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1968 Deluxe resurrection
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TDCTDI
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PostPosted: Sun Jul 09, 2017 3:27 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

As promised, the Crusty Pig gets its motivation back.
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TDCTDI
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PostPosted: Wed Jul 12, 2017 7:02 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I spent some more time with the Crusty Pig, I cleaned the rodent's nest & lots of silt out of the air cleaner & replaced the filter.
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Then I bent up a new fuel line & installed new fuel hoses & filter.
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TDCTDI
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PostPosted: Thu Jul 13, 2017 2:37 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Today, the Crusty Pig gets treated to a lift kit! No, not really, but I replaced the whipped Sachs...
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With a set of Bilstein shocks...
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And true to form, the Bilsteins pushed the bus up about an inch.
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PostPosted: Thu Jul 13, 2017 3:34 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Nice, I bet that makes a big difference.
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PostPosted: Sat Jul 15, 2017 2:14 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Now the Crusty Pig gets new shocks in the rear. I had a pair of 7100 series bilsteins that were the correct length.
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They just needed the correct sleeves for the shock bushings so I extracted the sleeves from the original shocks.
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Here's the height before.
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And after.
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PostPosted: Sun Jul 16, 2017 9:25 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

In my travels yesterday, I found another 1968 bus in a salvage yard. Knowing that I had some issues with the steering column in the Crusty Pig, I scored the one from the junk yard.
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Where I thought my problem was with the lock housing, I do have the correct 68 only housing.
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I was excited about getting a steering lock thinking that someone had removed the one in the Crusty Pig only to realize that it apparently was an option. The replacement lock housing didn't have the lock pin either.
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Nor does it appear to have been tampered with.
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And the steering shaft doesn't have provisions for a lock pin.
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Here's where the misalignment issues came from.
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Someone had replaced the column & shaft but tried to use the 68 lock housing.

So I cleaned up the rusty splines & threads.
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And blasted and painted the column. I need to blast & paint the lock housing & other parts before reassembling.
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PostPosted: Tue Jul 18, 2017 7:34 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I installed the steering shaft & the column tube after sand blasting & painting them, boy do they look out of place.
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PostPosted: Wed Jul 19, 2017 2:33 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Aside from finding a replacement column for the Crusty Pig, the reason that I pulled the column back out is that I was having issues with the ignition switch. When I turned the key to the "start" position, I lost power to the ignition. After tracing everything out, I found that the Chinese ignition switch was the issue & upon disassembly, I determined that it was designed incorrectly.

Here's the contact plate in the switch.
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That little dimple at 12:00 is what makes contact with the ignition circuit, once it sweeps past, it no longer sends power to the ignition.

So I found a thin washer to place under it, clamped them to a piece of steel & lengthened the dimple with a pair of pliers.
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Now, with the key in, not turned, it's an open circuit.
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With the key in run/on position, the circuit is closed.
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And, with the key in start position, the circuit is closed.
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YAY, it works now!
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PostPosted: Wed Jul 19, 2017 5:18 pm    Post subject: Ignition switch no power to coil during cranking Reply with quote

Just an FYI. If anyone runs across one of these switches.

Take a look at your starter solenoid. The Original solenoid came with one push on terminal on one side of the solenoid that is labeled #50 (s) for the Red/black wire that runs to the ignition switch.
See if your solenoid has push on terminals on both sides. If it does. Run a wire from the other side push on terminal to the ignition coil +positive #15.
Usually this terminal only receives power during cranking.
Due to the large voltage drop the starter creates. On later models with the introduction of electronic ignition. Engineers designed the ignition switch to cut out the cars accessories and give the coil full power during cranking through the starter solenoid.
Good luck
Tcash
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PostPosted: Fri Jul 21, 2017 2:58 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Sometimes stuff just doesn't want to play nicely, after sand blasting the ignition lock housing & a quick wipe down with acetone, I painted it only to realize that something had permeated the cast aluminum & caused the paint to fisheye.
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Oh well, time to blast it again & hose it down with brake clean & a good scrub with acetone again, with much better results this time. However, while trying to assemble it, it got scratched, screw it, I'm not starting over again.
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Then I realized that almost all of the wire connectors for the turn signal switch were either missing or broken.
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All of you connector snobs are going to have to look away now, because I'm not waiting for another few days for the correct brass connectors.
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But I removed the blue sleeves just to you.
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PostPosted: Fri Jul 21, 2017 5:48 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

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Non, correct brass open barrel connectors huh?

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Laughing
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PostPosted: Fri Jul 21, 2017 5:50 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

WOOHOOO! The Crusty pig LIVES!

Link


After half ass wiring up the ignition, putting some fuel in the tank & cranking a couple dozen times, figuring out that the coil was shot, replacing it, cranking a few more times, it finally fired up. After running for a few minutes & adjusting the fuel mixture, I found that I'll be removing the engine again, I don't think that there was a sparkler option on the generator, it's pretty cool looking though.

Sometimes you can easily figure out what the point of failure was that mothballed a vehicle to be forgotten by the previous owners, there was SO much wrong with this Bus, I cant figure out what single event caused it to be cast aside. Could it have been the brakes? Perhaps the generator or coil? Maybe it the lack of compression due to the never adjusted valves, or even the 1/4 turn of the steering wheel before the wheels got the message? Possibly it was the missing carburetor that was removed with the hopes of rebuilding & forever lost. The list goes on & on and I'm sure that I'll find more as I make more progress in making it road worthy.
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PostPosted: Sat Jul 22, 2017 4:16 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

On the same hunt that I tripped across the '68 parts Bus, I found a grille guard for a 1940s Mack, it was so cool I had to have it. Unfortunately, my wife didn't share my vision about repurposing it as a headboard for the bedroom. Then I thought about seeing if the could mount it to the Crusty Pig, in all honesty, it doesn't look too bad.
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It might need some modifications & adjustments but it kinda works.
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However, due the weight, I might just recreate it out of 1/4" stock vs the 3/8" stock that it's made of, that way I don't have to ruin this particular piece.
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PostPosted: Fri Jul 28, 2017 2:44 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

I finally got the steering column all reassembled & adjusted, the turn signal switch cancels as it should & it looks much better if I do say so myself.
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So I decided to try to wipe down the dash a bit so the new column didn't look so out of place.
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It's better... ish
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PostPosted: Sun Jul 30, 2017 7:59 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Today I finally went back & replaced the parking brake cable that was the incorrect part for my one year only bus.
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I sourced the correct one from WolfsburgWest.
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& installed it.
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Parking brake works now.
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PostPosted: Wed Aug 02, 2017 4:47 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Well... after having to rebuild the trigger group on my welder, I finally got back to repairing the sill on the rear window of the Crusty Pig.
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I sure wish that the trigger on my spot welder would cooperate as nicely
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PostPosted: Thu Aug 03, 2017 8:15 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

Nice work, dude! She's gonna be a squealin' hog when you're done!
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PostPosted: Fri Aug 04, 2017 12:31 am    Post subject: Re: 1968 Deluxe resurrection Reply with quote

You're making great progress here! I had the same issue with parking brake cables. Apparently the switch to the shorter ones was made in March 68.

Keep up the good work!
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PostPosted: Fri Aug 04, 2017 4:02 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

secretsubmariner wrote:
Nice work, dude! She's gonna be a squealin' hog when you're done!


Thank you sir! Since I'm keeping the single port 1600 I don't know about "squealing hog", more like screaming guinea pig.

metz wrote:
You're making great progress here! I had the same issue with parking brake cables. Apparently the switch to the shorter ones was made in March 68.

Keep up the good work!

And thank you to you too.

Here's today's Crusty Pig update, I need to get some more flappy sanding wheels so I just tried to strip some more paint.
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If you look at the repair on the window sill, you can see how quick bare metal flash rusts here from the humidity.
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PostPosted: Fri Aug 04, 2017 5:51 pm    Post subject: Re: 1968 Deluxe resurrection Reply with quote

TDCTDI wrote:
If you look at the repair on the window sill, you can see how quick bare metal flash rusts here from the humidity.

What fun!, take comfort in knowing that Rust mort removes flash rust and leaves a better paintable surface that if you got to it when it was shiny, procrastination pays off sometimes Wink

Keep it up, I love this thread!
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