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mcdonaldneal
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Joined: June 13, 2013
Posts: 2731
Location: Gullane, Scotland
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 Posted: Wed Mar 07, 2018 1:41 pm Post subject: US style towel rail bumper installation *pic heavy! |
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I'm embarrassed to say it has been two years since I took the bumpers off our late '69 Ghia. They've been blasted and painted and reinstalled incomplete, but I am now ready to put them together.
Or at least I would be if I hadn't just bought a zinc plating kit and I've decided to zinc plate the bolts before the final installation.
Anyway,
I've found assembling and installing the bumpers a little bit tricky, but it's mainly a case of working out the best order to do everything in. So, I thought I would do a pictorial 'how to' to help anyone else who is as visuo-spatially challenged as I am!
I've only done the front bumper at the moment, I will add the rear to this thread when I get around to it. I hope it helps someone!
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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper
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mcdonaldneal
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Joined: June 13, 2013
Posts: 2731
Location: Gullane, Scotland
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| Posted: Wed Mar 07, 2018 1:43 pm Post subject: Re: US style towel rail bumper installation *pic heavy! |
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First, gather the parts together.
This is pasted from another thread, but is a good guide to remind you of the bolt sizes etc:
| sputnick60 wrote: |
This next image is from the parts book and you can see how the various bolts, washers, nuts and rubbers go together.
List of Parts (its a bit wobbly because I don't know how to do tables in html)
PParttype…….DWG N..……..QTY……..……..……..vw part……..……..……..description
dome bolt..…….5……..……..……..4……..……..……..113 707 191 C……..……..……..screw bumper
washer…….…….6……..……..……..4……..……..……..N 12 228 2……..……..……..spring washer B 8
nut……..…………7……..……..……..4……..……..……..N 11 0008 8……..……..……..nut hex M 8
bolt……..……….10……..……..……..2……..……..……..N 10 240 4……..……..……..bolt hex head M 8 x 20
washer………….11……..……..……..2……..……..……..N 12 228 2……..……..……..spring washer B 8
screw…………….18……..……..……..4……..……..……..N 14 131 2……..……..……..screw fillister head AM 5 x 15
washer...……...19……..……..……..4……..……..……..N 12 225 1……..……..……..spring washer B 5
washer….……….22……..……..……..2……..……..……..N 12 228 2……..……..……..spring washer B 8
bolt……..………..23……..……..……..2……..……..……..N 10 370 1……..……..……..bolt hex head M 8 x 70
packing bow...27……..……..……..2……..……..……..141 707 181……..……..……..Packing Bow Front bumper guard
washer……..…..28……..……..……..2……..……..……..151 871 187……..……..……..washer 10.2 x 20 x 4
washer……..…..29……..……..……..2……..……..……..N 12 228 2……..……..……..spring washer B 8
bolt……..………..30……..……..……..2……..……..……..N 10 239 2……..……..……..bolt hex head M 8 x 18
bolt……..………..43……..……..……..2……..……..……..111 899 145 ……..……..……..bolt hex head M 8 x 27
washer………..…44……..……..……..2……..……..……..N 12 228 2……..……..……..spring washer B 8
washer……….…44……..……..……..2……..……..……..N 12 228 2……..……..……..spring washer B 8
bolt……..……….45……..……..……..2……..……..……..N 10 352 2……..……..……..bolt, hex head BM 8 x 55
rubber………..…52……..……..……..2……..……..……..141 707 253……..……..……..Rubber cushion outer front
rubber………..…53……..……..……..2……..……..……..141 707 255……..……..……..Rubber cushion inner front
washer………….54……..……..……..2……..……..……..131 821 150……..……..……..spring washer 8.1 x 22
bolt……..……....55……..……..……..2……..……..……..N 10 360 2……..……..……..bolt, hex head BM 8 x 60
Bolt……..……...56……..……..……..4……..……..……..111 899 145 ……..……..……..bolt hex head M 8 x 27
washer……….…57……..……..……..4……..……..……..N 12 228 2……..……..……..spring washer B 8
dome bolt…….62……..……..……..4……..……..……..113 707 191 C……..……..……..screw bumper
washer.……….63……..……..……..4……..……..……..N 12 228 2……..……..……..spring washer B 8
nut……..……....64……..……..……..4……..……..……..N 11 0008 8……..……..……..nut hex M 8
bolt……..….…..67……..……..……..4……..……..……..N 10 240 4……..……..……..bolt hex head M 8 x 20
washer…….…..68……..……..……..4……..……..……..N 12 228 2……..……..……..spring washer B 8
screw……..…...81……..……..……..4……..……..……..N 14 131 2……..……..……..screw fillister head AM 5 x 15
rubber……….…82……..……..……..2……..……..……..141 707 251 A……..……..……..Rubber seal bumper bracket cover
rubber………….83……..……..……..2……..……..……..141 707 353……..……..……..Rubber cushion bumper bracket rear
washer……….…84……..……..……..2……..……..……..131 821 150……..……..……..spring washer 8.1 x 22
bolt……..……...85……..……..……..2……..……..……..N 10 269 1……..……..……..bolt hex head M 8 x 38
Good Luck
Nicholas |
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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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mcdonaldneal
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Location: Gullane, Scotland
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mcdonaldneal
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Location: Gullane, Scotland
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2731
Location: Gullane, Scotland
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| Posted: Wed Mar 07, 2018 2:03 pm Post subject: Re: US style towel rail bumper installation *pic heavy! |
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If you are lucky, your overriders will be stamped to tell you which goes where. This one is stamped VR for Vor Rechts (Front Right) The others are VL, HL and HR, work it out!
As your bolts are loose, you can now slide the other overrider into position. First onto the towel rail, then onto the bumper blade. I should have mentioned to make sure that the rubber edging strips are in place.
You should now be able to slip the painted bracket/cover assembly onto the towel rail, and rotate it down into place and bolt it on to the blade.
Then secure the painted support to the overrider (loosely again).
_________________
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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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2731
Location: Gullane, Scotland
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| Posted: Wed Mar 07, 2018 2:14 pm Post subject: Re: US style towel rail bumper installation *pic heavy! |
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The outer parts of the towel rails can now be secured. They also have a rubber/plastic grommet protector.
I've mocked up the very outer securing bolt that goes through the bodywork (with its cut rubber sleeve) although obviously this is inserted when the bumper is attached to the car!
Again, the bolts and washers which secure the painted support to the overrider were originally painted body colour. I intend to install the bumper with the bolts all slightly loose, tighten them up, remove the bumper again and THEN paint the bolts, so that the paint is not marred by the spanner/socket.
The final result! As I say, I've taken it all apart again, so that I can zinc plate the bolts, but I'll document the rear bumper in the same way, when I get around to it.
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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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smuenchrath
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Joined: February 20, 2005
Posts: 376
Location: Calgary, Alberta
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| Posted: Wed Mar 07, 2018 3:08 pm Post subject: Re: US style towel rail bumper installation *pic heavy! |
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This is a great step-by-step instruction! Thanks very much for putting this together.
I hope this gets added to the stickies...
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68 Ghia Regatta Blue Convertible
69 Ghia Toga White Coupe
74 Westfalia |
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sputnick60
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mcdonaldneal
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NOVA Airhead
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Location: Richmond, VA
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| Posted: Thu Mar 08, 2018 7:16 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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Should be added to the Stickies!
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paul_round
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Joined: October 17, 2014
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Location: UK
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| Posted: Thu Mar 08, 2018 9:15 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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| This is great! Unfortunately it makes me realise how many parts I’m missing! |
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cal34
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Joined: May 24, 2015
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| Posted: Thu Mar 08, 2018 11:09 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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| Really great detail. Where did that parts list and image come from? |
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VeloMikey
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| Posted: Thu Mar 08, 2018 11:21 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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Great post! Who did your plating? A company across the pond or did you ship them to the states? Everything looks great!
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'58 Ghia 2387cc with a Berg / Folts 5 Speed
Ghia Build Thread https://www.thesamba.com/vw/forum/viewtopic.php?t=768748 |
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mcdonaldneal
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mcdonaldneal
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mcdonaldneal
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mcdonaldneal
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mcdonaldneal
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mcdonaldneal
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Joined: June 13, 2013
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Location: Gullane, Scotland
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| Posted: Fri Mar 09, 2018 9:10 am Post subject: Re: US style towel rail bumper installation *pic heavy! |
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The black bumper support brackets bolt on simply, with 15 or 16mm bolts.
Then, there's a fiddly process of attaching the painted covers with a cross head screw. A short screwdriver and a long temper are useful if your screw threads aren't nice and clean! I ended up running a tap and die, which helped.
The painted cover has a bump next to the screw, which seats in a slot in the black support. They should also have a rubber edging strip/seal to protect the car body. The final adjustment will be on the car.
_________________
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!
Last edited by mcdonaldneal on Fri Mar 09, 2018 9:18 am; edited 1 time in total |
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mcdonaldneal
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