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Restoration: 1960 Single Cab
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BarryL Premium Member
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PostPosted: Wed Jan 25, 2017 9:40 am    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

Eric&Barb wrote:
...that tin is to close off the side keeping the flow of cooling air flowing from the cylinders above, and keeping water/dirt/rocks kicked up by the rear wheels from the underside of the cylinders and push rod tubes.

Then it isn't used on split busses unless you discard your heater boxes and run J-tubes or do you use it with heater boxes?
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Eric&Barb
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PostPosted: Wed Jan 25, 2017 4:24 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

BarryL wrote:

Then it isn't used on split busses unless you discard your heater boxes and run J-tubes or do you use it with heater boxes?


Will not fit with HEs and used only with J-tubes.
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davidmelton
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PostPosted: Sun Feb 05, 2017 3:38 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

We added a t-handle to the engine lid. It is not period correct, but makes it so much easier to open the lid.

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Next, we add the missing rear-engine tin.

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Abscate Premium Member
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PostPosted: Sun Feb 05, 2017 6:07 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

Add some 7 mil nitrile gloves and clear safety goggles to,your Valentines Day gift list from Dad, Young LadyBus Mechanic. Good job on the hair tie back!

Very Happy

When you start rolling under you want to keep junk out of your eyes.

Do you have the Muir Book? Good section on safety there
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davidmelton
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PostPosted: Mon Feb 20, 2017 6:47 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

We took time over the 3-day weekend to start removing parts in preparation of media blasting and painting with an epoxy primer.

My wife came out to help!

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I was able to remove the engine today. For the most part, it was easier than I anticipated, except for removing the nut on the top right. It was a pain to remove.

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Some concerns about metal shavings inside the housing. Not sure where the shavings came from.

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Also found where the metal gas line is supposed to go through. This piece was not previously used or connected.

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cdennisg
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PostPosted: Mon Feb 20, 2017 6:54 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

^^^ Not for the fuel line. That is the tube the throttle cable passes through.

Metal shavings are likely leftover from using the flywheel to clearance the bellhousing during the 6-volt to 12-volt flywheel fitting.
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Eric&Barb
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PostPosted: Mon Feb 20, 2017 6:59 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

Metal shavings are not a big deal. You can see where the flywheel has barely touched the transaxle bell housing.

Clutch throw out bearing looks like it is not L/R even in relation to the input shaft. Needs to be shimmed over or the bearing will not last long.

Tube is for the throttle cable, not fuel line. Supposed to be a rubber seal to keep cooling air from leaking out around the throttle tube at the shroud, can use a fender washer clamped up against the shroud with that hose clamp to help with that.

Looks like you are missing front engine tin and dog house exhaust tube. Need a bolt in that slot of the tin at base of the cooler to keep shroud from opening up there, and probably need the foam seals for the shroud to oil cooler, exhaust shell and seals for the exhaust tube.

Need to get the spark plug clips for the rear of the shroud to both close up the three holes in the shroud to plug up cooling air from escaping and keep the plug wires from chaffing and shorting out.

Find stock rear tin that uses the sealing tin pieces around the heat riser tube.
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Eric&Barb
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PostPosted: Mon Feb 20, 2017 7:07 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

Also missing the spring for the thermostatic flaps.
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Eric&Barb
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PostPosted: Mon Feb 20, 2017 7:16 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

Here the fuel line goes around the left side of the shroud. Note there should be a bracket bolted to the left side of the shroud to hold the metal line from vibrating. Stock grommet in front tin keeps the metal line from getting cut on edge of tin hole.

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davidmelton
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PostPosted: Mon Feb 20, 2017 8:03 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

Eric&Barb and cdennisg, thank you for the detailed info!

1. My metal fuel line is pretty short and a rubber hose is attached to it and then to the fuel pump. Do you have a photo of the path for the metal line and how close it runs to the fuel pump?

2. I thought we had installed the front engine tin. The rear apron with the rubber that goes between is not depicted in my photos.

3. What does the dog house exhaust tube look like and where does it go?

4. Spark plug clips are on hand, but not yet installed!

Thanks again!

David
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Eric&Barb
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PostPosted: Mon Feb 20, 2017 8:43 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

1. Well the image posted above shows most of the route for the metal fuel line. Gets to about 2" from the pump.

2. #17 in the diagram on page 3.

3. #14 in same diagram.

Ignore the fuel line shown in the below images.

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4. Get R Done!
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Eric&Barb
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PostPosted: Mon Feb 20, 2017 8:59 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

This about the best image from the gallery for the pump end of the metal fuel line.

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1200 cc engines has a threaded in end of the fuel line into the fuel pump. 1500cc engine went to the short section of rubber between metal line and pump inlet.
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62DoKaGuy
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PostPosted: Tue Feb 21, 2017 10:34 am    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

davidmelton wrote:
We took time over the 3-day weekend to start removing parts in preparation of media blasting and painting with an epoxy primer.

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If you do one thing to modify the engine, I'd recommend nutserting that top left (DS) engine mount --- listened to the old man (my dad) after years of young-man's stubbornness and realized he might know what he's doing...you're moving along, though. Badass!
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EverettB wrote:
...I went at it from both ends but going from the rear didn't seem to do anything, although I did spray some rust breaker in there...

4/62 Double Cab
5/61 Panel (sold)
4/59 Single Cab (sold)
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mandraks
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PostPosted: Tue Feb 21, 2017 10:38 am    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

hmm, i think your metal shavings come from running a 1600 in a bus that came with a 1200. The larger flywheel will clearance the transmission, just a tad, the first time you start it....
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cdennisg
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PostPosted: Tue Feb 21, 2017 10:57 am    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

The driver's side top engine bolt boss should already have a nutsert in it. If not definitely put one in there. It can be nearly impossible to get a nut/bolt combo installed, much less removed, from that location with the offset oil cooler and proper shrouds in place.
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davidmelton
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PostPosted: Wed Mar 08, 2017 10:08 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

We just got the SC back after media blasting and epoxy primer coating. Some areas were better than I expected. Some areas were a lot worse. The prior primer was hiding a lot of bondo and holes.

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ryans65
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PostPosted: Thu Mar 09, 2017 6:00 am    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

Wow that thing is solid!!!
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davidmelton
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PostPosted: Sun Mar 19, 2017 7:59 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

We added the tabs to hold the rails for the front safari windows. We used screws to temporarily hold them in place until our welding skills are good enough to weld the tabs. We have a lot more practicing to do on the welder!

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We are going to add a retro-style reproduction fuel gauge (not pictured). We added a fuel sender to the gas tank.

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Replaced the oil screen and replaced 2 studs and all 6 nuts with gaskets and rings.

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Found the rubber stopper to go under the accelerator tube. Eric&Barb should be happy! Smile

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Added a panel van style grab bar to the front dash. Purchased it from Der Bus Hause who makes reproductions and advertises on The Samba. I had the handle powdered coated glossy black. This makes it so much easier to get in the Single Cab.

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We installed the rear safari window. We purchased it (along with the front windows) from Wolfgang International. The install was similar to the front windows, but the rear-window locks open all the way or it closed (unlike the front windows).

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Found a used spring the for the missing one for the thermostatic flaps.

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Eric&Barb
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PostPosted: Mon Mar 20, 2017 6:46 am    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

davidmelton wrote:

Found the rubber stopper to go under the accelerator tube. Eric&Barb should be happy! Smile


Nice find!

If you use the clamp there you will need to use a fender washer on the pipe to protect that rubber stopper from the clamp. Other wise the clamp will turn with the pipe and shove the rubber stopper inside, then the pipe will shift front/rear. VW originally used a grommet in the front tin to help lock the pipe from sliding, plus kept the pipe from getting cut thru.

Have you gotten the kind of accelerator boden tube that goes up front of the pipe. Without that the cable will often cut into the nose of the transaxle.
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PostPosted: Sat Apr 01, 2017 7:06 pm    Post subject: Re: New project: 1960 Single Cab ("Henry") Reply with quote

The PO had installed non-VW tail lights. And (sadly) had made the hole too big for the stock tail lights.

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So, I decided to install the 1963 stock tail lights because I could make the hole oval in shape and just a bit bigger.

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Unfortunately, we miscalculated the size of the hole by tracing around the tail light. And now the hole is too big. (Not followed: Measure twice and cut once.)

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Now we are thinking about using the correct 1960 tail lights and welding in some new sheet metal to hold them properly.

We purchased a good-sized compressor so we can start doing some body work with pneumatic air tools. Our old compressor was too small.

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After the disappointment at the tail-light-hole debacle, I decided to do something that was easy. We replaced the spark plugs, wires, and rotor cap.

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Next, we replaced the front and rear shocks.

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While replacing the shocks we learned that we were completely missing a Zerk fitting and several fittings were painted over on the front axle.
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