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DanM
Samba Member
Joined: June 07, 2002
Posts: 1330
Location: Falls Church, VA
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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 Posted: Mon Feb 28, 2022 9:59 pm Post subject: Re: Buggeee's 1966 Sportsmobile Camper by Travel Equipment Corp |
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| Buggeee wrote: |
I am working on a set of single port heads from a friend's stash, for a single relief case build for my 1966 Bus. They have a couple of stripped and frozen exhaust studs on one head and some marred and fozen studs on the other.
So this has effort has involved all the methods.
I started with PB Blaster and double nuts on one of the studs, to no avail. Another had smooshed threads from a POs efforts - so vice grips were called in, to no avail. Heat from the torch did not pursuade the old studs. One finally twisted off in the jaws of the vice grips, kind of close to the head, so I employed the welder and a nut.
After cooling, a small air impact wratchet was tried, followed by a larger impact gun, and it just twisted off even closer.
So I used a cutoff wheel to cut them flush and dinged the center with a punch, followed by drilling successively larger bits, keeping things well oiled along the way.
Once the hole was of a sufficient size, I think it might have been 17/64, I tapped it for 8mm 1.25 thread pitch.
The replacement studs went in, but were not snug and I knew they'd fail under tightening the exhaust nuts. Kind of like a loose tooth. Mainly because my holes were a bit off center and a thin shaving of the old stud still formed part of the wall in there.
Time for a time-sert. I love these insert kits.
It involves drilling a larger hole, then tapping that for the insert, then cutting a shoulder into that to accept the outer lip of the insert, then loading a threaded bit with an insert and screwing it in. When the shoulder hits the head, the threaded bit rotates through the insert, expanding the insert against the threaded wall of the larger hole, securing it.
Then just back out the tool and it's ready for use.
Here are the studs installed in the head.
The other marred studs were cleaned up by running a 8mm 1.25 thread pitch die over them. This metric tap and die set is from Harbor Freight and is inexpensive and invaluable but not precice enough for making space ship parts.
Because the T-handle would not fit between the studs, I just used channel locks.
They came out clean enough to readily install an exhaust nut.
There you have it. |
_________________
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
| SnowDaySyncro wrote: |
| Every setback is an opportunity to learn stuff and to buy new tools. |
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MaddMatt
Samba Member
Joined: April 25, 2009
Posts: 269
Location: tucson arizona
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| Posted: Tue Mar 01, 2022 6:10 pm Post subject: Re: Buggeee's 1966 Camper by Travel Equipment Corp |
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As requested
_________________
It will make it. Trust me.
Owned: 71 Superbeetle, 72 Superbeetle, 63 Baja (on 69 pan) 74 baja, 74 Karmann Ghia
Own: 71 Deluxe Bus |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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| Posted: Thu Mar 03, 2022 10:01 pm Post subject: Re: Buggeee's 1966 Sportsmobile Camper by Travel Equipment Corp |
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That picture looks a lot like one I posted earlier, but it's different. Much, much different.
I had been throwing this single relief case together with parts I swept off my floor as a temporary power plant. Then, for giggles I ran the numbers on the case against the technical archives and discovered that it's August 1966 (on the Beetle chart, December 1966 on the bus chart). That's about as numbers-matching to this bus as I could hope to get, and it was just by happenstance!
I took this mission from God for what it was and tore it right back down. It is now filled with a freshly ground VW crank, new bearings, rebuilt VW rods, brand new stock grind flat gear cam, new cam bearings and new lifters. Fresh as a daisy.
I had the parts on the shelf thinking they'd go in a dual relief dual port case... but this bus and it's single port, single relief engine just moved to the front of the line. 
_________________
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
| SnowDaySyncro wrote: |
| Every setback is an opportunity to learn stuff and to buy new tools. |
Last edited by Buggeee on Sat Mar 05, 2022 7:44 pm; edited 1 time in total |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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BarryL 
Samba Member
Joined: November 01, 2004
Posts: 14258
Location: Casa de Oro, California
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| Posted: Sat Mar 05, 2022 6:41 pm Post subject: Re: Buggeee's 1966 Sportsmobile Camper by Travel Equipment Corp |
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| Is that an "H" case? |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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VWTECHEDITOR
Samba Member
Joined: March 02, 2004
Posts: 99
Location: Southern Maryland, USA
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| Posted: Sat Mar 05, 2022 8:10 pm Post subject: Re: Buggeee's 1966 Sportsmobile Camper by Travel Equipment Corp |
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Good Evening,
The code information on your case indicates that it was a VW Factory rebuilt engine (symbol on the far left); that was a 1967 1500 single port engine (H0), and that it was an exchange (X = rebuilt) engine. The 5 digit number is a sequential build serial number.
I posted some info a while back as source material.
https://www.thesamba.com/vw/gallery/pix/382769.jpg
Regards
Art LeBrun
[email protected] |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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VWTECHEDITOR
Samba Member
Joined: March 02, 2004
Posts: 99
Location: Southern Maryland, USA
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| Posted: Mon Mar 07, 2022 7:38 pm Post subject: Re: Buggeee's 1966 Sportsmobile Camper by Travel Equipment Corp |
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Good Evening,
Installing that starter is a good upgrade. It is also supposed to be some small % more powerful. OK... I've had one in my green '69 Beetle for some time now; works great.
Art LeBrun
vwtecheditor |
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MaddMatt
Samba Member
Joined: April 25, 2009
Posts: 269
Location: tucson arizona
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| Posted: Wed Mar 09, 2022 12:59 am Post subject: Re: Buggeee's 1966 Sportsmobile Camper by Travel Equipment Corp |
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| VWTECHEDITOR wrote: |
Good Evening,
Installing that starter is a good upgrade. It is also supposed to be some small % more powerful. OK... I've had one in my green '69 Beetle for some time now; works great.
Art LeBrun
vwtecheditor |
I completely agree. This has become my first purchase with any new vw project. After years and years of replaced bushings, that hole on the bell housing tends to wear out. Self supporting starters all the way.
_________________
It will make it. Trust me.
Owned: 71 Superbeetle, 72 Superbeetle, 63 Baja (on 69 pan) 74 baja, 74 Karmann Ghia
Own: 71 Deluxe Bus |
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VWTECHEDITOR
Samba Member
Joined: March 02, 2004
Posts: 99
Location: Southern Maryland, USA
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| Posted: Wed Mar 09, 2022 7:50 am Post subject: Re: Buggeee's 1966 Sportsmobile Camper by Travel Equipment Corp |
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Good Morning,
A self-supporting 12 volt starter also has another benefit.
My engine test stand uses a bell housing from a "12 volt" Bus. I installed an adapter bushing so my 6 volt starter now works with it. When I test run an older 6 volt engine with a 109 tooth flywheel, I simply use a 6 volt starter. Flywheel, starter pinion and bushing all match.
When I test run a 12 volt engine with a 130 tooth flywheel, I simply swap out the 6 volt starter and use a self supporting 12 volt starter and then I don't have to worry about the bushing in the bell housing. Flywheel and starter pinion both match, no bushing involved.
Regards,
Art LeBrun
vwtecheditor |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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| Posted: Fri Mar 11, 2022 6:26 am Post subject: Re: Buggeee's 1966 Sportsmobile Camper by Travel Equipment Corp |
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A little update with a new steering stabilizer. Also I busted a grease fitting in the beam with the jack stand, which made me feel a little foolish. But I had this box of various metric fittings from Harbor Freight on the shelf, so no harm. All of the grease fittings on the beam took grease and the old grease that was pushed out at the ends was fairly clean. Everything so far points to this bus being cared for while it was on the road. (New cotter pin not pictured)
_________________
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
| SnowDaySyncro wrote: |
| Every setback is an opportunity to learn stuff and to buy new tools. |
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nlorntson
Crazy VW Lady
Joined: March 13, 2004
Posts: 3783
Location: Twin Cities, MN
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| Posted: Fri Mar 11, 2022 10:30 am Post subject: Re: Buggeee's 1966 Sportsmobile Camper by Travel Equipment Corp |
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It kinda looks like the rubber grommets to hold the brake lines are missing on the tab bolted to the top spring plate bolt. You absolutely need the rubber grommets in this location. |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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| Posted: Fri Mar 11, 2022 11:06 am Post subject: Re: Buggeee's 1966 Sportsmobile Camper by Travel Equipment Corp |
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| nlorntson wrote: |
It kinda looks like the rubber grommets to hold the brake lines are missing on the tab bolted to the top spring plate bolt. You absolutely need the rubber grommets in this location. |
You are absolutely correct they are necessary. For me, and any other reader, thank you for the comment as it is literally a life saving measure for some operator years down the road when the vibration of metal on metal might finally cut through a line. The grommets go here in these brackets, as well as everywhere the metal lines pass through round holes in the frame.
They are not in yet in these pictures and I should have noted a comment, which is now added to the earlier post. The brake line grommets have not arrived yet and the generic grommets that are good for hoses and electrical, which I do have on the shelf, are too thin-walled to have any shape or support once they are cut for installation here.
Another place to watch for this issue, which I learned from another Samba thread, is where the brake shoe is close to the short s-shaped brake line in the front wheels on these busses. The idea is to shape the brake line in a way that it won't get rubbed on by the brake shoe during its adjustment, operation or movement. Here I've circled the two spots, generally, in this picture:
I found this other potential wear spot for front brake lines in another thread and am editing this post to drop it here so I have it all in one place.... these next pictures are not my bus, just an example.
| AS350driver wrote: |
Now the junky 13 window has 4 correct 15” wheels on it, with fresh paint.
Also figured out an issue with uneven braking and wheel cylinders blowing out on the front right wheel. The bus started pulling left while braking, and I’d pull the drum and replace the lower wheel cylinder due to apparent leakage. It turns out, it was the hard line getting rubbed by the drum, which created a pinhole aimed at the lower wheel cylinder. It only leaked if I had had to get on the brakes very hard….then the pedal would go to the floor of course. New hard line installed, all is well again.
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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
| SnowDaySyncro wrote: |
| Every setback is an opportunity to learn stuff and to buy new tools. |
Last edited by Buggeee on Sun Mar 13, 2022 7:06 am; edited 1 time in total |
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Buggeee
Samba Member
Joined: December 22, 2016
Posts: 4408
Location: Stuck in Ohio
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