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After 50 years there's some light in the tunnel.
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BMFBMF
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PostPosted: Fri Jan 20, 2023 9:41 am    Post subject: After 50 years there's some light in the tunnel. Reply with quote

Hi Folks, finally bit he bullet and went into the tunnel to replace the gearchange coupling and plastic bush. Also took out the pedals. Got some questions ......

Guess I should weld this guy back up to full strength, up or is it OK for now?

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


The top and sides of the tunnel look amazing , as though they just left the factory. Little bit of rust on the bottom. Should I try to get some rust off and then hit it with cavity spray? any other ideas?

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


This picture below is taken though the gear-lever hole. White cord was tied to the tube when I pulled it out , hopefully to help pull it back in.

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Better picture of the bottom with the surface rust..

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

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1971 Stock South African Beetle 1300 : My mom's european "Thin Chick" spec. Completely stock with torsion bar front, swingaxle rear, smooth hubs, single MC, 40 mm shoes, 31PICT3 carb and 5 bolt drums all round, currently Running a 1976 SF:AS engine with the original SF:AD engine overhauled in a box, waiting to go back in one day.
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Mikedrevguy
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PostPosted: Fri Jan 20, 2023 10:05 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

Clutch hook doesn’t look like it will snap tomorrow, but while you’ve got it out, may as well address it.
I recently pulled my pedal assembly apart, cleaned, lubed, and reassembled.
For the hook, I welded in a bolt and brass bushing to eliminate the hook. There are similar assemblies that can be purchased in the classifieds.
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PostPosted: Fri Jan 20, 2023 12:12 pm    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

BMFBMF wrote:
... Should I try to get some rust off and then hit it with cavity spray? ...

There's a good product for this, but it's out of stock currently. Maybe you can find it elswhere? Here's a link:

https://www.eastwood.com/eastwood-internal-frame-coating-14oz-aerosol.html
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PostPosted: Fri Jan 20, 2023 3:14 pm    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

I painted mine while the pan was on a rotisserie. However if you can’t find a decent paint while it’s a roller buy some lanolin spray and coat the insides. It’ll stop rust and smell wonderful.
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PostPosted: Fri Jan 20, 2023 4:55 pm    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

BMFBMF wrote:
Hi Folks, finally bit he bullet and went into the tunnel to replace the gearchange coupling and plastic bush. Also took out the pedals. Got some questions ......

Guess I should weld this guy back up to full strength, up or is it OK for now?

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


I think mine was worse. Load up with grease when re-installing.
Image may have been reduced in size. Click image to view fullscreen.

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BMFBMF
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PostPosted: Sun Jan 22, 2023 12:21 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

Thanks for all the input folks, did some poking around last night and most of what looked like rust was actually just dust that it collected around the water drain hole. Wiped it down with a damp cloth and it's looking pretty good.

For the little traces of rust that are there, I wonder if I should paint it with one of those rust converter paints, before hitting it with the cavity spray?

After 50 years the rubber drain bung under the tunnel was as hard as rock, had to pour a bit of boiling water on it to soften it up enough to get it out. Otherwise still in perfect shape, it's amazing how old rubber can last.
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-----Slava Ukraini-----
1971 Stock South African Beetle 1300 : My mom's european "Thin Chick" spec. Completely stock with torsion bar front, swingaxle rear, smooth hubs, single MC, 40 mm shoes, 31PICT3 carb and 5 bolt drums all round, currently Running a 1976 SF:AS engine with the original SF:AD engine overhauled in a box, waiting to go back in one day.
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PostPosted: Sun Jan 22, 2023 2:42 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

BMFBMF wrote:
The top and sides of the tunnel look amazing , as though they just left the factory. Little bit of rust on the bottom. Should I try to get some rust off and then hit it with cavity spray? any other ideas?

I used Fluid Film Liquid A: http://fluidfilm.de/en/produkte/liquid-a/203/
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PostPosted: Sun Jan 22, 2023 5:48 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

Maddel wrote:
BMFBMF wrote:
The top and sides of the tunnel look amazing , as though they just left the factory. Little bit of rust on the bottom. Should I try to get some rust off and then hit it with cavity spray? any other ideas?

I used Fluid Film Liquid A: http://fluidfilm.de/en/produkte/liquid-a/203/


I'd use Fluid Film in that tunnel as well. It can prevent any future rust from developing as well.
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PostPosted: Sun Jan 22, 2023 5:57 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

Cusser
How many miles your Beetle had when you saw this?

Cusser wrote:


I think mine was worse. Load up with grease when re-installing.
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PostPosted: Sun Jan 22, 2023 7:07 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

If you’re worried about wear in the clutch hook, you might consider looking into one of these (ref. link below). I ordered and installed one several years ago, when I was refurbishing & restoring my floor pedal assembly. It’s worked perfectly so far.

https://www.thesamba.com/vw/classifieds/detail.php?id=1087010
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PostPosted: Sun Jan 22, 2023 8:49 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

My hook has about that much wear and I run it without worry. I drilled a small hole in the hook tip for a cotter pin to keep the cable hook from falling off on install. Some people use a small zip tie or rubber band.
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PostPosted: Sun Jan 22, 2023 10:58 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

edjose17 wrote:
Cusser
How many miles your Beetle had when you saw this?

Cusser wrote:


I think mine was worse. Load up with grease when re-installing.
Image may have been reduced in size. Click image to view fullscreen.


My 1967 bug had roughly 130k original miles on it when I pulled the pedal assembly to service and lube it. My clutch hook was worn just a bit more. I welded it up. I then smoothed out the area where the clutch cable rides and lubed it up with wheel bearing grease.

My 67' bug is primarily a weekend ride or doing errands during the nice weather during the week. So, it only gets a couple thousand miles put on it a year like most of our air cooled VW's these days. It should be good for a few decades before requiring any additional work.
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BMFBMF
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PostPosted: Sun Jan 22, 2023 12:50 pm    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

Thanks for the input guys, its a "right hand drive" as in "correct-hand drive " 🤣so the modified clutch pedal seems to be non existant for this type.

Once I cleared ou the dust from the tunnel around the drain , the metal seems in super good condition. Yee-ha....

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-----Slava Ukraini-----
1971 Stock South African Beetle 1300 : My mom's european "Thin Chick" spec. Completely stock with torsion bar front, swingaxle rear, smooth hubs, single MC, 40 mm shoes, 31PICT3 carb and 5 bolt drums all round, currently Running a 1976 SF:AS engine with the original SF:AD engine overhauled in a box, waiting to go back in one day.
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BMFBMF
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PostPosted: Tue Jan 24, 2023 1:33 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

Got a friend who works at CERN who is going to build the hook back up for me.

I just wanted to add that I'm now going to remove the drain plug every few years to clean it out to make sure water can easily drain out.

If you've not done that for many years, I suggest you check it out, dust collect there and can cause water to stop draining and rot out the tunnel.
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-----Slava Ukraini-----
1971 Stock South African Beetle 1300 : My mom's european "Thin Chick" spec. Completely stock with torsion bar front, swingaxle rear, smooth hubs, single MC, 40 mm shoes, 31PICT3 carb and 5 bolt drums all round, currently Running a 1976 SF:AS engine with the original SF:AD engine overhauled in a box, waiting to go back in one day.
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PostPosted: Tue Jan 24, 2023 3:49 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

And if you can’t find the right drain plug to use, you can fit an old tubeless tyre stem in there.

That’ll confuse people who want to know what you’re blowing up.
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PostPosted: Tue Jan 24, 2023 7:34 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

edjose17 wrote:
Cusser
How many miles your Beetle had when you saw this?

Cusser wrote:


I think mine was worse. Load up with grease when re-installing.
Image may have been reduced in size. Click image to view fullscreen.


That was from my 1971 Super Convertible, 140K miles.
The one on my 1970 sedan lasted longer, like 200K.
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PostPosted: Tue Jan 24, 2023 9:10 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

Welding that may change its temper and wear out faster. I'd either replace it, or spend time smoothing and deburring it, then use lots of sticky moly-type grease on it. Do the same for the cable eye. Casting flash can create sharp edges and stress points.
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PostPosted: Tue Jan 24, 2023 9:21 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

Why wouldn't you fix it or replace it before it breaks on the road . Good luck
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PostPosted: Tue Jan 24, 2023 10:46 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

baldessariclan wrote:
If you’re worried about wear in the clutch hook, you might consider looking into one of these (ref. link below). I ordered and installed one several years ago, when I was refurbishing & restoring my floor pedal assembly. It’s worked perfectly so far.

https://www.thesamba.com/vw/classifieds/detail.php?id=1087010


That's a nice idea.
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PostPosted: Tue Jan 24, 2023 10:55 am    Post subject: Re: After 50 years there's some light in the tunnel. Reply with quote

baldessariclan wrote:
If you’re worried about wear in the clutch hook, you might consider looking into one of these (ref. link below). I ordered and installed one several years ago, when I was refurbishing & restoring my floor pedal assembly. It’s worked perfectly so far.

https://www.thesamba.com/vw/classifieds/detail.php?id=1087010


I bought that when mine failed.

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