
Jason37, the place looks great to be child friendly, my place any kids would be gone & a search party called in.
Looks great Clatter, you will be rewarded for your efforts
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I think he meant "rare", as in "not well-done"
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Xevin Premium Member
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PostPosted: Tue Dec 12, 2017 10:30 pm    Post subject: Re: Black Fastback Build Thread Reply with quote

Jason37 wrote:
I always love how clean the background is in the pics. Makes me think that there is a huge pile waiting to topple down upon you just lurking out of frame.


There is and I’ve seen it. It’s a pile of goodness that you’d be even more impressed by seeing. I didn’t say it was a messy pile Very Happy Clatter’s a pro.
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67rustavenger wrote:
GFY's Xevin and VW_Jimbo! Very Happy

Clatter wrote:
Damn that Xevin... Very Happy Very Happy Very Happy

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I respect Xevin and he's a turd Razz

SGKent wrote:
My God! Xevin and I 100% agree Shocked
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Clatter
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PostPosted: Wed Dec 13, 2017 8:21 am    Post subject: Re: Black Fastback Build Thread Reply with quote

Jason37 wrote:
There is a huge pile waiting to topple down upon you just lurking out of frame.


Jason, you have been here before!

I have shelves of crap up to the ceiling.

Those clean pics are staged..

Everything I own, the bottom foot of it is covered with big nose mud! Evil or Very Mad
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Bobnotch
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PostPosted: Wed Dec 13, 2017 3:43 pm    Post subject: Re: Black Fastback Build Thread Reply with quote

I like how the cart turned out. It looks much better and more solid compared to the stuff you see advertised. Great job on it. Same applies to the heater box tins. My son might like seeing how they come out when you finally get done with them, as he does still have his bus boxes to rebuild (currently using 411/412 boxes on his Roadster).
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Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120
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Tram wrote:
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