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Buggeee's 1972 Super Beetle
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Busstom
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PostPosted: Mon Mar 13, 2023 12:48 am    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Nice job on the bung.
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Buggeee
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PostPosted: Mon Mar 13, 2023 4:10 am    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Rome wrote:
Your black on this repainted pulley tin is a good match to factory original. Did you use satin black? Its cloudier than "semi-gloss".
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Rustoleum 2X Satin Black
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PostPosted: Mon Mar 13, 2023 11:17 am    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Amazing work, Buggee. Am I confused, or is the bung welded to the tailpipe?? Confused

Buggeee wrote:

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Later peeps. Green Bug

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Buggeee
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PostPosted: Mon Mar 13, 2023 6:11 pm    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

vamram wrote:
...Am I confused, or is the bung welded to the tailpipe?? Confused

I drilled into it not caring if I tore through the peashooter tailpipe, but as it happens the tailpipe was not inserted far enough to get drilled. So, it's mounted into the muffler only.

Tonight I installed a pair of AN-6 bulkhead fittings for some future fuel injection lines, just because I want to, and am only using one for now to pass through the gas line.

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Buggeee
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PostPosted: Fri Mar 17, 2023 7:58 pm    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

In the last 2 years I've had a brand new Bosch starter last less than a year, two rebuilt Bosch starters last less than two weeks each, and one brand new Bosch starter that made it through half a season so far, and still working. This time I'm going to try a $64 generic starter. It had good reviews on Amazon, but does not have the shape to hold the blind bolt.

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So I welded a nut on a standard bolt and will use that.

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I needed a throttle cable tube for a later car but only had a shorter one for an early car. So I took that to Home Depot and the plumbing dude matched up a copper toilet riser connection while telling me about his aircooled days.
It's the same diameter, long enough to cut to size, and has a flared end that fits nicely in the mouth of the shroud.

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I put a rubber grommet at each side of the shroud and, on the rear, filled the upper part of the hole with half an electrical grommet, as I dont have the OE rubber piece in the stash right now. A fuel injection hose clamp holds the tube in place.

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Some kind of sticky foam tape around the edges closes the gaps in the oil cooler exhaust tin and then I assembled it. It's either for windows or a truck cap to bed application. I forget. Found it on my tool box, thank you past me.

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For the 75 amp alternator, I used a fine stranded 8 gauge cable for the charging wire, and proper connectors that are marketed for stereo amps and whatnot. I shrinkwraped them with marine wrap for this exterior application.

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The ground side gets a fresh transaxle to body strap.

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Last edited by Buggeee on Fri Mar 17, 2023 8:59 pm; edited 2 times in total
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Buggeee
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PostPosted: Fri Mar 17, 2023 8:03 pm    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

The Harbor Freight cherry picker helped me take the engine from the stand to a pair of car dollies on the floor. I lifted the body, rolled the engine under and lowered the body over it. From there, the Harbor Freight low profile floor jack lifted the engine up and I wiggled it into place. Things are starting to feel real over here.

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Buggeee
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PostPosted: Fri Mar 17, 2023 9:02 pm    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Busstom wrote:
Nice job on the bung.


Sounds dirty. Lol
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vamram Premium Member
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PostPosted: Sat Mar 18, 2023 6:09 am    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Looking so good it makes me feel dirty for gawking.
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Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
Click to view image
Save the Supers!!
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67rustavenger Premium Member
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PostPosted: Sun Mar 19, 2023 3:57 pm    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Mg50, was in the lead. I had ya both by a couple weeks.
Then you snuck your install in and took pole position.
I'm claiming 2nd! Wink

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Very Happy
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PostPosted: Sun Mar 19, 2023 4:48 pm    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Buggeee wrote:
The Harbor Freight cherry picker helped me take the engine from the stand to a pair of car dollies on the floor. I lifted the body, rolled the engine under and lowered the body over it. From there, the Harbor Freight low profile floor jack lifted the engine up and I wiggled it into place. Things are starting to feel real over here.


Well done grasshopper, well done. You've lapped me and I'm stuck in the pits for awhile. And yes, Rustavenger is right behind you.

That cherry picker is sweet.

I draped a HF chain hoist over a beam to lift my engine and remove the stand, using a 6ft. lifting sling (HF) under the motor. Then supported it with some stands under the heater boxes so I could remove the sling. I put jack underneath to lift enough to remove the stands.
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Buggeee
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PostPosted: Sun Mar 19, 2023 5:51 pm    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Humming along at about 2300 rpm



Link

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Last edited by Buggeee on Sun Mar 19, 2023 6:00 pm; edited 1 time in total
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Buggeee
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PostPosted: Sun Mar 19, 2023 5:54 pm    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

It survived its first start and phase 1 of the break-in procedure (about 2300 rpm for 20 minutes).

It's leaking badly from the oil filter, the ancient VDO oil pressure sender and one valve cover gasket.

The oil cooler is holding!!!

I'm taking the win and getting some Very Happy late dinner.
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67rustavenger Premium Member
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PostPosted: Sun Mar 19, 2023 6:24 pm    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Buggeee wrote:
It survived its first start and phase 1 of the break-in procedure (about 2300 rpm for 20 minutes).

It's leaking badly from the oil filter, the ancient VDO oil pressure sender and one valve cover gasket.

The oil cooler is holding!!!

I'm taking the win and getting some Very Happy late dinner.

Nice work. The engine sounds solid.

You have weird pit stop times. They seem to revolve around meal times. Wink

My hat is off to ya. The car looks fantastic and the engine runs very well for a fresh startup.

Congratulation's are in order! Thumbs Up
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vamram Premium Member
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PostPosted: Tue Mar 21, 2023 5:13 am    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Buggeee wrote:
Humming along at about 2300 rpm


Congratulations Sir! Sounds great!
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Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
Click to view image
Save the Supers!!
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Buggeee
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PostPosted: Wed Mar 22, 2023 8:56 am    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Well it turns out that my ancient VDO oil pressure sending unit was not leaking, which is a shame because I threw it away thinking that it was. It turns out that all of my oil galley plugs began leaking once the engine had gotten hot and run for a while. I don't know if it's because I didn't tighten the brass plugs enough for fear of stripping the magnesium case or whether it's because I used the wrong sealant, (I used Curil-T).

Either way the solution was the same I had to pull the engine, strip the front and back of it to get access to all the plugs behind the pulley and flywheel. I replaced them with aluminum plugs, and used Teflon paste for the sealant, because it's rated for temperatures and pressures far in excess of what this engine will see. I got it all back together the same evening. It runs like a top and doesn't leak a drop. Also I confirmed the thermostat is working so that's cool. Here's some pictures and videos.

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At idle


Link


At speed


Link


Thermostat open when hot


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cjsuner
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PostPosted: Wed Mar 22, 2023 9:22 am    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Great to see and hear Buggee! Hopefully I can get mine to sound as smooth as yours!
Also totally jealous of the massive clean work area you have haha
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Buggeee
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PostPosted: Thu Mar 23, 2023 9:36 am    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

With the help of a vacuum brake bleeder from Harbor Freight attached to the air compressor, the brake lines were filled with fluid and bled of air bubbles. Its a tedious process even with the vacuum pulling the fluid through the empty lines.

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The brakes are adjusted, emergency brake cables are taught, and she is itching to go outside and play. Its raining though, so I said No! Also, there are no seats. Smile We are one week away from the big indoor car show, so if my maker is willing, it looks possible!!!

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Buggeee
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PostPosted: Thu Mar 23, 2023 9:47 am    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

cjsuner wrote:
Great to see and hear Buggee!


Thank you CJ, I really appreciate the encouragement Very Happy
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Buggeee
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PostPosted: Thu Mar 23, 2023 9:48 am    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

vamram wrote:
Buggeee wrote:
Humming along at about 2300 rpm


Congratulations Sir! Sounds great!


V its really happening!
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Buggeee
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PostPosted: Fri Mar 24, 2023 7:53 pm    Post subject: Re: Buggeee's 1972 Super Beetle Reply with quote

Buggeee wrote:
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First drive (again!) Made it to the gas station and back. It's a start.


I drove my bug today! Really nice to get some windshield time in this one, even for just a few miles. It's been years!

It runs terrible once it warms up, so I'll sort that out tomorrow. I swapped carbs to a real Solex tonight on a lark and it behaves the same. Tomorrow is a new day.

It runs and drives!!!


Here is a memory of the first drive the first time:

Buggeee wrote:
First fill up...

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