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Flap over voltage regulator
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The Beatles beetle
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PostPosted: Thu Dec 27, 2018 8:21 am    Post subject: Flap over voltage regulator Reply with quote

I was looking through the 1971 beetle ownerís manual and I saw a flap hanging over the voltage regulator under the rear seat. It looks like itís made out of paper and that there might be more under the rear seat.

See image: https://www.thesamba.com/vw/archives/manuals/71bug/page51.jpg

Is there any more paper in there or is that the only place where it has it?
If anyone can make the dimensions for it, I would appreciate it.
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Maddel
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PostPosted: Thu Dec 27, 2018 8:46 am    Post subject: Re: Flap over voltage regulator Reply with quote

The original cardboard tends to sort of scorch...
I used heat-resistant thin resin material (like a conductor plate) instead.

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.
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The Beatles beetle
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PostPosted: Thu Dec 27, 2018 9:08 am    Post subject: Re: Flap over voltage regulator Reply with quote

Maddel wrote:
The original cardboard tends to sort of scorch...
I used heat-resistant thin resin material (like a conductor plate) instead.

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Do you have the dimensions for it?
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Maddel
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PostPosted: Thu Dec 27, 2018 10:59 pm    Post subject: Re: Flap over voltage regulator Reply with quote

Will work on the bug today and take the measurements for you.
May be I'll be able to locate the original cardboard one too for the dimensions.
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glutamodo Premium Member
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PostPosted: Fri Dec 28, 2018 4:36 am    Post subject: Re: Flap over voltage regulator Reply with quote

Modern (and better) solid state Bosch regulators are even more important to keep protected - as the entire top "cover" of that style regulator is actually D+... the raw generator output, so basically, it's live when the engine is running, something you definitely don't want some stray metal object to slither down there and come in contact with.
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Maddel
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PostPosted: Fri Dec 28, 2018 1:24 pm    Post subject: Re: Flap over voltage regulator Reply with quote

Excavated the original charred cardboard cover, here are the dimensions in millimeters:

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Image may have been reduced in size. Click image to view fullscreen.
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The Beatles beetle
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PostPosted: Sat Dec 29, 2018 2:43 pm    Post subject: Re: Flap over voltage regulator Reply with quote

Maddel wrote:
Excavated the original charred cardboard cover, here are the dimensions in millimeters:

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.

Thank you so much, Maddel! Iíll make one for my bug next week
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vamram Premium Member
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PostPosted: Sat Dec 29, 2018 3:04 pm    Post subject: Re: Flap over voltage regulator Reply with quote

Maddel wrote:
The original cardboard tends to sort of scorch...
I used heat-resistant thin resin material (like a conductor plate) instead.


Where can you get that thin resin material?
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The Beatles beetle
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PostPosted: Sat Dec 29, 2018 7:47 pm    Post subject: Re: Flap over voltage regulator Reply with quote

Maddel wrote:
Excavated the original charred cardboard cover, here are the dimensions in millimeters:

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.

Sorry if I sound very exigent but can you tell me its thickness?
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Maddel
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PostPosted: Sun Dec 30, 2018 3:49 am    Post subject: Re: Flap over voltage regulator Reply with quote

vamram wrote:
Maddel wrote:
The original cardboard tends to sort of scorch...
I used heat-resistant thin resin material (like a conductor plate) instead.

Where can you get that thin resin material?

May be my description was a bit misleading... Embarassed
I used this epoxy glass cloth GFK material - but I'm in Germany.

Translation from the German vendors web shop:
Quote:
Fiberglass (glass fabric-based laminates) is a pressed material consisting of special fiberglass cloth impregnet with thermosetting epoxy resin binder. The material has good processability characteristics. Compete successfully with metals, plastics, carbon fiber. Exellent electric performance and mechanical properties.

Applications: Is ussed for manufacture of gears. transformer spacers, electrical generators, low voltage insulating washers, warm wheels, bushings, bearings, cams, seal rings, pulleys and other articles of industrial application. The material is applicatedmaiinly in transformator and motor engineering, houshold appliance engineering, switch engineering, measuring devices, machine and instrumental engineering.

I think in American English it's called glass-fiber reinforced plastic (GRP).
I'm sure there are many providers of such sheets in the States.
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allenw
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PostPosted: Sun Dec 30, 2018 5:42 am    Post subject: Re: Flap over voltage regulator Reply with quote

GRP is what we call Fiberglass in the US
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Maddel
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PostPosted: Sun Dec 30, 2018 6:34 am    Post subject: Re: Flap over voltage regulator Reply with quote

allenw wrote:
GRP is what we call Fiberglass in the US

So do we over here! Laughing


The Beatles beetle wrote:
Sorry if I sound very exigent but can you tell me its thickness?

Here you go...
- original card board: 0.7 millimeters
- alternative fiberglass sheet: 0.5 millimeters
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vamram Premium Member
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PostPosted: Sun Dec 30, 2018 7:16 am    Post subject: Re: Flap over voltage regulator Reply with quote

Maddel wrote:
vamram wrote:
Maddel wrote:
The original cardboard tends to sort of scorch...
I used heat-resistant thin resin material (like a conductor plate) instead.

Where can you get that thin resin material?

May be my description was a bit misleading... Embarassed
I used this epoxy glass cloth GFK material - but I'm in Germany.

Translation from the German vendors web shop:
Quote:
Fiberglass (glass fabric-based laminates) is a pressed material consisting of special fiberglass cloth impregnet with thermosetting epoxy resin binder. The material has good processability characteristics. Compete successfully with metals, plastics, carbon fiber. Exellent electric performance and mechanical properties.

Applications: Is ussed for manufacture of gears. transformer spacers, electrical generators, low voltage insulating washers, warm wheels, bushings, bearings, cams, seal rings, pulleys and other articles of industrial application. The material is applicatedmaiinly in transformator and motor engineering, houshold appliance engineering, switch engineering, measuring devices, machine and instrumental engineering.

I think in American English it's called glass-fiber reinforced plastic (GRP).
I'm sure there are many providers of such sheets in the States.


"Fiberglass" explained by a German engineer!! Laughing Thanks, Maddel, not laughing at you, but at the simplicity of the translated then filtered down answer.
_________________
Eventually, "we are what we pretend to be.íĒ
Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
Click to view image
Save the Supers!!
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AlmostHeavenWV_VW
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PostPosted: Mon Jul 29, 2019 7:24 pm    Post subject: Re: Flap over voltage regulator Reply with quote

I made my own VR 'flap' today:

Discovered that the 'Heavy Duty' 3-ring binders have a semi-rigid plastic resin type board in them when I was replacing a broken binder.

Then, following the the footsteps of TDCTDI, I thought "Hey that'd make a good cover flap for the VR!"

So....
Here's the plastic/resin board from inside the 'binding' of the 3 ring binder:
(It's from a 4" binder, IIRC)

Image may have been reduced in size. Click image to view fullscreen.


Take the bolt off the driver's side of the rear seat rail:
Image may have been reduced in size. Click image to view fullscreen.


Slide the resin board under the seat rail, choose your orientation/ placement of the resin board and mark it. Then, remove the board and drill a hole/slot for the seat rail bolt to pass through. I also trimmed the corner to allow the board to fit better up against the B-pillar:
Image may have been reduced in size. Click image to view fullscreen.


Slide the board into place, and re-fasten the rear seat rail bolt.

Before
Image may have been reduced in size. Click image to view fullscreen.


After
Image may have been reduced in size. Click image to view fullscreen.


Best of all, it was free! (or $5 if you need to buy a binder to cannibalize)

Happy bug'n!
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The Beatles beetle
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PostPosted: Tue Aug 06, 2019 5:13 pm    Post subject: Re: Flap over voltage regulator Reply with quote

AlmostHeavenWV_VW wrote:
I made my own VR 'flap' today:

Discovered that the 'Heavy Duty' 3-ring binders have a semi-rigid plastic resin type board in them when I was replacing a broken binder.

Then, following the the footsteps of TDCTDI, I thought "Hey that'd make a good cover flap for the VR!"

So....
Here's the plastic/resin board from inside the 'binding' of the 3 ring binder:
(It's from a 4" binder, IIRC)

Image may have been reduced in size. Click image to view fullscreen.


Take the bolt off the driver's side of the rear seat rail:
Image may have been reduced in size. Click image to view fullscreen.


Slide the resin board under the seat rail, choose your orientation/ placement of the resin board and mark it. Then, remove the board and drill a hole/slot for the seat rail bolt to pass through. I also trimmed the corner to allow the board to fit better up against the B-pillar:
Image may have been reduced in size. Click image to view fullscreen.


Slide the board into place, and re-fasten the rear seat rail bolt.

Before
Image may have been reduced in size. Click image to view fullscreen.


After
Image may have been reduced in size. Click image to view fullscreen.


Best of all, it was free! (or $5 if you need to buy a binder to cannibalize)

Happy bug'n!

Thatís actually a great idea. I made one out of an old rubber floor mat, so far no problems except itís flimsiness. Iím not running a VR because of the alternator conversion. In its place, I have a small fuse box for my accessories. Cardboard was out of the picture but I wanted to get an idea of what I could make with different materials.
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DesignBuild
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PostPosted: Fri Jun 11, 2021 3:14 pm    Post subject: Re: Flap over voltage regulator Reply with quote

If you wanted to do the GRP you just need a sheet or two of glass or tempered Masonite. Wax the surfaces very well, place a sheet of woven glass cloth on the surface and slowly and carefully saturate the cloth with catalyzed resin. Let it get tacky and apply the other piece of waxed glass or waxed Masonite and apply some weight. Let it cure.

Carefully pry the pieces apart using a bit of heat from a hair dryer. When you get it free trim as necessary. You can use pop rivets to attach it to the channel the wires go through using short pop rivets. If you heat it with the hair dryer you can put a 90 degree bend in the GRP and then fasten the GRP behind the VR. with one bent edge over the VR to protect the connections from contact with the under side of the rear seat.

You can get a kit at auto parts stores that included the resin, cloth and roving, and a tube of liquid catalyst. There is usually more than enough resin for this application. Actually there should be enough resin and materials to make an air dam if you can construct a template to form it against.
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