Black Fastback Build Thread

[Clatter]

When a few days go by without my posting up,
The posting work piles up!

Spent a day getting the two lower-ends ready to go to spin-balance.
Lot of work sussing all the fasteners and wire-wheeling, zinc plating, etc.

One thing i always do is indicate the ring in before tightening ring to fan.

Noodled around test-fitting the bearings and crank.
Counterweights seem to clear, will need to really check when the time comes.

Loaded them up and off to Schroeder's for a spin-balance.
Seeing if they might blast a case as well..

Here's four different types of breathers found on the type 4 (ignore plugs in holes).
There are a few more. No wonder people hate type 4s so much.
Days of soaking these in the ultrasonic with this old Oil Eater solvent..
Got them all nice and clean inside so the blasting sand won't stick up in there.
Dumped the sludgy old solvent down a mole hole that has been torturing me for years.
Damned moles are way harder to trap than gophers..!

The paint store doesn't sell the Axalta epoxy any more, just Nason.
That damn Nason epoxy that had solvent pop over Axalta high-build..
Only solution was to special order a gallon at almost $400!
A poor craftsmen blames his tools, but i need all the help i can get.
Plus more clear, more supplies.. *sigh*.
Wences will put this stuff to good use this weekend..!


Finally got around to hanging my fuel pump.
Is that some clunky contraption or what?

In place and tight.
I'm sure some stupid reason to take it all back out will show up soon.
Ran the feed around in a loop so the break connector has slack to move.

Time for a pressure test,
Only,
I'm skeered!
Dollars to donuts it will be leaking way up in the tunnel..
Way up in the tunnel... No way to fix without the body coming off the pan...
Please... Please.. I'll be good, I will..

Rather than know the harsh truth, i decided to continue my self-delusion.

Drilled some holes, hung some hangers.

This took most of a day.

What you think?
Think it will work?
Enough flex in that little section to keep from shaking apart all those fittings?



Took it all back apart to touch up where i chewed the paint,
and hard lines to be polished at Ian's.
If it's going to be leaking everywhere,
At least it will be pretty doing so.


Do you smell gas?

I smell gas..
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Bus Motor Build

What’s That Noise?!?

[rosevillain]

It would be impossible not to recognize all of the work, time, effort, and dollars being lovingly poured in to this amazing project by the only guy that would catalog it to this extent. Your dedication to this build is inspirational. Thank you, man, you're great.

Please disregard the following.

Why carbs?

[Clatter]

[Clatter]

A whole day spent on finishing off the muffler..

Drug the bumper down from the attic and bolted it up.
Cut the old tail pipe end off and did several off/on test-fits as i creeped the edge of the cut back until it fit right.
Off/on, off/on.. Won't pain y'all with pics.

Finally final-welded it..

Welding Wind Gauge.. All of these dots were done the same, except for the wind.

Wasn't sure what I'd find in here; imagined the drill bit getting tangled around fiberglass packing like in a dirt bike muffler..

Welded these nuts in as suggested.
Wasn't easy, as it's so tight the gas is gone by the time the wire gets down there.

A tight bend, without being a kink, dig?
Pretty happy with how this came out.

Went ahead and spent a bunch of time manicuring welds.

Rigged up a couple of caps to leak-check the thing with soap bubbles.

Pinholes eternal
Wind blows but what can you do
Sooty exhaust spots

My O2 sensor cap has no washer,
Plus, the seams on this muffler leak like crazy all around.

Pinhole chasing leaks
Cheapo Cherry Bomb muffler
Throwing pearls at swine
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Bus Motor Build

What’s That Noise?!?

[Bobnotch]

[eyetzr]

Awesome exhaust work Clatter. The seams will seal up after you get this thing running and scaring the neighbors.
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I think he meant "rare", as in "not well-done"

[Brent]

[Clatter]

WhooHoo!

My Main Man stopped by early yesterday,
And the weather cooperated perfectly.

Hung lights from the canopy roof to get heat into the parts,
And started right in while the wind was calm.
These were parts i had already prepped and painted the side you don't see; "ready to shoot".
Well supervised!

Right away Wences saw things that weren't up to standard.
As he is shooting the first coat of base,
He's all "you sure that's good enough?"
You can guess my answer..

So after a few more rounds of 400, the parts got shot for reals.
Dig the guy's right arm..

Watching him shoot just bends my brain.
He ran a paint gun every day for 20 years.
He's constantly twisting this knob and that on his gun,
Feeling with his other hand how the air flows.
It looks like he's shooting his own hand about half the time.
Shooting his hand, twisting knobs, shooting his hand..
Blows the dust off with a couple of quick passes just lightly triggering for air,
Then he zaps the paint on in these swift stabs.
He's so damn good with that paint gun, I'm not really even understanding what he's doing, and i'm right there watching him do it..!
Y'know what i mean by all that?
It's like watching a magician..



While that other stuff was drying i got coached thru some sanding.
150 on a block shows all of these flaws on top of the tank.
It got hammer work and mud and more sanding and high-build.

Wences took some top tin to the next level.

This looks WAY different than it did yesterday morning..
I was trying to sand this flat, and no matter what i did, it wasn't flat.
THIS is flat.

How does a guy get so good at sanding?
You would think that anyone could sand something flat if they really tried, right?
Like, how dumb am i that i can't even sand something..?
He's really nice to me, and tries to coach me, and I'm getting better.
But it's hard to come face-to-face with the fact that you SUCK.
When this guy is here, there's no more denying it..



One more (hopefully last) coat of high-build went onto the top tins and tank.
Afternoon wind was up, and we were already in about 7 hours or so,
So we called it a day.

I'll be doing the last round of 400, (if i can ) and then,
If the weather cooperates,
Wences should be by next week to do a final spray.

Until then, paint needs to go into the sun to dry.
He did a trick where you mix a little base coat in the clear to make it more sparkley.

MMmmm.. Sparkles.
Me likey sparkles.

Sparkle sparkle..


_________________
Bus Motor Build

What’s That Noise?!?

[Clatter]

Spent the day sanding 400 wet.

Tank and top tins ready to shoot.

Saying a prayer to the weather gods..

_________________
Bus Motor Build

What’s That Noise?!?

[Jason37]

Say one for me as well... we have snow on the ground here.


Might I say, that tin looks incredible! And don’t feel bad about the sanding, this should be close to the last of it and then hopefully you’ll never have to do it again.

[nogoodwithusernames]

All I’ve got is “wow”. That motor is gonna be rad
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71 Squareback, 1.7l T4 w/ crank trigger fuel and spark
(Conversion thread https://www.thesamba.com/vw/forum/viewtopic.php?t=732508&highlight= or https://shoptalkforums.com/viewtopic.php?f=1&t=151375&sid=f0542d44a322d290c29d6609fac7f215 )
74 914, 2.0L w/ D-Jet

-Derek

[catbox]

Impressive work as always sir.
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"...these cars were preferred by the racers because the strut front suspension results in far superior handling than the regular torsion bar front end..." - Keith Seume.

[Bobnotch]

[Clatter]

[eyetzr]

Clatter, do not listen to these nay-sayers. The sanding never ends. Lies, all lies. It never ends.
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I think he meant "rare", as in "not well-done"

[djway3474]

Mr Miogi says
Sand Right
Sand Left

[twinfin]

Very Thparkley! I say "ship it". Sorry i went MIA this weekend ...my bus left me stranded at home with no beer. Would have been fun to to watch the Magic Show!
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"It's knowledge to learn from your mistakes. But it's wisdom to learn from others!"
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“He that goeth to bedde wyth Dogges, aryseth with fleas.”

"The Blue Submarine"
1977 Campmobile, Type 4 2.0 liter Federal, Non-Catalyst, Fuel Injected with Valvetrain from the type4store, 411 Heat Exchanger Preheaters, S&S Header, Supertrapp Silencer. ...and a lot of help from Clatter and TCash and friends!

[Bobnotch]

[Clatter]

Wences came by after work yesterday to shoot paint.

As he watched the base coat dry,
He said "Too Cold".
And that was that.
No shooting of clear; have to wait until it's warmer.
A cloud came right in front of the sun, and the heat lamp wasn't enough.
Real bummer, because the wind was very calm.
Lesser men (like me) would have pushed forward anyway and made a mess.


Tomorrow is supposed to be a few degrees warmer, then it gets cold for at least a week (or all winter).
Wences is also going to skip out of work a bit earlier so we have more time before the sun starts setting.
There are afternoon winds, so the window of opportunity is small; wind down, but still warm enough.
Tomorrow is GO Day.
Do or die. Now or never. :snipersmile:

Such is the life of the outdoor builder..


Everyone contributes to this project,
First Wences,
And now his boss, letting him out of work early (again).
Thanks Karl!
I owe you one..
er, another..
Owe you another..

And Wences, and everyone else..

If this project ever ends,
I'll be dedicating the remainder my life to service work, realigning my karma.
Because,
Man,
I have such a big debt of gratitude to so many out there now.

_________________
Bus Motor Build

What’s That Noise?!?

[Clatter]

10+ hours..

I’ll let the pics tell the story.

It was a very good day.

_________________
Bus Motor Build

What’s That Noise?!?