Great Grandpa’s 1964 Sunroof Bug Full Stock Restoration

[Adriel Rowley]

[tcoop1100]

Yes, you've had the short stud kit installed- try adjusting to .006" intake and .008" exhaust, see how it runs and how it sounds while driving.
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Aloha,
Tim
January '57 Sedan with April '64 40hp big bore

[mukluk]

When long stud heads are repaired/converted using short stud inserts, both the intake and exhaust lash should be set to .004" or the later .006" specification.
https://www.thesamba.com/vw/archives/manuals/practicalwork_engine/39.jpg
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1960 Ragtop w/Semaphores "Inga"

[tcoop1100]

I wasn't aware of that. Good to know, thanks.
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Aloha,
Tim
January '57 Sedan with April '64 40hp big bore

[matthew henricks]

Thank you Guy's. I will check my heads tomorrow and try to re-set the gaps. I am plan to pull the fan belt to eliminate that too.



Today was some more fun crossing things off the list. First up was the horn. It no worky...

Traced all wires for continuity. I then figured out that 64 does NOT use the steering coupling ground cable. Dooh! Pulled that off but still no joy.

https://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=111971246


- Pulled the horn and tested it on the bench. Works.
- Checked voltage to the horn going direct to ground. 6V.
- Checked voltage at the horn through the horn circuit. 1V. OK...
- Re-seated and added DI-electric grease to all connections. Still 1V.

Started checking voltage back from the horn and found my steering column wire is not solid. The clip to the actual column is loose. How the heck do you fix that?

Sunroof. It is not smooth and hard to close. Going to snap the crank.

- Headliner panel. Padding too thick & 3M adhesive failed. Need to re-do
- Not enough grease on the cables. Added more.
- Crank end point not right. Going too far. Fixed that.
- Headliner material @ opening loose. (Again lousy adhesive) fixed that.

Much Better but no headliner panel in right now. I need to see if TMI sells that by itself as i really need to totally re-do it.

I then installed the seals for the sunroof. Was being cheap and used some rubber cement. Big mistake. 30 minutes later it was all removed and this time automotive seal adhesive. A bit of a job but pleased. This is for sure a measure twice, glue once thing.

(Note the ultra hard to find black hole caps. I did seat it all the way after image taken )

Tow hitch wiring. Pulled apart the old one and cleaned it up. Cleaned all the oil & tape mess on the cable. Not sure if i want to use the repro Hella unit or the original unit. Original is beefy. Hella is cheesy. i also am still working out the wire routing plan.

That is it for 2022. We will for sure finish the bug in 2023.

See ya next year.
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1964 Original Owner build Thread. https://www.thesamba.com/vw/forum/viewtopic.php?t=702135&highlight=

Ambulance Fan's. https://www.thesamba.com/vw/forum/viewtopic.php?t=627707&highlight=

Parts i am looking for:
64 bug nice used front/rear Black LHD floor mat.

[Adriel Rowley]

[matthew henricks]

23 items left on the list to finish the bug. 5 of them are critical to driving and conducting shake down drives. The rest are cosmetic/detail.

Tested the engine today by removing the fan belt. Knock still there.

Tomorrow i hope to re-adjust the valves to test that too but this knock is separate from the normal ticking of the rockers which i can also hear. Will report.

Adjusted the brakes again as they are dragging. Should disc brakes (front) drag on the rotor? I need to learn a little there as there is nothing that opens the rotor when you release the brakes. They have alot of drag. Maybe i just needs some miles on them. Hmmm...

Pulled out my parcel tray and cleaned it up. This was a find probably 30 years ago. Literally a sign on the window at 7-11. This and a roof rack for $25.

Found my bottom trunk liner. Could not figure out where it was and did not think i tossed it. Anyone know what the purpose of this was? It is 1/8" tar board that sits under the trunk liner. Don't see it in the WW catalog. I may have to re-make it as t is getting long in the tooth.

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1964 Original Owner build Thread. https://www.thesamba.com/vw/forum/viewtopic.php?t=702135&highlight=

Ambulance Fan's. https://www.thesamba.com/vw/forum/viewtopic.php?t=627707&highlight=

Parts i am looking for:
64 bug nice used front/rear Black LHD floor mat.

[mukluk]

[matthew henricks]

Thank you Mukluk for that info. Fixing that tab is going to be a joy unless i pull the steering column out. Maybe if i pull the gas tank. We will see.


An update on the engine knock.

I have short stunds in the heads.
Adjusted the valves to .004". No change.
From cold up to warm. No change.
High RPM of idle. Noise increases pace so no change.

Got out my wood dowel again.

I think it is coming from the drivers side and in the cylinders/heads. I can't get the dowel anywhere to positively detect it but as i moved from side to side it is more apparent on the drivers side. I can get a dowel on the case in many places and i do not pick up the sound.

Was thinking exhaust for a second but nope.

Hmmm....
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1964 Original Owner build Thread. https://www.thesamba.com/vw/forum/viewtopic.php?t=702135&highlight=

Ambulance Fan's. https://www.thesamba.com/vw/forum/viewtopic.php?t=627707&highlight=

Parts i am looking for:
64 bug nice used front/rear Black LHD floor mat.

[matthew henricks]

Spend some time yesterday chasing the horn issues. Pulled the gas tank to look at the steering column wire attachment. Not as bad as i though but i think i am going to solder it to make sure. May have to pull the column to do that right.

Sat back to think about what else would cause resistance or intermittent contact. I have checked every wire and loose voltage at the steering column.
Good everywhere else. What is left is the bearing at the steering wheel. I did not clean that or pull it. Lets get after it.

Ever wonder what the steering lock engagement looks line in the steering column?

This electrical path is glossed over in most of the horn diagnostics i read.
The ground path from the steering wheel side of the horn goes through the turn cancelation ring, then to the copper disc on the column, through the compression spring and into the bearing. From the bearing to to column and then down to the wire that goes to the horn.

Passing electricality through a bearing is not generally a good idea but here we are. Lets take it apart and grease it with Di-electric grease. It was pretty dirty but smooth. Now it is clean and smooth.

Put it all back together and no change. Man....


I think my problem is the lousy fit between the bearing and the steering column. I have 1/16" movement meaning a 1/32 gap on all sides. The bearing shows wear on the ID surface. OK... New bearing then. Maybe not.

I was reading about this in a few troubleshooting threads but no solution other than replacing the bearing. Read a number of threads about fitment issues with the new bearings.

I think i am going to wrap some copper sheet around the column to build up the gap. Will see how that works out.
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1964 Original Owner build Thread. https://www.thesamba.com/vw/forum/viewtopic.php?t=702135&highlight=

Ambulance Fan's. https://www.thesamba.com/vw/forum/viewtopic.php?t=627707&highlight=

Parts i am looking for:
64 bug nice used front/rear Black LHD floor mat.

[Adriel Rowley]

Did some research of my own, didn't find what I was looking for, though did find a thread simply titled "Horn." To see if it applies, read through and on page three Split Junkie suggests adjusting the contacts, which one has reported solving a non working horn: https://www.thesamba.com/vw/forum/viewtopic.php?t=...9d2c1377d8.

The other thing I be checking is the resistance between each stage, those that can be reached.

Hope this helps.
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Please consider I am Autistic, so I process information differently and still working on social skills. Thanks.

Dad's 1964 Beetle purchased September 1968.
https://www.thesamba.com/vw/forum/viewtopic.php?p=9252810#9252810

1971 Sunroof Squareback with Fuel Injection
http://www.thesamba.com/vw/forum/viewtopic.php?t=219811&highlight=squareback+rejuvenation

[pastellgreen]

This. I doubt it is the bearing that causes trouble.

[matthew henricks]

Thank you Adrial & Pastellgreen.

I was actually reading that thread on Sunday and heading towards the relay idea when the bearing came to mind.

For sure it is not the contacts (at the steering wheel) as they are not even installed at this point. I am simply shorting the brown wire to the horn ring on the wheel with alligator clips.

Systematically speaking I have checked everything.
- Horn works on the bench with 6V
- 6V power at horn Black/yellow wire when connected direct to ground.
- Shorting horn wires (bypassing the horn) 6V at column base.
- 6V at top of column
- Intermittent 6v at steering wheel based on manipulation.
- Continuity to ground for the brown wire to the base of the steering box.

Maybe with the wheel on the column and under normal conditions the weight of your arms keeps that grounded and that is why it is not a normal trouble spot?

I am fine with the relay but want to understand this too.

in that thread and the only place i can positively effect either continuity or voltage is at the bearing based on how i manipulate the steering shaft in the bearing.
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1964 Original Owner build Thread. https://www.thesamba.com/vw/forum/viewtopic.php?t=702135&highlight=

Ambulance Fan's. https://www.thesamba.com/vw/forum/viewtopic.php?t=627707&highlight=

Parts i am looking for:
64 bug nice used front/rear Black LHD floor mat.

[pastellgreen]

The shaft should not have play to the inner bearing shell. There is a open conical bush that is pushed between the steering shaft and the bearing by the strong spring (part 50). This bush installed should avoid any play and should create a proper electrical connection.

[Adriel Rowley]

[Sash_Bay]

I believe this was the interior you were looking for


http://www.classicvws.com/interiors/material.php
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69 Hightop Baywindow
73 Lowered Baywindow
63 Bug

Owned:
68,69,70,& 71
65 Standard Split
67 Bug
66 Fastback
68 Ghia

[Sash_Bay]

and this the tar boards??

https://www.classicvwbugs.com/classic-vintage-vw-v...ar-boards/
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69 Hightop Baywindow
73 Lowered Baywindow
63 Bug

Owned:
68,69,70,& 71
65 Standard Split
67 Bug
66 Fastback
68 Ghia

[Käfer2]

[matthew henricks]

[tcoop1100]

Matthew-
I've had good luck with Weldwood contact cement to reattach loose edges, etc. It's messy (stringy) and finicky (no do-overs, once it's stuck, it's stuck) but it works better than anything else I've tried.
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Aloha,
Tim
January '57 Sedan with April '64 40hp big bore