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mcdonaldneal
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Joined: June 13, 2013
Posts: 2648
Location: Gullane, Scotland
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2648
Location: Gullane, Scotland
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wcfvw69 
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Joined: June 10, 2004
Posts: 13389
Location: Arizona
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 Posted: Sat Apr 06, 2019 5:14 am Post subject: Re: 1978 Kombi front end rebuild. Plans, for comment! |
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Well done Phil. It looks great.
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2648
Location: Gullane, Scotland
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2648
Location: Gullane, Scotland
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2648
Location: Gullane, Scotland
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| Posted: Mon Apr 08, 2019 2:48 am Post subject: Re: 1978 Kombi front end rebuild. Plans, for comment! |
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I finished the weekend with good progress. Brakes now installed and bled, steering column reattached to the gearbox, greased the centre pin and the beam. All good.
I have a question.
Most of the steering elements have split pins or safety washers, which makes sense- they are clearly critical components.
I have noted:
Pitman arm nut, large tab washer
Drag link, tie rods and steering damper all have castellated nuts and cotter pins
Ball joints, nyloc nuts
Have I missed anything? Specifically, should the steering coupler nuts have safety washers fitted? I ordered a pack of mixed tab washers a couple of months ago, but I can’t remember what they are supposed to be for!
Thanks in advance
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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
Samba Member
Joined: June 13, 2013
Posts: 2648
Location: Gullane, Scotland
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| Posted: Tue Apr 09, 2019 1:12 am Post subject: Re: 1978 Kombi front end rebuild. Plans, for comment! |
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I think the answer to my question above is that the steering coupler nuts were originally castellated, so should have a safety lock. I’ll put tab washers on.
When I got to the top end of the steering column, a new, spiky collar piece had appeared (at least, I don’t remember seeing it before!) I think it is a spacer to take up play around the column where it passes through the bearing. I cleaned the bearing and degreased everything and it seems to fit together and function ok!
Another question I need/want to work out: which is the inflow side of the washer valve assembly? It might not matter, but one hose will be under pressure from the washer fluid bottle, and one isn’t. I’ll look into 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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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2648
Location: Gullane, Scotland
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| Posted: Sat Apr 13, 2019 8:59 am Post subject: Re: 1978 Kombi front end rebuild. Plans, for comment! |
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I’ve not been documenting this as closely as sometimes, but I’m pleased to say that the Kombi is back together and I have been for a test drive to bed in the new brake pads! 
I can report that the ‘clunk’ in the steering has gone and the whole steering setup is much tighter (in a good way!) I set the toe-in with the curtain rod method to about 1/8” at the tyre tread (spec is between zero and 1/4”) and I notice the steering doesn’t centre quite as firmly as before, so I might increase the toe-in to the full 1/4”. I set the drag link after I had set the toe-in.
The brakes are working well, but I’ll need to give a bit of time to really comment. It’s hard to believe that they won’t be better than having one or two seized pistons!
It was a pretty major job to tackle for the first time, so I’m glad it’s more or less over. Apart from cleaning and painting, I ended up; adjusting the steering box and changing the oil, replacing the adjustable tie-rod, replacing three ball joint boots and adding grease zerks, as well as totally rebuilding the brake calipers and fitting new hoses.
Thanks very much for all the advice and comments. It really does make a tough job much easier for a relative beginner to know that help is at hand!
Here are some before and after pictures. Now I need to get ready for our next camping trip!...
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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
Samba Member
Joined: June 13, 2013
Posts: 2648
Location: Gullane, Scotland
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