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1968 Deluxe resurrection
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TDCTDI
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PostPosted: Thu Mar 30, 2017 3:09 pm    Post subject: 1968 Deluxe resurrection Reply with quote

After dragging an early Bus out from under its favorite tree where it sat for the last 25-30 years I've decided to just do the basic things to get it road worthy again, then perhaps start replacing the necessary panels as it's being enjoyed as a beater.

Here's the crusty pig as found.
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Unfortunately, the gentleman's grandson enjoyed chucking rocks at it.

Swapping some tires onto it to get it rolling again.
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Dragging it out.
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& dragging it to its new home.
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TDCTDI
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PostPosted: Thu Mar 30, 2017 3:26 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

One of the first projects was to replace the windshield gasket, so I pulled it out & carefully saved the original trim.
Here's the new gasket.
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After pulling the windshield I found the expected rust in the frame but I just cleaned up what I could, treated it with Extend & painted over that.
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Then I transferred the original trim into the new gasket & reinstalled the windshield.
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TDCTDI
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PostPosted: Fri Mar 31, 2017 7:01 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

The next thing that I dealt with is replacing the drivers door glass, what a PITA! I really wish that I had known that the window regulator, scrapers & vent window gaskets all had to be removed just to get the glass in the door, I would have sourced them before tearing it all apart. While still not water tight, it's a start towards keeping the birds & cats out.

Anyone want a vintage bird's nest?
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I wish I could get potato chips as crunchy as that headliner is.
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TDCTDI
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PostPosted: Fri Mar 31, 2017 4:32 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

So then I pulled the engine out.
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So the could get to the fuel tank.

Great news, gas tank still holds fuel. Bad news, it still has fuel in it.
OOH & look, correct acorn nutted '68 only transmission.
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Out with the tank.
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Aside from being dirty as hell, it's not too bad.
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Neither is the inside of the tank.
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Last edited by TDCTDI on Sun Apr 02, 2017 7:03 am; edited 1 time in total
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notchboy
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PostPosted: Fri Mar 31, 2017 4:40 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I can smell that old gas from here....um sorry I mean turpentine! Nice find brother. Keep us posted. Cool
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otiswesty
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PostPosted: Fri Mar 31, 2017 4:46 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

That tank is pretty much spic and span, obviously ethanol free gas. Smile
Nice find
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TDCTDI
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PostPosted: Sat Apr 01, 2017 12:19 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Thanks notchboy & otiswesty. Yes it was pretty rank, I drained it out, flushed it with water to ensure that the tank didn't leak a the seams, dumped that, gave it a good cleaning with some Draino, flushed that, cleaned it again with some muriatic acid, flushed it a few more times with water & hooked up the shop vac to dry it out.
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Then gave it a couple treatments with Ospho. After that dried, I sloshed some ATF in it.

After the insides were treated, I purtied it up.
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PostPosted: Sun Apr 02, 2017 5:00 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I spent some time cutting the old engine seal & removing it.
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And then sliding the new ones in place.
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Then cleaned the engine bay a bit.
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Then finally wrestled the tank back in place.
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PostPosted: Sun Apr 02, 2017 12:07 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Great find! interested to know more about this 68' only trans.. whats different about it? and how do you know its a 1 year only deal other than the acorn nuts
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TDCTDI
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PostPosted: Sun Apr 02, 2017 12:21 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

cdennisg shared this with me:
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
Apparently the ratios and possibly the final drive are different & very well matched for the low power of the original single port engine. I've also read that the gears are different & not as strong as the later transmissions.
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TDCTDI
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PostPosted: Sun Apr 02, 2017 4:06 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Several of the one year only parts that I have already noticed/encountered are:
Transmission
Rear view mirror (but this might also be for '69)
Parking brake cables
Rear brake drums/backing plates
Door handles
Center bench seat
Paint color
Black upholstery
Brake master cylinder
Lack of firewall between engine/fuel tank
Sliding door hardware
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Dana Champion
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PostPosted: Sun Apr 02, 2017 5:26 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Loving the Arizona Yellow ! Looks like a nice score ! My older brother bought one in '74. It had been repainted inside and out burnt orange and yellow. Finding one someday would be cool.

Peace, Dana
Very Happy
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stryker1
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PostPosted: Sun Apr 02, 2017 6:10 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I have the same bus as this one. Mine is a built date of feb 15 1968. Arizona yellow also but only og color left is inside and engine bay. Needs to be painted, in primer now but running. Will be following your thread. Looking good
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TDCTDI
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PostPosted: Mon Apr 03, 2017 6:47 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Thanks Dana, you stand a better chance to find one (and a better one) in your neck of the woods, good luck!

stryker1, I'm kinda flattered that your first post is here, thanks! You should start a thread, I'm sure that we'd all love to see your Bus, I know I would.

The steering had 1/4 turn of play at the steering wheel before there was any movement at the wheels, I inspected everything & found that 95% of the slop was at the center tie rod/front tierod/drag link (depending on who you talk to.).
I replaced that & the steering only has about 1/2" of play now.
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PostPosted: Tue Apr 04, 2017 6:10 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I had my buddy dismount the old tires so I could send the wheels to be sand blasted.
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PostPosted: Wed Apr 05, 2017 7:41 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I got the wheels back.
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They were literally SAND blasted (silicosis anyone?).
Found a few bent lips & coerced them out with a drift & a BFH
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Then I slathered them down with some Ospho.
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PostPosted: Wed Apr 05, 2017 3:22 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

While the engine is out, the axles are much easier to access & can be removed without dropping the dirt & grime on yourself, so I took advantage of this & removed them to rebuild the CVs & put new boots on.

I started by digging the caked on grime out of the bolts.
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With the axle out, suddenly the brake hose is much easier to get at also.
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After removing the axle, I discovered something that I've never seen in all the years that I've been working on these.
My CV joints have hubcaps.
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After removing the cap, I removed the CV & then marked the inner race, the cage, and the outer race.
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Then cleaned & reassembled the CV.
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Then reinstalled it on the axle with a new boot & grease.
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PostPosted: Thu Apr 06, 2017 2:19 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Spent a little more time with the crusty pig today, I replaced the drivers side rear brake hose before installing the rebuilt axle.

After breaking the brake hose looseI noticed that the flare nut was seized to the line so I cut the hose, removed it & heated up the flare nut & worked it loose.
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Then I used one flare wrench to hold the t-union while I loosened the other end of the hose.
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Then installed the new hose & axle. Due to the wear in the CV races, I made sure to flip the axle so that the CVs would have new surfaces to ride on.
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PostPosted: Thu Apr 06, 2017 2:42 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I like your style... Start deep in, get the mechanicals going, and do good work as you go. But oh, my, you have a lot more work ahead of you...

But once you commit, you've just got to go for it with full confidence that at the end of it, you will have a real running bus. Nice!

BTW, where did you get the window seal that accepts the trim? I have a '73 Wild Westerner that needs all new seals. And all new trim, too, though the clips that join the trim are in good shape and I think I can get replacement trim.
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TDCTDI
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PostPosted: Thu Apr 06, 2017 3:00 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Thanks jtauxe.

I've learned that if I can at least drive it, I can do little bits at a time without being overwhelmed with a complete tear down. Eating that elephant one bite at a time. I don't care if it's ugly but I'm not going to sacrifice safety & dependability.

I got the windshield gasket from Rock Auto for $23 but it was the only option for gaskets they had. Wolfsburg West has all the gaskets with or without the grooves & has the trim too.
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