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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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 Posted: Thu Dec 31, 2020 9:17 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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| ach60 wrote: |
Wow! Great job finding the issue.
Everyday you get closer to......I don't know?
I think I'd have the "new" drum machined down,
I wouldn't even know how to start looking for the longer stub axle,
and I wouldn't know about the matching gear that goes on the long axle.
I'll defer to the experts though. |
How did we not notice this? 😂
_________________
1959 Single Cab “Otto”
1500 single port | 1963 small nut/big brake transaxle | CSP Disc Brakes | dual circuit m/c | Deutsch Polster seats |
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ach60 
Samba Member
Joined: May 14, 2001
Posts: 4139
Location: Santa Maria
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| Posted: Sat Jan 02, 2021 12:09 am Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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So are these the drums I got "new" ones at the VW Classic?
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Good Luck
Al |
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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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| Posted: Sat Jan 02, 2021 12:18 am Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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| ach60 wrote: |
| So are these the drums I got "new" ones at the VW Classic? |
Nope these were the drums on the truck.
_________________
1959 Single Cab “Otto”
1500 single port | 1963 small nut/big brake transaxle | CSP Disc Brakes | dual circuit m/c | Deutsch Polster seats |
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crukab
Samba Chef
Joined: December 13, 2002
Posts: 6116
Location: Vermont
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| Posted: Sat Jan 02, 2021 2:14 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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Nice score on the truck, 27 years later ... 
I like the TLC you have taken on the paint & logo's, Earlie RED trucks are cool, not the boring white.
My 1st Vw was a '59 Singlecab, bought in Colorado for $400 in 1980:
Fight your way through this brake/axel issue and you'll be rolling !
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Tom
My Pops:
http://www.thesamba.com/vw/forum/viewtopic.php?t=604100&highlight=
I know you will always be with me, rest in peace with no more pain. 8/13/14.....
In the yard right now:
'51 Dodge 5 window truck
'65 Bug
'66 Singlecab
'82 Rabbit Truck Diesel from CALI 
'86 Doublecab W/T
'91 Vanagon carat/wolfsbrg.Tiico
'88 Dodge Ram pickup
'11 Jetta Wagon |
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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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| Posted: Sat Jan 02, 2021 2:35 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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Nice!
Shopping for machinists now. Does anyone have suggestions in the San Jose area?
_________________
1959 Single Cab “Otto”
1500 single port | 1963 small nut/big brake transaxle | CSP Disc Brakes | dual circuit m/c | Deutsch Polster seats |
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don.ville
Samba YardMan
Joined: February 07, 2008
Posts: 2829
Location: West Palm Beach, FL
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| Posted: Sat Jan 02, 2021 3:03 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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| bobrk wrote: |
Nice!
Shopping for machinists now. Does anyone have suggestions in the San Jose area? |
Give this place a call...
Nice work on the SC by the way... 
_________________
67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro
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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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| Posted: Sat Jan 02, 2021 8:25 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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That's hilarious! But you can only get banh mi there now! 😂
_________________
1959 Single Cab “Otto”
1500 single port | 1963 small nut/big brake transaxle | CSP Disc Brakes | dual circuit m/c | Deutsch Polster seats |
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BulliBill
Samba Member
Joined: July 09, 2004
Posts: 4572
Location: St Charles, MO
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| Posted: Sun Jan 03, 2021 11:02 am Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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Ray Schubert (Mark Merrill's collection mechanic) will know of machine shops around San Jose. He's hard to get a hold of, but you can try [email protected]
Bill
_________________
I'm looking for these license plate frames for my fleet:
Coeur D'Alene - Lake Shore Volkswagen
Mission VW - San Fernando
Thornton VW - Stockton
Thanks for any help! |
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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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| Posted: Sun Feb 21, 2021 5:49 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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Oofff, finally got some work done on a glorious San Jose late winter day. I think I have all the brake plumbing done, except for the new master cylinder installation.
Front brake lines from my disk brake kit.
Rear flex lines and a new hard line for the rear
Also put these babies in, not easy.
Scoping out the new master cylinder installation
Little worried it will foul on the sway bar...
Remembering the hack job we did to adapt late too-long e-brake cables to an early bus. LOL
_________________
1959 Single Cab “Otto”
1500 single port | 1963 small nut/big brake transaxle | CSP Disc Brakes | dual circuit m/c | Deutsch Polster seats |
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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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| Posted: Mon Feb 22, 2021 8:06 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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Well, I think it’s gonna work. My empi spacer kit has triple-square 12 point bolts for which I don’t have a bit so that’s holding me up. Put everything up there just to see how it was going to fit though. Looks good to me!
_________________
1959 Single Cab “Otto”
1500 single port | 1963 small nut/big brake transaxle | CSP Disc Brakes | dual circuit m/c | Deutsch Polster seats |
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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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| Posted: Wed Feb 24, 2021 7:20 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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Spent some time getting the master cylinder mounted. Pretty sure I got the correct pipes hooked up to the right spots. Can't wait to get some fluid in there to test it.
EMPI spacer kit
Brake lines connected
Brake light switch connected
Front brake line on the bottom, rear on top
You can see them up there...
_________________
1959 Single Cab “Otto”
1500 single port | 1963 small nut/big brake transaxle | CSP Disc Brakes | dual circuit m/c | Deutsch Polster seats |
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ach60
Samba Member
Joined: May 14, 2001
Posts: 4139
Location: Santa Maria
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| Posted: Wed Feb 24, 2021 8:47 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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| bobrk wrote: |
Oofff,
Remembering the hack job we did to adapt late too-long e-brake cables to an early bus. LOL
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My head hurts from those pictures, another ghost from the past comes back to haunt me!
And all I had to do was order this, VW Cable Shortening Kit, Parking Brake
Qty: 1 Code: 3169
https://www.jbugs.com/category/vw-dune-buggy-off-road-emergency-brake-cables.html
Funny what you can learn from a Dune Buggy.
_________________
Good Luck
Al |
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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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| Posted: Wed Feb 24, 2021 9:33 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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LOL
At least I didn't have to make a spacer for the new master cylinder!
_________________
1959 Single Cab “Otto”
1500 single port | 1963 small nut/big brake transaxle | CSP Disc Brakes | dual circuit m/c | Deutsch Polster seats |
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Who.Me?
Samba Member
Joined: July 14, 2014
Posts: 2206
Location: UK (South)
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| Posted: Thu Feb 25, 2021 11:56 am Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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I tried that kit, but the first time I yanked up on the handbrake to test it, it just ripped out. Tried tightening the grub screw even more, but it just stripped the hex head.
There are a few threads in the FAQs on more reliable ways to make the cables work. I think Glideking's solution in his Funky Truck thread is the most elegant though.
_________________
Andy
Looking for info on my truck's history. Are you from Campbell California or nearby. Do you recognise it? ... http://www.thesamba.com/vw/forum/viewtopic.php?t=636786 |
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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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| Posted: Thu Feb 25, 2021 1:18 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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Yeah, when I saw “set screws” I was like, naw.
_________________
1959 Single Cab “Otto”
1500 single port | 1963 small nut/big brake transaxle | CSP Disc Brakes | dual circuit m/c | Deutsch Polster seats |
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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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| Posted: Thu Feb 25, 2021 10:04 pm Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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| bobrk wrote: |
Brake lines connected
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So I put the front lines in next to the pedal (bottom of the picture) and the rear line and switch at the other end.
Is that right?
Ok, just read 15 pages of the 20 page dual circuit conversion FAQ. I have them backwards, and need to decide if I want to T the front brakes for another brake light switch. 🙄🤔😂
_________________
1959 Single Cab “Otto”
1500 single port | 1963 small nut/big brake transaxle | CSP Disc Brakes | dual circuit m/c | Deutsch Polster seats |
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ach60
Samba Member
Joined: May 14, 2001
Posts: 4139
Location: Santa Maria
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| Posted: Fri Feb 26, 2021 12:47 am Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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| Who.Me? wrote: |
I tried that kit, but the first time I yanked up on the handbrake to test it, it just ripped out. Tried tightening the grub screw even more, but it just stripped the hex head.
There are a few threads in the FAQs on more reliable ways to make the cables work. I think Glideking's solution in his Funky Truck thread is the most elegant though. |
| glideking wrote: |
Usual problem of having non stock length hand brake cable when using "big nut" rear brake drums with early bus.
For years I used these off road cable ends and cut down the long '67 length cables. I used Loctite and they have never slipped.
Problem is there is very little room for adjustment as the cable stretches and brake lining wears. The hex section is too large to fit into the compensating lever and can't go through the tubes to remove the transaxle or RGBs. Once the cables have stretched they must be replaced. Later split buses have much more room for things like coupling nuts and treaded rod. No such room in the early bus. These are one time only use because they smash the cable.
Always looking for a better way. Turns out I had the solution all this time. I make my own aircraft control cables. This tool is $19 bucks from Aircraft Spruce.
3/32 tin plated copper swages are a perfect fit and stronger than the factory ends.
Here is the total length I used for a '67 brake backing plates with a stock '59 rearward positioned hand brake lever. Even with shrink tubing they fit easily through the chassis tubes.
It is beginning to look like 1959 under here. Now there is plenty of room for adjustment and the cables can be easily removed and installed.
Kurt |
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Good Luck
Al |
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ach60
Samba Member
Joined: May 14, 2001
Posts: 4139
Location: Santa Maria
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| Posted: Fri Feb 26, 2021 12:49 am Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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| bobrk wrote: |
| bobrk wrote: |
Brake lines connected
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So I put the front lines in next to the pedal (bottom of the picture) and the rear line and switch at the other end.
Is that right?
Ok, just read 15 pages of the 20 page dual circuit conversion FAQ. I have them backwards, and need to decide if I want to T the front brakes for another brake light switch. 🙄🤔😂 |
| glideking wrote: |
Here's another long winded one.
I have been trying to find a way to have a dual circuit master cylinder without modifying my pedal pan cover.
First some background info. Some early cars had a one circuit hydraulic braking system. Problem was when you had a leak or other failure some where you lost all braking. Early hand brakes used to be called EMERGENCY brakes for a reason. The idea behind a dual circuit system is you would still have half of the system still woking front or rear depending on failure location or which reservoir went dry first. So dual is a desirable improvement.
This is the dual circuit master I have been using for the last 200k miles for twenty + years. Varga ind. Bras. Made in Brazil. Very good quality, affordable. A direct replacement for a '79 bus with disk brakes like the ones I have on Funky. Wonderful. Components that were designed to work together. Problem is it requires a spacer to clear the reservoir to the frame and a VW Rabbit pickup mounted backwards or an expensive '67 only reservoir. It also has one of the outlets on the bottom so my pedal pan don't fit! Like so many of us I have run without a pedal pan, dirt, sand and mud getting all over my freshly greased shift linkages, cables and bushings. Bad.
I could cut holes in my pan right? That would be too easy. Easy is not a requirement. I am here to amuse myself.
I found this curious looking thing on the web. It was $30 and includes the reservoir and seals at 85 mm between centers. It clears the beam without mounting it backwards. Cheap enough just to get the reservoir that will fit. But wait! It is exactly the same specifications as my '79 master.
(edit)
| Eric&Barb wrote: |
VW Fox from searches on line shows as a 20 mm MC piston size.
1967 Bus is 22 mm.
1972-79 Bus is 23 mm.
Will be interesting to hear if the pedal pressure is a lot easier during braking and how high the pedal is from the floor when pressed down. |
Could the master be used too? Too bad it has those bumps on the bottom.
I sawed off the unused bosses on the bottom. It fits without the spacer and the lid is accessible through the floor.
This pedal pan will now fit but it is for a '65 or so. It has a bulge for the steering box and bumps in back for a bigger master. I know they are all interchangeable but it is fun to see if I can get the right one to work.
I had to take another 4mm off the back to clear the pan. Hey it was 30 bucks.
No bumps. No holes. Flat around steering box and what a fabulous color! Screws holes are machine threaded same as engine tin.
The outlets are all now on the sides. I now have a full tilt dual circuit master cylinder hiding behind a correct '59 pan! I know, I know but it made me really happy doing it. It fits! Now I have to make it work.
I shortened the clevis and the pushrod. The nut must never touch the plunger during operation. Red arrow. There must also be some wiggle room here when the pedal is at rest.
First problem is the pedal return spring hits the frame preventing full depression of the master. This is important. It would defeat the advantage of a dual circuit during a failure if you can't press the pedal down enough to use the remaining circuit!
I cut clearance for the spring. Now we have full function.
A side tip. Here is how I wind up the pedal return spring easily. Bailing wire through a deep socket for comfort. The scratch in the paint the spring leaves gives it that stock VW authenticity.
We won't know how well this works until testing in April 2016. I will run it in both front and rear failure modes.
See you at OCTO
Kurt |
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Good Luck
Al |
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ach60
Samba Member
Joined: May 14, 2001
Posts: 4139
Location: Santa Maria
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| Posted: Fri Feb 26, 2021 1:10 am Post subject: Re: Bob's 1959 Single Cab Pickup — "Otto" |
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Photo of Kurt "glideking" I took in 2016(?) at Kelly Park
Craftsman with the 1959 Single Cab Restoration Thread "Funky Truck"
I recognized the Truck, from reading
https://www.thesamba.com/vw/forum/viewtopic.php?t=...unky+truck
which I had been following in 2016.
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Good Luck
Al |
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bobrk
Samba Member
Joined: March 07, 2002
Posts: 288
Location: Beautiful Downtown San Jose
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