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68 bug sitting in shop for 18yrs
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zodlaw
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PostPosted: Sat May 13, 2017 2:29 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

I love it when a box shows up. My lowered ball joints, front brake kit, pop out screw kit and my adjusters.
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Soon as the weather gets nicer will put in the pop out windows I got in a trade, it will be nice not having those laying around anymore.
Having a hard time figuring out where I want to be with the beam. Its going to be at least a 2" Smile
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68 build that had been sitting for 18yr in a garage.
http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

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zodlaw
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PostPosted: Tue May 16, 2017 3:17 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Marked my cuts for the beam and its looking like 3" If I want I can always cut off another .5 on each side to make it 4.

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Going to see if I can wait and fit the tires and rims up before I weld it out to see if I need more or less. If less I will run 1/4 spacers.
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68 build that had been sitting for 18yr in a garage.
http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
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zodlaw
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PostPosted: Thu May 18, 2017 7:59 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Well finally started cutting the beam. The pipe cutter is not as good as the first one I used on my first beam, but it will have to do. I will even out the cut before I fit up.

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I think if I was to do it again I would just use a sawzall and some big hose clamps.
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All ready to go to work to get fit up and welded out. I only have a few days to get this done so I will just stick with 3" I am sure it will be fine as most that use these rims run a 2" beam.

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I will try and post some more progress pics of the beam in a day or so.
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68 build that had been sitting for 18yr in a garage.
http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
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zodlaw
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PostPosted: Tue May 23, 2017 10:24 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

so been working on the front beam. I made a small fixture to hold the beam flat. I just got some 1/4 angle to throw in there to make sure its strait. Cut some the brackets and used a chisel to get the rest off. Its little extra work but it saves from having to fill in.
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and the other side.

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This pic is just the fit up. I actually was going to do a 3" beam but. I did not know you can not measure off of the end brackets. I will def not use that type of pipe cutter again. :/ I did not have this problem with my first beam I did. Mine seems to be offset about 1/8 inch Top was 1/4 longer than the bottom tubes combined. So cut it on the band saw and fixed it so its 3 1/2. That is as narrow as I want to go. It will be a true 3" after the dropped spindles go on. They kick out the sides a 1/4 on each side.

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The adjusters I set at 90 deg. This will lay beam and is good for air shocks. I might open up the slot on the top again like I did on my last adjusters for more adjustment.
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When I actually weld this up I will have a lot more clamps and the tube. I will be grinding the tube ends at an angle to get good penetration. My only thing is the adjusters are just a little bit smaller in diameter so I will have to shim them to get them even all the way around during fit up. Might see if I can machine some sleeves.
All for now.
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68 build that had been sitting for 18yr in a garage.
http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0
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zodlaw
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PostPosted: Wed May 24, 2017 6:01 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

I cleaned up the burs on the inside of the adjusters so they turn nice and smooth and I figured I want more adj room. I did this on my last beam I did and it worked out well. I still have to add some side rails at the top so the alum block does not flop around. I will prob do that tomorrow .
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http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0
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zodlaw
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PostPosted: Fri May 26, 2017 3:43 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Started to make the sides and fit them up.
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Tacked them in place, I will be taking off the extra material later. Taking a 4 day weekend so the beam will have to wait till I get back after woodburn bug show.

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And the ball Joints, I really hate doing these things but what ever to save a few bucks so I can buy more parts. The uppers came out pretty easy more or less. I tried all my vw buddies and they did not have the special tool so I had to cut them out. Yes I hate to admit it I had to cut these things out. It took like 5 min, rather than the few hrs I wasted trying to get them out. Smile
One other thing you need to be really careful and not cut into ball joint sockets so go slow.

First I put a channel in the ball joint
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Then I popped out the middle section with a drift and whacked it a few times and its magic!


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And there it is all in its battered beat up glory.

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The final results.
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Going to clean them up a bit get the ball joints in a maybe paint them. I still have not made up my mind what to use yet on the front beam. I would like to fit the whole thing up and get it in before paint to maker sure I am happy with everything. If I am lucky I will get the ball joints pressed in tomorrow or Monday. All for now.
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68 build that had been sitting for 18yr in a garage.
http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
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bus guy
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PostPosted: Sat May 27, 2017 1:13 am    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Great progress!! 👍🏻
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zodlaw
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PostPosted: Sat May 27, 2017 5:07 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Thanks, things are moving slow though. The good thing is it give me more time to think about how I want it to turn out in the end...

So got some time to install some ball joints.

First gave them a good wire wheel clean up. I did not want to paint these yet so I just cleaned up just around the area I was installing. I will clean up the rest later as I have time.

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I Got the line lined up will the slot. Sometimes they will shift on you a hair when your pressing them in. This one turned out good. Also its a pain in the butt finding the right size tool to press the ball joint in with.

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The finished product after checking to make sure everything was flush and flat to the surface. I had to readjust the clamp twice to get it to flatten out the ball joint.
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I got Three done! I ran out of batteries and time. I will finish the last one up on Monday. Also I would pull the boots off of the lower ball joints before you install them. This is much easier, as you don't take the risk of ripping the boot.
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I will try and get some pics of the last lower ball joint install. If anyone ever needs to do them it will at least be here. All my pic are on the samba so no dead pic links.
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68 build that had been sitting for 18yr in a garage.
http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0
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zodlaw
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PostPosted: Mon May 29, 2017 1:25 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Finished up the last ball joint and they are all done.

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If I get some more time I might just install the pop outs I have since I have a screw kit now.
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68 build that had been sitting for 18yr in a garage.
http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
http://www.thesamba.com/vw/forum/viewtopic.php?t=591100&start=0
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zodlaw
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PostPosted: Thu Jun 01, 2017 8:09 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Finally got around to getting the oval head sheet metal screws for the rear along with the screw kit. I have had these pop out windows since last year finally getting them installed. I would never own a bug with out them period. Its just so much nicer to drive with them.

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So I will post up some more tomorrow as I finish it up. I will try to take some more pics so you can get an idea of how easy it is to install these.
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http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

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zodlaw
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PostPosted: Fri Jun 02, 2017 4:02 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Installed the window brackets.
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Next I cut out the window being careful not to cut the head liner and pulled back the end to find the factory holes.

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Then I notched out the head liner where the bracket goes.


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Pressed on the used white trim that I got with the windows. Now I think these might be a little short because they might be for early pop out windows. you can't really see them anyways. Just make sure you pull the trim with the og windows so this does not happen. I got these on a trade so I guess its a little late.

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Put the screws in. Also there are little bars plates that go with the window that the screws go into. Make sure you get those with the windows.

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As for the rear brackets, there are dimples you have to feel around for and make sure you find them before you put the screws in.
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Not much else but they look good installed and I can't wait to roll with them.

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Might get some small items at the show like a knob for latch on the seat. I pretty much have spent all my current funds on my front beam. Smile
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68 build that had been sitting for 18yr in a garage.
http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
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Buggeee
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PostPosted: Fri Jun 02, 2017 7:43 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Popouts Rock Cool
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zodlaw
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PostPosted: Sat Jun 03, 2017 5:39 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Yes I would have to agree totally....

Good day at Woodburn bug show and met up with some guys I have not seen in a while. This is my fav part..

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Got to love the dollar parts

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Here is a tribute to my old pile. It was the lowest fat chick there hands down. Razz Its being driven so that is cool.
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New owners mod.

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The motor is still the same.. But its getting a 1776 that is waiting to be installed.
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This was my haul for the day. As I mention I spent all my $ on my front end parts so it was little slim, but I did good. $3

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On the way home stopped by the old owner of my current bug that is moving and this is what I will do for bug parts... Lots of scrap metal Razz

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Not much else is going on and it was good to hook up with some people.
This next week hope to finish work on the front beam and have some more updates.
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68 build that had been sitting for 18yr in a garage.
http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
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zodlaw
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PostPosted: Tue Jun 06, 2017 8:29 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Got to do a little work on the adjusters and ground down the extra tab I welded on.
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I eyeballed them, they look good though.

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Notched the angle so the adjusters could sit at 90.
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Getting closer ...

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I still need to make a shim for the adjusters dia are a little small.

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And cleaned up the brackets...

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Just need a bit more time. I was also thinking about pulling the body off the pan not sure I want to do that until I have all the parts for the irs swap I am thinking of doing. Smile
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http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

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PostPosted: Wed Jun 07, 2017 7:22 am    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Love watching the progress on this.
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zodlaw
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PostPosted: Wed Jun 07, 2017 9:14 am    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

I want to get this thing on the ground but don't want to cut corners. I learned a lot from my pile too. I am more motivated when I can post some progress up, I feel like I am getting somewhere. Smile Hope to get maybe few more parts at the Seattle show. I also got the wrong window crank. I don't think its the right year. My 69 had plastic strip down the middle with chrome out sides. I have not seen too many of these at the swap meets. It was a $1 mistake so I am OK with it. LOL.
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http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

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zodlaw
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PostPosted: Tue Jun 13, 2017 5:15 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Well been really busy at work fabing stuff up so that make me not want to do my own. LOL I am seriously getting to old for this. Anyways I got the front end all fit up. Double checked the measurements and check the angle of my adjusters.

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I think one of my tacks that I ground down must have broke. the top adjuster is slightly off. There is some slop in them so I think I am ok with it. My welds have also seen better days. Will have to clean them up a little and put the other brackets on.

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So no going back I hope its not too narrow at 3 1/2 inches. Its sure going to tuck the rims though. Smile
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http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
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slowlearner
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PostPosted: Tue Jun 13, 2017 10:24 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

I'm relieved to see you're keeping the shocks. Narrowed beams are not my fair and I won't go there, but the shocks are vital.

Beyond that, well done getting an old car back on the road and driving. Try not to scrape it on the ground too much. Wink
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zodlaw
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PostPosted: Wed Jun 21, 2017 10:18 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

So I got some more time and figured I would pressure wash the brackets and coat the insides since I will not be able to paint them once they are welded on.
Used this stuff works great and figured it would not burn off.

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They turned out pretty good.

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Got the brackets welded on. I get nervous at this point as I don't want to screw this up. LOL I triple checked cross and center and sides.

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At the end of the day I welded on the steering dampener.
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Its nice to have most of it done. Now need to cut the spring packs down and dimple them with the arms on. I still trying to figure out if I want to move the shock mounts back 2 inches so the air bag on the shock does not hit the arm.

Prob clean up the beam some and move the grease fitting over so I can grease it with the steering box moved. Now for some motivation..
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All for now
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68 build that had been sitting for 18yr in a garage.
http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

Bagged 69 pile (SOLD)
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zodlaw
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PostPosted: Thu Jun 22, 2017 5:31 pm    Post subject: Re: 68 bug sitting in shop for 18yrs Reply with quote

Spent today cleaning the arms up. They were really dirty but I did not want to pressure wash them. They turned out pretty good but also took up most of my time..

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I also did wash the seals between the arms and beam with the pressure washer and after that pop the end caps out with a rod.

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Next on the list.
Wash the spring packs and fit them up to cut them.
center punch,dimple and cut spring packs.

It will prob not be till next week maybe get some stuff done at home on the bug.
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http://www.thesamba.com/vw/forum/viewtopic.php?p=8119987#8119

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