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esde
Samba Member
Joined: October 20, 2007
Posts: 6152
Location: central rust belt
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 Posted: Fri Mar 10, 2023 3:45 pm Post subject: Re: October 52 Zwitter |
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| Rome wrote: |
Is there more to the case that is damaged which we don't see in this photo? Does the decayed area below the lower right of the oil pump cover go entirely through the case thickness? If not, and there is no other heavy decay, you could have the case either ice blasted or vapor blasted. Walnut shells or even baking soda (DIY?) would work well but with the risk that the shell particles would blow into the oil passages.
Then again, if the inside of the case's sump area is heavily pitted, the case may indeed no longer be reliably useful.
Are you using strong heat (MAPP gas at least, or oxy-acetylene torch) to heat the engine fasteners prior to loosening? |
Yeah, there's more to that damage than meets the eye. To start, the case flange there is supposed to have holes for the M8 through bolt, but it's just gone and the bolt was sitting in the mud. That bottom section of case is now porous and weak, you could probably poke a pencil through it. But I knew this when I bought it, and it was part of my bargaining angle. It's a shame it sat in the wet mud, that's a death sentence for magnesium.
As for disassembly, I have developed a ritual that works. First night is spray it all down with bolt loosener, and then hit every nut and screw with the torch, then more loosener. Then I go around and see what loosens easily. Last night I got the shroud off, but the cylinder tins are stuck fast. No matter, a few more rounds of heat and soak and things will loosen up. I generally cut the exhaust nuts free of the studs. It's tedious but nowhere as tedious as replacing exhaust studs..
At least one piston is stuck, in those cases I cut and split the cylinder from around the piston.
SD
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that. |
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esde
Samba Member
Joined: October 20, 2007
Posts: 6152
Location: central rust belt
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| Posted: Sun Mar 12, 2023 7:15 pm Post subject: Re: October 52 Zwitter |
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This engine is especially terrible. So much so that it's worth posting.
For starters, the engine was seized, and unknown to me the previous owner had made spark plug adapters that fitted a grease fitting. He was thinking that by filling the cylinders with grease under high pressure, it would force the engine free. Not bad in theory, but the reality is that the pressure leaked at the cylinder heads and completely filled the cylinder tins with grease. #3-4 tin was FULL and grease was well into the fan shroud. 3 maybe 4 tubes worth, mixed with the expected mouse nests, walnuts, acorns and dead things. This is after scraping handfuls of muck away
The good side to all that grease is that the cylinder head nuts were not stuck, and the heads came right off.
Look, more grease
All 4 cylinders obviously trashed, so this is my method to remove them.
cut from the edge to right at the case. Top and bottom make things easier
Then use a thin chisel in the kerf and split the cylinder free\
full face shield needed, I had glasses on and took a chunk of fin to the temple, and it bled profusely.
Thats where I left the case. If I'm lucky I get a salvageable crankshaft and maybe a cam gear.
The other stuff is cleaning up ok. The distributor is crusty, but it's mine so I'll do my best.
Tins will clean up
Everything gets several rounds in the cabinet till it's clean.
Current state. I hate having boxes of dirty parts, so I get things at least clean enough for self etching primer before packing it away.. getting there
Heater sleds and J tubes are in the cabinet, and actually better than I thought. I'll post up some pics when I break them down to clean
SD
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that. |
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EverettB 
Administrator
Joined: April 11, 2000
Posts: 70838
Location: Phoenix 602
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Two Glove Boxes
Samba Member
Joined: March 03, 2005
Posts: 890
Location: Texas
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esde
Samba Member
Joined: October 20, 2007
Posts: 6152
Location: central rust belt
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| Posted: Thu Mar 16, 2023 7:27 pm Post subject: Re: October 52 Zwitter |
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| EverettB wrote: |
Nice, that grease is crazy though!
I think the oil filler tube might be cut shorter than stock?
It looks pretty short in that photo |
Well, it's a clean cut on the end, but who's to say someone didn't trim it at some point in the past. I'll measure it when I have the parts back out. Things were a little chaotic so I packed the clean parts into a bin.
Shortly after taking the last round of pictures I realized that there was likely nothing salvageable in the case. The case was wrecked, and the crank looked trashed, but I was determined for some reason to get it split. Took about an hour, and I had to destroy a piston and then cut the rod end free of the wrist pin.
I was wrong, the cam gear sat in the water and is wrecked. I salvaged the bearing dowel pins and head studs, a gland nut washer, and the crank dowels.
The heads did clean up well, and are listed for sale, as I won't be using them. I have a correct month case that will get built with 36hp parts, and dressed with these 25hp accessories.
SD
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that. |
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ryans65
Samba Member
Joined: February 16, 2016
Posts: 1292
Location: Yulee FL
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| Posted: Tue Mar 21, 2023 6:54 am Post subject: Re: October 52 Zwitter |
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Seth painted my single cab, he's a talented guy you're in good hands!
| esde wrote: |
Finally it's off for paint, was such a whirlwind day I forgot to take any pictures. The shop was started by two guys that had previously worked at a well regarded shop in Maryland. Their business is Slam City, and everything I saw happening made me confident I was leaving the car in good hands.
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esde
Samba Member
Joined: October 20, 2007
Posts: 6152
Location: central rust belt
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| Posted: Sat Aug 05, 2023 11:45 am Post subject: Re: October 52 Zwitter |
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After patiently waiting for it's turn in line, Zwitter #599 has finally gotten it's turn. Doors and fenders back off, body off the pan, and the guys at Slam Sity are working through the list of things that are known issues. There were some headliner bear claw pieces that needed welding, seat belt mounts I forgot, and another two dozen pinholes that I had missed welding.
I'll keep pics coming as milestones are made and pics get back to me.
Other progress:
There is a remote possibility that the original engine has been found. I intend to send off for a birth certificate with this engine number, to see if it will be verified, fingers crossed
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that. |
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VW_Jimbo
Samba Member
Joined: May 22, 2016
Posts: 10640
Location: Huntington Beach, CA
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| Posted: Sun Aug 27, 2023 1:22 pm Post subject: Re: October 52 Zwitter |
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Nice progress! Looks to be in very capable hands!
Keep the pictures coming!
_________________
Jimbo
There is never enough time to do it right the first time, but all the time necessary the second time!
| TDCTDI wrote: |
| Basically, a whole bunch of fuckery to achieve a look. |
| 67rustavenger wrote: |
GFY's Xevin and VW_Jimbo!  |
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esde
Samba Member
Joined: October 20, 2007
Posts: 6152
Location: central rust belt
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| Posted: Wed Oct 11, 2023 8:33 pm Post subject: Re: October 52 Zwitter |
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Fully smoothed and flipped
Sprayed with Clausens rust defender
https://www.clausenautobody.com/proddetail.php?prod=rust-defender
Should be fitting doors and fenders soon!
And while this is being done, I'm busy at home working on the correct engine tin. Robert Chambers helped out and did an amazing job bringing the correct carb back from the dead.
SD
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that. |
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bally
Samba Member
Joined: April 29, 2006
Posts: 1190
Location: Melbourne, Australia
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| Posted: Wed Oct 11, 2023 10:04 pm Post subject: Re: October 52 Zwitter |
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| Oh boy! That is looking sooooooo good! You must be delighted! |
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Rome
Samba Member
Joined: June 02, 2004
Posts: 10175
Location: Pearl River, NY
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| Posted: Thu Oct 12, 2023 12:21 am Post subject: Re: October 52 Zwitter |
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| Quote: |
| Sprayed with Clausens rust defender |
Excellent progress, to see your Zwitter in a single color even though the top coat is still coming. The rust defender reminds me of the occasional Cal-Look color Porsche Sepia Brown-
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finster
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Joined: May 26, 2012
Posts: 9265
Location: not far from the madding crowd
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| Posted: Thu Oct 12, 2023 1:46 am Post subject: Re: October 52 Zwitter |
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looking good. interesting that they masked off the rear grilles
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"we're here on Earth to fart around" kurt vonnegut
nothing lasts, nothing is finished, and nothing is perfect... |
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esde
Samba Member
Joined: October 20, 2007
Posts: 6152
Location: central rust belt
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| Posted: Thu Oct 12, 2023 4:44 am Post subject: Re: October 52 Zwitter |
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| finster wrote: |
| looking good. interesting that they masked off the rear grilles |
I had already gotten the space behind the grilles painted with azure blue, so getting a contrasting color back there would just make more work.
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that. |
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Jimone
Samba Member
Joined: August 01, 2021
Posts: 381
Location: Kansas
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esde
Samba Member
Joined: October 20, 2007
Posts: 6152
Location: central rust belt
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| Posted: Thu Oct 12, 2023 8:05 am Post subject: Re: October 52 Zwitter |
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| Jimone wrote: |
| nice. thats a great update. |
Thanks Jim.
Feels good to see this sort of progress. Much more rewarding than pictures of filler and sanding, though hat is part of the process..
_________________
modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that. |
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esde
Samba Member
Joined: October 20, 2007
Posts: 6152
Location: central rust belt
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| Posted: Sat Oct 14, 2023 7:38 am Post subject: Re: October 52 Zwitter |
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So this primer goes on thick, which is extremely good for filling pits and slight imperfections.
I finally got my OG front fenders fixed and delivered to the shop. All of the doors and fenders are taking a trip to the blasters to get a few rust spots that were missed. Or that started in the last year. Probably the trip to the show, where it was covered in morning condensation didn't do me any favors.  BUT, my son will talk about it forever so I don't have any regrets.
Headlight bucket was thin and roached on the bottom, as happens when they sit with the headlights removed. I harvested a bucket from another fender that was also thin on the bottom and then cut the repair piece from the top
Welded the 58 peanut mounts closed
And repaired the front corners and flanges. Ran into a few problems as my mig machine isn't holding steady voltage on the lowest settings. Bleh. But I did get it done
SD
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that. |
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esde
Samba Member
Joined: October 20, 2007
Posts: 6152
Location: central rust belt
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| Posted: Tue Oct 31, 2023 5:29 pm Post subject: Re: October 52 Zwitter |
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My son made things difficult, and said he wanted to dress as the zwitter for halloween. Not being one to back down from a challenge..
https://www.thesamba.com/vw/forum/viewtopic.php?t=786172
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Robert Chambers
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Joined: August 11, 2005
Posts: 222
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| Posted: Tue Oct 31, 2023 5:39 pm Post subject: Re: October 52 Zwitter |
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Awesome costume! Great job! Wonderful to see his interest in and working with you on the projects!
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'63 OG 117 Herbie Replica
'56 Euro Oval Deluxe
'52 Standard Zwitter
'63 OG 117 |
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Jimone
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Joined: August 01, 2021
Posts: 381
Location: Kansas
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VW_Jimbo
Samba Member
Joined: May 22, 2016
Posts: 10640
Location: Huntington Beach, CA
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| Posted: Wed Nov 01, 2023 10:05 pm Post subject: Re: October 52 Zwitter |
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Very cool costume! Nicely done!
_________________
Jimbo
There is never enough time to do it right the first time, but all the time necessary the second time!
| TDCTDI wrote: |
| Basically, a whole bunch of fuckery to achieve a look. |
| 67rustavenger wrote: |
| GFY's Xevin and VW_Jimbo! |
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