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mcdonaldneal
Samba Member
Joined: June 13, 2013
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Location: Gullane, Scotland
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 Posted: Fri Oct 14, 2016 11:39 pm Post subject: Re: 021 905 205P distributor refresh (pics) |
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| H2OSB wrote: |
Reading through this thread has taught me if I need one of these dizzys, I'll buy a rebuilt one from Glenn.
johnL (aka H2OSB)
www.superbeetlesonly.com |
You're absolutely right, of course, John. 
(Except Glenn 'won't touch them').
tasb, SGKent and wcfvw69 have a lot of experience between them and have made this thread what it is, which is a caution to anyone thinking of refurbishing one of these later, aluminium distributors, a fund of tips for anyone that does take it on, and a demonstration of how long and involved it can get for an enthusiastic amateur. (Which is probably the majority here) 
I have learned a huge amount from similar threads on TheSamba, and I am grateful to those experts who continue to offer great advice (and much more!) in the face of relative ignorance. I can now rebuild Bus and Ghia clocks, wiper motors, altitude adjusters, carburettors and much more, where I couldn't before, and if I can't end up with a working distributor out of all of this, it's not the end of the world. 
Just happy to share my experiences, good and bad! 
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1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper
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wcfvw69 
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Joined: June 10, 2004
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Location: Arizona
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| Posted: Sat Oct 15, 2016 8:09 am Post subject: Re: 021 905 205P distributor refresh (pics) |
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| mcdonaldneal wrote: |
| H2OSB wrote: |
Reading through this thread has taught me if I need one of these dizzys, I'll buy a rebuilt one from Glenn.
johnL (aka H2OSB)
www.superbeetlesonly.com |
You're absolutely right, of course, John.
(Except Glenn 'won't touch them').
tasb, SGKent and wcfvw69 have a lot of experience between them and have made this thread what it is, which is a caution to anyone thinking of refurbishing one of these later, aluminium distributors, a fund of tips for anyone that does take it on, and a demonstration of how long and involved it can get for an enthusiastic amateur. (Which is probably the majority here)
I have learned a huge amount from similar threads on TheSamba, and I am grateful to those experts who continue to offer great advice (and much more!) in the face of relative ignorance. I can now rebuild Bus and Ghia clocks, wiper motors, altitude adjusters, carburettors and much more, where I couldn't before, and if I can't end up with a working distributor out of all of this, it's not the end of the world.
Just happy to share my experiences, good and bad! |
I think anyone who wants to try and refurbish one of the DVDA or 70's aluminum distributors should jump right in a give it a go. It's not hard to do and as the OP is stating, there's lots of great threads on this site to help guide you through the process. The other good news is you can buy these unwanted core distributors at the VW swap meets for almost nothing. I bought several of them for $4 dollars each at the last show I attended. Only one of them wasn't rebuildable.
In my mind, it's SSOO worth the process. My bus was missing the correct 211905205Q 1971 DVDA distributor. I sourced a core at a VW swap meet for a whopping $25 bucks. When I disassembled it, I was extremely pleased that all it required was a deep cleaning, two fiber washers and then relubing the parts with oil or Bosch grease in the appropriate spots. I sourced the correct NOS vacuum can for it as well.
So, I have less than $100 dollars in this refurbished distributor that is in perfect condition and works absolutely flawless. The difference in driveability with a correctly refurbished original distributor/carb vs. the aftermarket Chinese garbage sold today is night and day.
We all see the folks posting daily about their poorly running engines with aftermarket Chinese carbs or distributors. If they'd only reinstall the correct refurbished carb and distributor combo, their problems would be over.
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Decades of VW and VW parts restoration experience.
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**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
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mcdonaldneal
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Joined: June 13, 2013
Posts: 2649
Location: Gullane, Scotland
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| Posted: Sun Oct 16, 2016 1:25 pm Post subject: Re: 021 905 205P distributor refresh (pics) |
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It wasn't that I didn't believe SGKent, but I finally understand what he meant by getting the inner shaft polished and deburred, and how beautifully it slips through the inner bearings when you've done it. It really doesn't need a hammer (except when it get stuck a teeny bit before it's fully polished!)
I have everything cleaned and preliminarily greased, so that I can decide which bits to use to make three good units. Mainly moving stuff like thrust washers and condenser clamps between units.
I definitely don't want to mix up shafts and bodies that go together, but one advance plate has a missing/broken butterfly spring retainer, so I have made a retainer out of high temperature electrical heat shrink. I'm not sure how well that will last, but it's functional for now!
Lastly, I put together the centrifugal advance mechanism and springs, and even though I followed my own orientation instructions, two of the units have the drive dog wanting to go on backwards... grrrr 
I'll try and work out what has happened there tomorrow. 
Last pic shows the order of small shim, fibre washer and large shim that goes between the advance plate and the distributor body.
_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper
Stop dead photo links! Post photos to The Samba Gallery! |
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Tcash
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Joined: July 20, 2011
Posts: 12844
Location: San Jose, California, USA
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| Posted: Sun Oct 16, 2016 2:33 pm Post subject: Re: 021 905 205P distributor refresh (pics) |
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One of the things you want to measure is the Cam lobe. The part the points rubbing block rides on. These wear out on the ramps (corners) and the flats over time.
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mcdonaldneal
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Glenn
Mr. 010
Joined: December 25, 2001
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| Posted: Sun Oct 16, 2016 2:53 pm Post subject: Re: 021 905 205P distributor refresh (pics) |
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They don't wear, unless the rubbing block collapsed and the points gouged the cam.
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74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
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mcdonaldneal
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wcfvw69
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| Posted: Sun Oct 16, 2016 3:15 pm Post subject: Re: 021 905 205P distributor refresh (pics) |
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I've seen some cam blocks on the distributor shafts that were severely worn. It appeared that grease/oil got embedded with grit/dirt under the points wear block and grinded the cam lobes undersized. You could visually see the groove where it was worn undersized.
Others I've seen had scratches in the area that I simply polished off w/1500 grit sand paper with oil on it.
Here's a couple of pics of the worst one I've seen. This DVDA distributor was simply junk and was cannibalized for a few usable parts.
**note all the fine grit/dirt that was found all over these parts when it was disassembled.
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc
Decades of VW and VW parts restoration experience.
The Samba member since 2004.
**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours** |
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Tcash
Samba Member
Joined: July 20, 2011
Posts: 12844
Location: San Jose, California, USA
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| Posted: Sun Oct 16, 2016 3:41 pm Post subject: Re: 021 905 205P distributor refresh (pics) |
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| mcdonaldneal wrote: |
| Tcash wrote: |
One of the things you want to measure is the Cam lobe. The part the points rubbing block rides on. These wear out on the ramps (corners) and the flats over time.
Tcash |
I'll look in my Bentley, but I didn't think I'd seen a spec for this?
Fortunately, all of the cam lobes look ok, but I'll try to find a spec. |
I have not seen a spec. just pick the ones with the most consistent measurements.
Tcash |
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busdaddy
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Location: Surrey B.C. Canada, but thinking of Ukraine
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| Posted: Sun Oct 16, 2016 4:16 pm Post subject: Re: 021 905 205P distributor refresh (pics) |
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| Tcash wrote: |
| mcdonaldneal wrote: |
| Tcash wrote: |
One of the things you want to measure is the Cam lobe. The part the points rubbing block rides on. These wear out on the ramps (corners) and the flats over time.
Tcash |
I'll look in my Bentley, but I didn't think I'd seen a spec for this?
Fortunately, all of the cam lobes look ok, but I'll try to find a spec. |
I have not seen a spec. just pick the ones with the most consistent measurements.
Tcash |
Since the points never ride on the full width of the cam I suspect it'll be easy to spot a worn one by the dip in the middle of the cam.
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mcdonaldneal
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Location: Gullane, Scotland
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mcdonaldneal
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| Posted: Mon Oct 17, 2016 6:50 am Post subject: Re: 021 905 205P distributor refresh (pics) |
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Long story short...
I had actually written my instruction for reinstalling the points cam shaft onto the main shaft the wrong way around on page one of this thread.
Cross checking with Bentley, the drive dog orientation thread and this thread:
Finding TDC
Shows that if the drive dog has the small segment to the left, then the notch above the points cam should be facing towards you.
Like this:
It just remained to reinstall the points plates, clips, condenser clamps and the one good set of points and rotor I had to hand, and I'm almost done. (I would hate to leave the thread incomplete!) I do need to drive the pins back in and replace the retaining spring and the oil seal 'o' ring, but I can do that tonight.
Looks like I've got three distributors that should be in perfect working order!
Thanks to everyone for their help, tips, advice and for making this thread an information point for anyone considering this type of refurb.
Cheers!
_________________
1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper
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williamM
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| Posted: Mon Oct 17, 2016 9:26 am Post subject: Re: 021 905 205P distributor refresh (pics) |
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 Very nice write up and great comments from the group- especially about re-assembly and orientation of weights and points cam- then the removal of the clip- pure golden.
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Tcash
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Joined: July 20, 2011
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Location: San Jose, California, USA
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| Posted: Mon Oct 17, 2016 2:25 pm Post subject: Re: 021 905 205P distributor refresh (pics) |
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I had actually written my instruction for reinstalling the points cam drive dog shaft onto the main shaft the wrong way around on page one of this thread.
I edited your first post on page one. Can you please review and see if I got it right?
http://www.thesamba.com/vw/forum/viewtopic.php?p=8193965#8193965
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mcdonaldneal
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Wildthings
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| Posted: Mon Oct 17, 2016 3:11 pm Post subject: Re: 021 905 205P distributor refresh (pics) |
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| mcdonaldneal wrote: |
I definitely don't want to mix up shafts and bodies that go together, but one advance plate has a missing/broken butterfly spring retainer, so I have made a retainer out of high temperature electrical heat shrink. I'm not sure how well that will last, but it's functional for now!
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The original plastic acts as both a retainer and a bushing. With the way you have yours installed at this point in time the springs are functionally going to be longer than they should be. Someone needs to come up with an aftermarket replacement for this part. |
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mcdonaldneal
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mcdonaldneal
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Glenn
Mr. 010
Joined: December 25, 2001
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| Posted: Thu Nov 17, 2016 9:21 am Post subject: Re: 021 905 205P distributor refresh (pics) |
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I just picked up a 205P core and will be rebuilding it for a friend.
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74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
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wcfvw69
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Location: Arizona
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| Posted: Thu Nov 17, 2016 11:26 am Post subject: Re: 021 905 205P distributor refresh (pics) |
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| Wildthings wrote: |
| mcdonaldneal wrote: |
I definitely don't want to mix up shafts and bodies that go together, but one advance plate has a missing/broken butterfly spring retainer, so I have made a retainer out of high temperature electrical heat shrink. I'm not sure how well that will last, but it's functional for now!
|
The original plastic acts as both a retainer and a bushing. With the way you have yours installed at this point in time the springs are functionally going to be longer than they should be. Someone needs to come up with an aftermarket replacement for this part. |
The bushing part is what's really needed. The spring end fits snuggly on it over the pin. W/out the bushing, the spring will flop around on the pin. I have a few cores that are perfect minus those broken bushings/retainers. I need to do some research to find a work around for it.
One thing for sure though, these original Bosch distributors that are still tight with good points cams and non-worn advance weights and pins sure do work beautifully after they have been disassembled and cleaned of the 40 years of dirt and old dry grease. Even better with NOS vacuum cans bolted up to them.
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc
Decades of VW and VW parts restoration experience.
The Samba member since 2004.
**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours** |
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