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56 vert Jimmy Sprinkles
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esde
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PostPosted: Sun Nov 10, 2024 7:59 pm    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Sooooo
it's been a busy summer driving and enjoying this car, and I have not updated this thread. The cars runs well, and I am pretty happy with it at this point. It's been all over locally, and has only left me stranded twice. Once the points got tight, a little grease on the cam and opened them back up, and I was on my way. The other was the starter, occasionally it just refuses to go. usually it does eventually, but this time my friends got to push so I could show them how to pop the clutch Very Happy
A dozen cars and coffee mornings, a few shows, farmers markets, ice cream stands, and Flanders All Air Cooled Gathering. If you know the last one, you know.
Waiting for the tow lights to get mounted
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Hanging with Schwing and Shotwell
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Campsite
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Show field
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Next to my friend Jays 57, that I did the floors and channels on. He's really done a great job making it a nice car again
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Back in the barn, tucked to the side for winter, next to my 62 oval clone (I welded in the rear window when I was 18 )
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Next step for this car I think is finishing its engine, as the zwitter will want the current motor back, and then seat covers. And I've done a few small things along the way, like replace an incorrect curved visor with the right one, and I have found a rear ashtray with great chrome, as this one is beyond polishing.
Peace. SD
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Zwitterkafer
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PostPosted: Sat Jun 08, 2024 11:17 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

That's great news! There's nothing like a quality Bowden tube. It used to be that all you had to worry about was a high mileage clutch cable fraying and dragging after it cut through the Teflon liner inside the spiral coiled wire of the Bowden tube. Sadly, many new parts these days require a critical examination before installation.
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PostPosted: Sat Jun 08, 2024 9:14 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Nice sleuthing! I have not seen that fault, ever! Ever time I read about the lack of quality of the parts we are dependent upon, my heart sinks. It always makes me look at the writing on the wall. Wish those that manufacture were more vested in GOOD QUALITY, instead of less than okay.

Glad you found it and hope the next tube is a good one!
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PostPosted: Sat Jun 08, 2024 7:50 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Awesome, put that little nag behind you.
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cory464 wrote:
if you aren't perfectly centered in the hole you will have issues when you tap it.
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esde
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PostPosted: Sat Jun 08, 2024 7:12 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

SUCCESS!
I started with all of the easy stuff. Shifter off, shift coupling back out, inspecting all of the clutch cable mechanics..
My problems were a combination of two faulty new parts. The shift rod coupler had one lock screw indexed a few degrees off from the other. So the shift gate for 1 was not where the reverse lockout plate wanted it to be.
The second was a tough one, that I found by chance. the clutch felt right, but was acting like it didn't have the pedal fully depressed. I had my son step on the pedal while I watched from underneath, and noticed the bow in the bowden tube was disappearing!? WTF! Further inspection, showed the black plastic coated cable sheath was getting pulled into the crimped end about 3-4mm, when the clutch was released it would slowly creep back out. I don't even know how I noticed it was so slight. Swapped the bowden tube and all is good! Drives well and doesn't leak a drop!!
No clue where the bowden came from, could have been EIS, Wolfsburg, or CIP1.
Taking it to a show tomorrow and then the farmers market, will post some pics along the way!
SD
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esde
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PostPosted: Mon Jun 03, 2024 10:34 pm    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Dan22 wrote:
Thanks for the oil filter mount pix. It looks like it tucks nicely up there and quite serviceable.

You may consider welding up that crack in your bumper mount someday. That provides rigidity to the whole panel and other cracks can generate.

And I think you clutch is dragging if you have trouble getting into gear. Could be adjustment or pilot bearing, or a bad clutch plate.


Thanks Dan.
I am refraining from any welding on the car for now
I have uncovered enough a fair amount of stuff that needs attention, but I am not going to dive into it until my zwitter is complete. Gotta have at least one nice car to drive Wink
And, I had originally assumed the clutch was not the problem, because it worked before.. but then today I had talked w Matt Steedle and his thoughts are also to look at the clutch again. I'll try the low hanging fruit first, so pedal assembly/ clutch cable/ shift linkage all get inspected tomorrow eve.
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PostPosted: Mon Jun 03, 2024 8:55 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Thanks for the oil filter mount pix. It looks like it tucks nicely up there and quite serviceable.

You may consider welding up that crack in your bumper mount someday. That provides rigidity to the whole panel and other cracks can generate.

And I think you clutch is dragging if you have trouble getting into gear. Could be adjustment or pilot bearing, or a bad clutch plate.
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esde
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PostPosted: Sun Jun 02, 2024 9:22 pm    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Progress.. as always two steps forward and one back.
Oil filter bracket:
I wasn't going to drill holes, so this pretty much meant I had to use the bumper mount bolts. This is standard practice on later cars, but early cars have the overrider brace bars in the way. I ended up using some spacers and longer bolts to get around the brace, and it worked out well.
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Yes, the oil hoses are close to the fender, there's room to slip a business card between them, but no more. Not on purpose, thought I had measured to leave more room..
Adjusted the clutch, and set the timing, put the top down and pulled it out for the first time this year..
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Gave it a quick rinse with the hose
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This is the engine I built for my 52 zwitter, and it has maybe 2 hours of run time on it. Still running break in oil for sure, probably should change it out asap Shocked

Link

The engine runs nicely, and the transmission is quiet!!
But, it does not like to shift into 1st or 2nd. If I select R, 3 or 4 then I can quickly engage 1st or 2nd. Sitting still in neutral, depress clutch and you cannot go into 1 or 2. I suspect that something in the pinion stack is tight, but will call some people smarter than myself for 2nd and 3rd opinions..
ARGH.
But hey, and least everything that needs to be done has already been cleaned...
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PostPosted: Fri May 31, 2024 9:49 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

esde, thanks for that informative reply. Agree, with new bearings and a replacement case, checking the pattern was warranted. Those pinion shims can indeed take a long time to find. (None at Weddle?) I once scrounged a good one from a parts splitcase that was lying around taking up space. Making a shim adjustment of course means backtracking and undoing that dialed-in gear stack, which becomes less fun every time. For sure, fingers crossed that all is well and much improved. Cheers!
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esde
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PostPosted: Tue May 28, 2024 4:08 pm    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Hey there ZwitterKafer, that is a good question, and a detail that I didn't document. I actually got yellow marking compound on my hands, and then everything that eve and stopped taking pictures. If I had been rebuilding a ring and pinion back into their native case, I wouldn't stress the pattern and would just put it back with he same shims it had. But, as I had to use a different case, I was nervous and did check the pattern. I was lucky and the pattern was acceptable the first time. It could be better, but changing it meant finding bunch of shims that are only available from the people that hoard them... so I left it alone. The contact is well centered on the tooth, but slightly towards the outside of the ring gear radius, and slightly more backlash than is spec for a new build. If I had a thicker pinion bearing shim, it would have moved the pinion into the ring, possibly correcting the pattern and backlash. But then I thought about how many gearboxes I've torn down that were very loose, and didn't make much noise, and decided to give this a shot. Fingers crossed right?
SD
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PostPosted: Tue May 28, 2024 11:00 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Just now I discovered and went through the splitcase transmission rebuild in this thread. Looks like nice work that followed the workshop manual, but I have a question: After the final pinion adjustment, did you check the contact pattern between ring and pinion? It will be interesting to see how it performs and if it runs much quieter than before.
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TomVaughan64
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PostPosted: Tue May 28, 2024 10:25 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Thank you for the information on the Blue WW seals. I am getting to that point on one of my projects and now I will know what to watch for.
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Dan22
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PostPosted: Tue May 28, 2024 9:18 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Show us how you mount your full flow oil filter, please!
Very Happy
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PostPosted: Tue May 28, 2024 8:42 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Wow. That's a good P.S.A. on the seals, thanks. And they are my usual go-to source for these goodies, and Poppy needs a right-side seal right now Confused
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esde
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PostPosted: Tue May 28, 2024 5:44 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Passenger side axle seal was leaking, which led to lots of bad words and gear oil spots on my barn floor.
First time I pulled the drum and discovered this:
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you can see a bit of the o-ring pinched between the axle and shim, I figured this was maybe the issue and replaced it. Nope, still leaking
Even though the spacer was stamped VW and had a nice surface, I swapped to for a known good one. Nope
Break down and replace the seal, which was a brand new seal from WW.
Remove the old one and this is what I find
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Now, by this point in my life I've replaced hundreds of oil and grease seals, and I'd be shocked if I had caused this, but hey I'm not immune from making a mess of things, so maybe it's my fault. I cleaned everything up, make sure the seal bore is clean and deburred the edges, and install a new blue seal from WW.
Which promptly tears the same way. ARGH.
I installed a cheap generic black seal two days later, and all is good so far. I am going to draft my email to the guys at WW regarding this. The seal compound has terrible tear strength; I installed the second one on a press, so it was perfectly square to the bore, and watched the blue rubber just bunch up and come loose along the edges.
BEWARE:
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And then on to more fun. Adjusted and attempted to bleed the brakes, which were uncooperative. Ended up replacing the master, even though it looked sort of fresh, and bingo! Everything bled perfectly.
One of the cool things about these cars is that when the system is clean and has good lines and hoses, they will pretty much gravity bleed. Just needed to pump the brakes to get the last air bubbles to the end, and one last pump to get clear fluid, and better than ever before. SO CLOSE
Just need to mount the oil filter (this engine has a full flow filter) and improvise a signal indicator ground (due to some wiring gremlins) and we will be test driving.. hopefully to the farmers market next weekend.
SD
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PostPosted: Sun May 19, 2024 2:01 pm    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Quote:
we are going to repair this pad. It's unusable as is, shedding and falling apart. But, some friends that are art conservators had suggestions and hell, it's worth a shot. I'm going to add a layer of horse hair, and see if I can encapsulate the whole thing in black urethane bed liner. It seems to be some sort of rubber or bitumen coated sisal or horsehair, so I think this idea is not too far from the original.. and I don't have anything to lose..

The horsehair/coir mat served as an intermediate layer under the cardboard trunk liner, to spread out heavy items placed directly on the cardboard because the trunk floor had dips and metal pipes which could broadcast thru the cardboard.

How about getting some 1/2" or 3/4" thick woven jute material from a fabric store, making a rough tracing of the entire area using your remnants, then spraying them with 2 coats of rubberized undercoating? That would give you the resiliency of the original along with moisture protection, and a near-stock appearance. A friend in CT used that approach to make under-carpet sound insulation floorpan mats for his Ghia a few years ago. Might take a few days to fully dry, but with our warmer spring days you could hang them up on a clothesline outside in the sun.
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PostPosted: Sun May 19, 2024 8:50 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Awesome update! Jimmy loves ice cream! Especially with sprinkles! This Jimmy loves ice cream with sprinkles! So, I would bet your Jimmy does too!

You may want to just want to use a cheap, insulated butt connector on that exposed wire connector. I would hate to see you allow the smoke out of the wires!

Have you seen the tools in this thread?
https://www.thesamba.com/vw/forum/viewtopic.php?t=86982&highlight=tool+kit

Engine looks great!
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GFY's Xevin and VW_Jimbo! Smile
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esde
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PostPosted: Sun May 19, 2024 8:22 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

67rustavenger wrote:
Seth, The trunk liner/under liner question came up recently in the 58-67 forum.
Matthew Hendricks had a suggestion and Andy T. as usual had factory info.
https://www.thesamba.com/vw/forum/viewtopic.php?t=791639&highlight=liner

Sadly, no one makes a re-pop under liner.
Being the clever guy that you are, I'm sure that you can make a suitable replacement under liner.

I've seen some bogged wiring hacks before. But never a split nut for the headlight wiring? WOW!


Sooooo, after some discussion, we are going to repair this pad. It's unusable as is, shedding and falling apart. But, some friends that are art conservators had suggestions and hell, it's worth a shot. I'm going to add a layer of horse hair, and see if I can encapsulate the whole thing in black urethane bed liner. It seems to be some sort of rubber or bitumen coated sisal or horsehair, so I think this idea is not too far from the original.. and I don't have anything to lose..

I was all over the car tracing electrical gremlins last night till 3, and pretty well identified the worst issues. Some will get fixed now, some later, or over time.. it's just too much to do at once. I eliminated a relay and re fed the turn signal circuit, and magically they worked again! Imagine that, eliminate several feet of added wiring and we eliminate the problems! Who would have thought.
I may keep the headlight relays though, as it does keep full load out of the switch. If I do keep it I'll get rid of the sketchy crimp connectors and clean up the installation. And the split bolt is just special. I expect to see them inside a trough while tracing splices in industrial buildings, not under the hood of my car. Though I need a long term plan for the wiring before I change it, so for today it gets wrapped and stays.

And, while looking for the throttle tube spring assembly, I found this tool roll that I got from a 55 parts car. It's missing all the tools, but I can find them over time and it will stay with Jimmy. If anyone knows what tools are appropriate please speak up!
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To end on a positive note, I roughly timed the engine, and it fired right over. I love it. Getting closer to my first run to the ice cream stand..
SD
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67rustavenger
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PostPosted: Sun May 19, 2024 5:12 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Seth, The trunk liner/under liner question came up recently in the 58-67 forum.
Matthew Hendricks had a suggestion and Andy T. as usual had factory info.
https://www.thesamba.com/vw/forum/viewtopic.php?t=791639&highlight=liner

Sadly, no one makes a re-pop under liner.
Being the clever guy that you are, I'm sure that you can make a suitable replacement under liner.

I've seen some bogged wiring hacks before. But never a split nut for the headlight wiring? WOW!
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GFY's Xevin and VW_Jimbo!
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PostPosted: Sat May 18, 2024 6:35 am    Post subject: Re: 56 vert Jimmy Sprinkles Reply with quote

Nice update Seth...looks like you're moving in the right direction for some summer driving. I'll be interested in the "rewire" project as I'll be doing a complete harness in my 55. I'm gonna upgrade whatever I can when doing so as I'll be 12 volting my bug and want to be sure to have circuits for whatever a 55 doesn't have...

Jim
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