66 Squareback, "Rusty" :)

[one4house]

Another project moved onto its new owner. It was a fun ride. I will miss it, but I don't let old cars sit. This one was sitting.

onto the next one.......
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My Old 64 Field Find
My Old 66 Squareback
My Old 66 Beetle
My Old 70 Squareback

[JeeJeeJason]

[one4house]

[dkvmatt]

What alternator conversion is that?
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1970 Volkswagen Notchback- Bunky

[one4house]

[JeeJeeJason]

What fuse box is that? Looks clean and hardly can tell it's aftermarket once mounted.
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1968 FI Squareback

[one4house]

Link

Another project off the list thanks to.........

http://www.aircoolednut.com/erkson/ttt/engine/gen2alt.htm
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My Old 64 Field Find
My Old 66 Squareback
My Old 66 Beetle
My Old 70 Squareback

[one4house]

Wow. I've ignored this thread for a while. Thought I would update with a fun little project I did last week.

I've been told, and always thought, that the stock fuse block it's a weak link in the electrical system. I decided to change mine the other day. I now have a blade style fuse block in place of the stock one. No more spinning fuses to reestablish contact our knocking out a fuse when reaching for the trunk release.

From this

To this

With this. Note: I had missed one jumper between blocks in this picture. This is only for reference. I did not realize it was wrong until I was installing and had to correct it.

Spaghetti
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My Old 64 Field Find
My Old 66 Squareback
My Old 66 Beetle
My Old 70 Squareback

[one4house]

First successful trip in the books. I decided to take a 1/2 day at work and fetch my case and rotating assembly from Qualitat in Grand Prairie. Doug had me set up and ready togo in no time.

It was an eventless trip down and back. The car ran good. I was getting 27 mpg. nothing to complain about, but it wasn't "right." Seemed sluggish at low RPMs and a little hard to start when hot.

When I got home I swapped out the idle shutoff circuits for a set of regular old idle jets. I also took the time to check the timing. I thought it might have too much timing, but it was the other way around.

The car has always had a 009 in it since I got it. I was so happy with how the last engine ran with it that I decided not to swap it, even though I have a much better SVDA under the hood in the toolbox.. When we set it the other day, I was aiming for 30* at 3000 rpm / full advance. When I checked it today it was about 24* at full advance. No wonder it was not "right."

After readjusting the timing it runs a lot better in the lower RPM. Changes always seem better initially. I am going to take her for a spin once the sun goes down and see what I think. I also bumped up the idle a little bit. I had it in the 850/900 range, and it liked to flicker the oil light when warm at idle. Now I am in the 950 range and the flicker is gone.

Also learned something new today. I have always heard conflicting stories about 12V and 6V flywheel / crank compatibility. Today I got, what I believe to be, a definitive answer to the puzzle from someone with 30+ years of VW mechanic experience.

Here are pictures of the two cranks in question:

6V Crank

12V Crank (My Crank)

Because of the extra machining on a 12V crankshaft, you can use either a 6V flywheel or a 12V flywheel on a 12V Crank. Because of the lack of machining on a 6V crank, you can only use a 6V flywheel on a 6V crank. This subject seems to be cloudy for many and it was for me until today. With pictures it all make sense.

If you put a 12V flywheel on a 6V crank, the flywheel does not seat on the crank surface. I have heard this causes excess stress on the end of the crank, turns it into an egg shape and ruins the trust area of the case. Enough with school....How about some scenery from the road?

Yeah, I take pictures while driving. If you see a swerving Squareback in the DFW area, steer clear.
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My Old 64 Field Find
My Old 66 Squareback
My Old 66 Beetle
My Old 70 Squareback

[one4house]

Boy was that a saga. Between stripped studs, crazy allergies, leaky pushrod tubes, transmission clearancing......there was a lot of learning going on. This is going to be a long post because I believe in sharing what I have learned to help anyone that might have the same issues in the future.

One of the things I had to consider for my build is the fact that I have a 6 volt transmission in this car. The engine i took out was 6 volt flywheel and 6 volt starter. The rebuild longblock I purchased is 12 volt. Here is an obstacle.

There are a couple of things you have to consider when putting a 12 volt flywheel in a 6 volt transmission. The first being that you need to run a 12 volt starter. The 6 volt flywheel is 1/8" smaller and has fewer teeth. That gives you two options: 12 volt VW starter with a conversion bushing put into the transmission or an auto-stick starter that does not require the use of the bushing area. Here is a picture of the auto-stick starter in place, and the bushing that would need to be replaced if you were to go with a standard 12V starter.

On a normal starter, there is a shaft that is supported by the bushing. These shafts are different sizes between the 12V and 6V starters. The auto-stick starter is self-supporting. The part number for Oreilly's and Autozone are 16300. Or Bosch SR-17X. The Oreilly's option was only $40 with a lifetime warranty.

The other thing you have to consider is making room in the bell housing for the larger flywheel. Is just takes the right tools and some patience. We had the engine in and out 3 times to get it right. Next time I would not be so conservative with my grinding. Here are some pictures.

In my case, you pretty much had to make room the whole 360 degrees. Going into it I thought that there would have to be certain areas to clear. Now I know you just need to grind that shit out.

Here are the after pictures. In my case, we needed to clear a 1/16" all the way around going 1.5" deep. This gave us about .050" clearance inboard and enough room around for the flywheel to spin freely.

Before we went to put the engine in to find out where we needed to grind, I put some oil in the block. The engine was fully assembled. This was about 8:00 on Friday night after a long day at work. As we get the engine on the jack to stab it, we notice fresh, clean oil leaking everywhere. WTF!

Come to find out I had reused the pushrod tubes out of the old build without changing the rubber seals. What a horrible mistake. I had to take the whole thing apart to change out the pushrod tubes. I was not a happy camper, but I learned an important lesson. Live and learn.

I woke up early yesterday. I was pretty sure we had all of the bug worked out. I was out in the shop by 6 am. The car was running by 4 pm. I was wanting it done far earlier in the day, but you can't rush an engine install. I missed a VW only VW show about 60 miles from my house. I guess I 'll have to go next year.

Once we go it all together, I followed my parents to the lake in the car. about 5 miles into it's madden voyage, it sputtered and stopped dead. I instantly hit the ignition off and saw smoke under the dash. I feared the worse.

Luckily one of the wires from the coil to the choke fell off and grounded out. I caught it quickly and saved myself. I do have a wire to attend to, but it was an easy roadside fix. Nothing major, thank goodness.

Finally it is back on the road. Here is a video of the initial startup after a little tuning.


Link


It sounds really loud in this video, but it is really quiet. We took the time to seal up the exhaust as best we could. She is running like new. I have the idle at 900 RPM. It is tip top now.

I also found this from one of my local VW friends.....

NOS for $90. I offered him more, but he wouldn't take it. He got a good deal in the past and was more than willing to pass the good deal to me. (Thanks Kirk)

I attempted to put it on this go around, but I was worn smooth out with all of the other problems and needs. I could not get the big nuts on the upper heater tubes loose from my current exhaust. I am going to locate a clean set of those upper boxes / tubes to attach to this exhaust and put it in at a later date. I just wanted the car on the road.

I have now put about 40 miles on it. All is well. It got me to the lake and back, and it got me home today. Speaking of the lake, seeing sights like this after working our ass off for a week sure makes it nice.

Some days are better than others. Let me know if you have any questions.
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My Old 64 Field Find
My Old 66 Squareback
My Old 66 Beetle
My Old 70 Squareback

[one4house]

[Clatter]

[Clatter]

[ataraxia]

I learned a long time ago - if you don't see a receipt that details the work that was done on an engine rebuild and when it was done, assume it was not done properly.

You're real lucky that it didn't seize up on you on a highway run. Nice to hear the parts can be used again though.

[one4house]

[Clatter]

Nice to see things coming along...

Hate to see you get PO'ed, but it does happen.

And,
You had been warned, right?
It did say 'Hood Ride' on the back, so you knew what to expect.

Once you get it shaken out, it should just run and run for years.
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Bus Motor Build

What’s That Noise?!?

[one4house]

[Bobnotch]

Adam, did you get your trans axle issue figured out yet? Basically where you want to grind, is at the 4 engine bolt thrus. You only need to take a little off each (mainly at the highest points of each), IF the transaxle is still a 6 volt unit. However, you might get lucky and have a 12 volt swing axle trans in the car already, that someone installed a 6 volt conversion bushing into (yes they make them to go that way too). That part doesn't really matter since you've already got the AT starter (self supporting).

The engine looks good. Sorry to hear about your exhaust stud though. That sucks, but it's also not to be unexpected.
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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

[one4house]

As far as this weekend goes, working on old cars can wear your ass out sometimes. Friday was my mom's surprise birthday party. Saturday I woke up way early and went from Sadler to DFW to austin to DFW and back to Sadler. What a long day of driving.

Today was spent troubleshooting and trying to get the engine back into my Squareback. Had it not been for a rouge exhaust stud both losing its threads and breaking off in the head, I would be driving it right now. Nothing like getting everything almost ready to put back in the car to figure out you have to tear it all down and take parts to the machine shop.

Looks like my first drive with the new engine will be delayed for a bit. I have a good relationship with a local machine shop. I'm hoping they will have some time this week to get the head back in order. I have never seen a head stud so seized in a head.

We tried double nuts, heat, lube, more heat and all that just to get it to where it broke flush. Then we drilled it out and worked for an hour with an easy out before the tip of the easy out broke off in the hole. Like I said, thank god we love these old cars or I might have turned mine into a BBQ tonight.

Now I hope to have her back on the road Wednesday. I need a day off after this weekend.

At least the rebuilt engine looked great. Here are some pictures.

As I bought it. Many thanks to Bsnean for offering this one up for sale.

Testbud build showing signs of care and quality. (Thank you Darrell)

I am swapping out heads because my tin is single port and the heads are in great shape.....except for that one exhaust stud

Rebuilt dual port heads.

This is how far I got when the head stud decided to derail things. All I had were heater boxes, exhaust, distributor and carbs. I was about a hour or two away. Now I am a day or two away. Till the next battle.

After everything is back together I will have a rebuilt engine, new clutch, new starter and great weather. It is about time to drive for hours each night in weather that doesn't make you sweat.
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My Old 64 Field Find
My Old 66 Squareback
My Old 66 Beetle
My Old 70 Squareback

[one4house]