China Clipper's Official 1971 Super Beetle Project page!

[Chinaclipper]

Well, winter has raised it's cold head here in the Midwest, so, at least for now, auto body painting in my garage is probably on hold. My little kerosene heater isn't quite efficient enough to maintain the temps needed, and I wouldn't want the open flame around the paint spray anyway.....

What does that leave?

I DID get the bug on all four wheels, then proceeded to get her on dollies so I could move her around a bit easier.
I also made a space so I could set up my engine stand, then I'm not working on it. It looks tight, I know, but it works.

I can sand, I suppose. I can still dress up/paint the wheel wells, easy fender work (more fender work??) when it's a day I can, temperature wise, and maybe even get started with the motor. Sigh, yeah, the motor.

You know, other than moving the darn thing out of the way occasionally, I haven't even TOUCHED the thing in 3 years. That is a MAJOR question that needs to be answered: ie, what will it take to get it up and running like it should. The last time I started it was 3 years ago when I needed to get it up to it's now 3 year spot in the garage, so I have no idea what it will take. A full rebuild? Just the bottom end? TBD...

So, I got an engine stand, an engine mount bracket thingee from someone here on Samba, and hopefully I can get that started for the winter project, where a cold garage won't necessarily prohibit me from working.
Stand bye for more questions and ideas, I can only imagine.......
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China Clippers Official 1971 Super Beetle Project!
https://www.thesamba.com/vw/forum/viewtopic.php?t=728089&highlight=

[Buggeee]

I built my first engine in my basement during the winter. I had a neighbor kid help me carry it down there... and then back up the next spring ready to go. Drained it of oil first, of course.
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1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Chinaclipper]

This weekend was cold in the garage, so I only got one day in. Saturday was a wash, but the weather was a bit better Sunday. Warm enough to do a little "dressing up" on the front suspension. I draped and sprayed the ol' rattle can spray in flat black ( I use Rustoleum)
And yes there was a LOT of reconstruction/welding in that area

It took awhile to get the fenders off then back on, but there ya have it.
Wait until the next day I can get in and start up again!

I suppose I should remove that ID tag on the brakeline huh?
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China Clippers Official 1971 Super Beetle Project!
https://www.thesamba.com/vw/forum/viewtopic.php?t=728089&highlight=

[Buggeee]

It looks great. I love that stuff for a quick clean up.

Are you going to seam seal the welding scars? (not for looks, it's a clean job, but for protection from corrosion)
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1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[VW_Jimbo]

Looking awesome! Wow! What a transformation! Baby steps pay off, huh!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[Chinaclipper]

Thanks VW_Jimbo_. Always good to hear from ya.

[Chinaclipper]

I got all the sound absorb/deadening material down today. I will still need to do the doors, and I am contemplating doing the roof as well.
Anyway, here tis....

Yeah just warm enough to put the stuff in. You can see my ol' faithful kerosene heater in the background in the second picture. And yes, I do NOT use it when flammables are being used, like paint, gas, acetone, etc.

I used the heat gun to soften and make the stuff more pliable and sticky, then the tool to push it in place. It really does seem to deaden the sound; I hope it is worth the work.

I will be putting WCM's padding on top of the luggage tray and also a carpet kit, and will use the extra for some padding over the back seat on the headliner install.
Of course, the bug will have the "period correct" carpet kit all around.
_________________
China Clippers Official 1971 Super Beetle Project!
https://www.thesamba.com/vw/forum/viewtopic.php?t=728089&highlight=

[vamram]

Looking good. My 2 cents - make sure you do something about the C pillars. I cleaned out the death foam when I was salvaging my '73 Super, and I don't think I did a good job of putting in an alternative sound deadening in that area, and I get a LOT of engine noise at speed.
_________________
Eventually, "we are what we pretend to be.’”
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!!

[Buggeee]

Excellent
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1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[tzepesh]

[Chinaclipper]

Happy New year Everyone.
Just realized it's been a while since I've done anything on the bug.

Reviewing the last posts, I am going to cover the "C" pillar area-gonna have to wait until the weather warms-that stuff just doesn't fit well in 30 degree weather. Brrr....

Next big project is to get the cool "engine bracket-holder-thing-so-you-can-put-it-on-a-HF-engine-stand" drilled, welded, and mounted.

Then, I start work on the engine. (Deep breath)

No clue what I am gonna find, it is going to be a journey, me thinks.
Best wishes to all, waiting for warmer weather....
_________________
China Clippers Official 1971 Super Beetle Project!
https://www.thesamba.com/vw/forum/viewtopic.php?t=728089&highlight=

[Chinaclipper]

Today, being reasonable warm, it was time to get moving on the engine. First order of the day, find and drill the hole for the kwel new engine stand mounting thing for the "hitch pin" to hold it in.

After determining a level, I put the device in the ol' vice, started it with a punch, then started the hole with an 3/16th. No problems, went in nice and smooth, so I jumped right up to the 3/8th, the size of the hitch pin I was using. A little work with the round file, we were good. I used one of those hitch pins I found at Ace Hardware with the neat little ball on the end that kicks out with a little spring. You know the one.

Then, I slid the engine (I had it on top of an old plastic bin lid, so it was really slippery) into place, tilted, one way then the other, and the boss helped put the two straps under the engine. Not too bad, the darn thing only weights about what, 250 pounds?

Then, I used a length of chain to gather the ends of the straps together. An engine hoist put it right where I needed it. Then again, I utilized the help of my lovely wife, and got her in place. (the engine, not the wife-she was fine) Naturally I made sure wifey was completely out of the way should the engine or stand fail.

Et voila!

Then, after looking at it for awhile, I started taking it apart. Good news-Only 1 bolt, yup one bolt was rusted shut and broke, and it happed to be in the throwaway part of the muffler, so that was nice.

Took awhile to figure out how to get the doghouse off; forgot to take off the generator belt (rookie mistake) and then had to figure out a way to get the thermostat off. Which was on and in place, by the way-not sure if it's still good tho.

Got the carburetor and intake manifold off; yes the heat riser is plugged and will need clearing. Carb had only 1 bolt holding it on, the hoses to the pump looked terrible, and oh, on the left hand side of the engine, (facing front) the heater box had been stuck closed. No heat there. The PO had attempted to fix a large hole above it on the package tray using fiberglas, and a lot leaked down and fiberglas-welded that left side heater box closed. So, a few minutes with a chisel and small hammer, a little WD-40, and she operated like a champ! An easy fix with the engine out.

I'm thinking I will break it down to the top end, check out the heads, replace prn, and replace the pistons and cylinders, and have someone else do the bottom end, which could mean the crankshaft and its buddies. There is a shop in Omaha that does these things-I just don't feel real comfortable about the bottom end, splitting the case and stuff. We'll see.

And there ya have it.
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China Clippers Official 1971 Super Beetle Project!
https://www.thesamba.com/vw/forum/viewtopic.php?t=728089&highlight=

[Buggeee]

My wife helps me bleed the brakes.

The hitch pin was a great idea. The engine is such a fascinating mechanism to study.
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1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Chinaclipper]

Motor time, as they say. So it was to be today. Weather in the 20's, but the garage heater was working, so should I.
First to get all the tin off, and the heat exchangers, and hope nothing snaps or (yuck), twists off IN THE HEADS OR CASE.
Just watched a good video from Slade on "Top End Rebuild" (the first three were more about "taking it apart", so apt for me.


Link


You can watch his whole sequence-it's a good refresher if you can get thru a lot of his "extras". (Sorry Slade)

His tip for using Blaster and Vise grips on the stainless steel tin screws is definitely a good one; I highly suggest it as well. Only lost one screw- and of course, IT WAS IN THE HEAD. Since I am not sure yet if I'm gonna need new heads, I figured one way or the other, it would at least be a good skill to practice.
so:
Here's the nasty one: Argh...

So, clean and drill with a 1/8" bit to start, after you get it going with a nice punch. The SS tin screws (bolts?) are a M6x1.00, if anyone is keeping score; I think it's a 12mm length, but I could be wrong. (about 1/2'?)

Then a 5mm drill to set it up for the tap (I used a 3/16th- its 4.763mm-close enough) Then follow that with the M6x1.00 tap; about $9 at Ace Hardware.

Cleaned up the top, and there ya have it-perfect fit, ready for the SS tin screw. Slade has suggested hex bolts instead of screws- I just may do that.

After I got all the tin off, it was time to get the heat exchangers off. No problems, took it real slow, and no stripping or busted studs or pulling studs, so bonus there. I did have a few areas that need minor repair. Slade has a video for that too. He uses a combination of Bondo Self-adhesive patches and JB Weld. It's not perfect, but it works. This steel is very lightweight, and welding would probably burn thru, so, well you get it.


Link

Here's mine

And again....

I didn't have enough time or energy to attempt the heat exchange fix today, but you get the idea. Best wishes everyone.
_________________
China Clippers Official 1971 Super Beetle Project!
https://www.thesamba.com/vw/forum/viewtopic.php?t=728089&highlight=

[Buggeee]

Nice work tapping that screw
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(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[67rustavenger]

[tzepesh]

I have two other methods for pulling screws: One is with a crew puller (reverse thread conical tap), works pretty well. The other (may not work for SS screws!) is to use the MIG welder to make a blob on top of the screw, then pus a nut on, weld it to the blob and then unscrew. That heat also helps to start it.
Looking forward to your work!
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'74 1303S, L98B Viperngrun (extra glitter), German Look
'64 1200, Sea Blue, under restoration

[VW_Jimbo]

Nice update! I have had to timesert or TIG weld many heads at that spot. Nice job on the fix. When I would rebuild heads and they had a screw stuck in them. I would drill out the broken remnants and a tiny bit of the aluminum. Then another employee of the shop would TIG up the hole and let me know it was ready. I would tap new threads and run through the valves.

It was a very rare day that the steel screw shank would come out. You got really lucky!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[Chinaclipper]

Today I decided to do a compression check before I tore the darn thing down completely. I figured I'd do the valves (they were loose) then spin the engine with my high-power 1/2" drill.

I had oil in her, and I spun 'er with no gauges or anything connected for about 3 minutes to get oil flowing. I was gonna rig up something neat to the oil pressure switch, with a 12 V battery and a light, but heck, I watched the oil come out of the heads so I figured I had lubrication.

Now I figured the drill would spin it rapidly enough; I removed all the sparkplugs, and of course there was NO manifold or carburetor to worry about. (My drill DID overheat once-I limited the subsequent time of rotation after it cooled down to about 5-6 seconds)

Results: #1-105 pounds #2-95 pounds* #3-110 Pounds #4- 110 pounds.
I had my helper watch the dial, and after a few tries (and patience from her) she got it right.

*I re-checked #2 after I squirted some oil into the cylinder and it jumped to 145 pounds
Now, remember, this engine has NOT turned over since maybe October of 2019.

Well, I am re-thinking the need for a full engine rebuild. I did NOT expect that. There is almost no play in the "for and aft" when I tug on the pully-I don't have a dial indicator but that looks promising.

I got some engine degreaser and went to town.

She looks nice and clean now.

Tentative plans:
1) Clean and degrease all tins-paint and repair or replace as needed
2) Either get a new thermostat ($120-gulp) or try to "restore" my old one.
3) Seals on the tubes, and, what the heck, new tubes too.
4) replace Oil cooler, replace front (flywheel) oil seal. Inspect clutch/pressure plate.
5) Clean manifold, clean pistons, rings; new seals where needed
6) Put it back together!

Wondering if I should replace rings? Hmmmm

Also, I haven't had the heads off yet, so that could be another possible thing that needs addressed or replaced. I gotta' take the heads off to replace those tube seals. I KNOW they are SHOT.

Also-I did discover that the right lower engine mount (when in the car-flywheel to front) I am using for the engine stand is stripped
I'm guessing it was the torque from the drill when I was checking the compression? So that will have to be dealt with pre-installation of the engine. Helicoils?

Worst case scenario? I will recheck compression when it's installed, run it, and see how she goes. If I need to pull the engine and really do a full rebuild, well, so be it.
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China Clippers Official 1971 Super Beetle Project!
https://www.thesamba.com/vw/forum/viewtopic.php?t=728089&highlight=

[Buggeee]

That's all great news. Run it and see how it goes from there.

Timesert instead of helicoil.

I got my dial gauge cheap from either Amazon or Harbor freight. It's good for setting front wheel bearings too.
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1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764