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Old June 22nd, 2005, 02:19 PM   #1
STROHMA
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Join Date: Aug 2004
Location: Ohio
Posts: 17
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Since I finally got my Bug to a point where a picture actually looks like something I decided to do a introduction.

First this is my first voyage into VW Air cooled. I've prievously built a 67 Mustang convertable several camaros, a few differnt trucks, And a 74 Bronco. I figured it was time for a bug. The last VW I owned lasted about 10 minutes, it was a 81 Rabbit Diesel and I drove it in a demolition derby. Split the car completly in half and it was still running. If I wouldn't have lost the clutch I would have still been in it.

Anyway on to the Bug. Its a 1972 standard I bought completely stripped out. Shell came on one truck and everything else on another. Talk about a jigsaw puzzle. I'm still trying to identify some pieces left over. It started out as a standard 4 speed but since my wife can't drive stick I located a AutoStick to put in it. Most people call me crazy for taking out a good 4 speed and going to a out of production trans. but when it all in pieces whats a few more.

It took almost a year to go from parts to this
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Old June 22nd, 2005, 02:29 PM   #2
STROHMA
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I started with the pan replacing both halves because the PO left it sit outin the back yard for 7 or 8 years seperated from the body. While I was at it I rebuilt the beam adding adjusters to drop the front some. The pan was then coated top and bottom with bed liner I'll see if it works for undercoating. I tore apart the IRS only to find out everything was new CV's bushings and seals. Next I replaced all the brakes I never skimp on brakes. In the future I plan on going to Disc at least on the front but for now drums will have to do.

After the pan I turned to the engine. The problem was the engine only turned 1/4 turn then stopped dead. Again the PO strikes. Tearing into the heads showed the engine sat outside with the air cleaner off. one cylinder was completely rusted up. This also trashed one head. Further inspection showed the rest was almost brand new. No wear on any thing, So new jugs haeds and various parts and the engine was ready.
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Old June 23rd, 2005, 06:34 AM   #3
STROHMA
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Next thing to be done was a quick go through of the AutoStick tranny. I was able to purchase a NOS pressure plate but every clutch I bought turned out to be a standard 6v 4 speed clutch. Three different Supppliers sent the wrong one. I now have a collection of 6V clutches if I ever get a 6V bug. I ended up getting my old clutch relined at the local truck and transmission rebuilders. After the clutch the next problem was the Oil pump, AutoSticks use a dual pump on the engine It took several days of searching I finally found a company the made the seals for the pump Rebuilt pumps for these a expensive. Other items that were hard to find are Vacuum lines in the right metric size I ended up with US sized that I stretched ( them heavy duty hydrolic line are a pain to stretch out, The rubber bushings on the clutch arm got replaced with nylon bushings I made from high temp nylon scraps from work. I bolted everything together on the pan started it up and it seamed to run fine The transmission even shifted.

The body was completely stripped, the only rust was from where the brake resivor leaked and ate the panel just in front of the hinges, nad some mall pin holes from stone chips. We sand blasted the bad spots, replaced the rusty panel from a cut up piece off the junk Bug I had to by to get the tranny. then a little bondo, lits of fill primer, sealer and paint. It sat for 3 months since I didn't feel like working in a unheated garage lat winter at 10 -20 degrees.

I'll put up some pictures when I find them I seem to have misplaced all th resto pics on my computer.
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Old June 23rd, 2005, 06:46 AM   #4
STROHMA
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I might as well add the next saga of this introduction even though I haven't finished figuring out everything. I always heard VW air cooled engines were easy to work on. Why can't I get this one to run right???? [img]style_emoticons/<#EMO_DIR#>/confused.gif[/img]

First test drive the car ran great at 35 mph. at 50 it topped out then slowed down to 40 after a mile. It overheated and died. After cooling down I limped it home. I checked the timing and found out it was almost 40 degrees retarded, I can't believe it even ran like that. So I retimed it replaced a dirty fuel filter ( rusty gas lines eat these things up quick). Second test drive it ran good all the way up to 60MPH I didn't want to go any faster on a new engine. When O got home it was smoking hot. If you search the cutting board you'll see the dialog on this issue. Thanks to the board I believe I found the problem. Someone in the past removed the bottom air deflectors on the engine. Since they weren't there and ths Bently manual doesn't mention them in the section for rebuilding an engine I didn't even know about them, That sucked.

I was to lazy to pull the engine and tear it down for a couple little tins, so I bought adjustable push rod tubes ( the good expensive ones not the cheap plastic ones) and in about an hour and a half I had lower cooling deflectors. I started it up, Ihad to play with the carbto get it to idle having problems wit it also. after about 2 mins messing with it I noticed oil all over the floor. I guess I didn't get a tube in right because it pumps it out as guick as the pump can run. Going to have to tear it apart again. Hope the second times a charm.
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