tag:blogger.com,1999:blog-58208249946342855712024-03-06T01:23:59.255+01:00Volksback...just another aircooled addict...Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.comBlogger431125tag:blogger.com,1999:blog-5820824994634285571.post-37085019443167588782021-01-02T12:10:00.001+01:002021-01-02T12:11:59.803+01:00Franzis Adventcalendar VW Käfer: The final product <p>Here are a few pics of the final product. The base plate with sound module and a fancy "mirror cover" with the 1970 VW beetle on display.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgElXEuxZsxo0P_7f_I78MffRGae_nyX7FPGl3JQpJkHM1AiVQxzILt9mR3Os54-UCyX0u_CPhwrW9f00qvgP4KoETtOwR_BTZpWQ83vWoy25rLx0h_1fUnxnmyXlU_gfyaKrDSMBvoUGQx/s2048/IMG_20210102_114428.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgElXEuxZsxo0P_7f_I78MffRGae_nyX7FPGl3JQpJkHM1AiVQxzILt9mR3Os54-UCyX0u_CPhwrW9f00qvgP4KoETtOwR_BTZpWQ83vWoy25rLx0h_1fUnxnmyXlU_gfyaKrDSMBvoUGQx/w640-h480/IMG_20210102_114428.jpg" width="640" /></a></div><p>The sound module tries to replicate the typical boxer engine sound, but it sounds a bit like it was recorded with the microphone in a tin can, so the sound is far from perfect, but okay for such a toy.</p><p> There were 2 different background displays - mountains and a lake: <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHI_JCce7Ww_Db87wd-kzNNy7kcmtRHF7mD0yaWUOWgKs12yrwrFq_dVKAAcd3RmB8JpSzYYhrvnRVmmcZ59QOGXQ_GQDPeYWAKZJ2lUTdKclPMOK7_W6Sp1f8MeyfUbst1P103zyJ16nO/s2048/IMG_20210102_114438.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHI_JCce7Ww_Db87wd-kzNNy7kcmtRHF7mD0yaWUOWgKs12yrwrFq_dVKAAcd3RmB8JpSzYYhrvnRVmmcZ59QOGXQ_GQDPeYWAKZJ2lUTdKclPMOK7_W6Sp1f8MeyfUbst1P103zyJ16nO/w640-h480/IMG_20210102_114438.jpg" width="640" /></a></div>and a british looking cottage:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhJIvZRBP2V6KCrPVwwuuE3_wA9ZJq_sAt07B7e1YeJD939N632cF0Xv18eyI7d75j4kv4ns-LnrMNW8cIC4OTWMubLY2rzq3gCze2-4QFFtLcKEBM-6wQuxqBtHftt6FWkzKelzPTDYcy/s2048/IMG_20210102_114508.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhJIvZRBP2V6KCrPVwwuuE3_wA9ZJq_sAt07B7e1YeJD939N632cF0Xv18eyI7d75j4kv4ns-LnrMNW8cIC4OTWMubLY2rzq3gCze2-4QFFtLcKEBM-6wQuxqBtHftt6FWkzKelzPTDYcy/w640-h480/IMG_20210102_114508.jpg" width="640" /></a></div>As there were 24 "pockets" to fill, besides the beetle in pieces, there was a whole bunch of other "crap" comming with the model, like a set of memory cards with some info about the beetle, a soft cloth to clean the mirror and a book which also had a lot of history of the VW beetle as well as a daily page with info about the "gift of the day" and little a note pad with self-adhesive stickers.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG5BczFgZhCRWd-DiRD93iEGU8KKQn_v8WMQjTyMQemMjL25uTeH00PGBNDiue5wxdMBSrCJq_Ypu2Zbizj39H29XnoiNp-H8hdAezeo0k6FoH_Psj18cS7npQXXhdZV6bEAGqhnUBMPx0/s2048/IMG_20210102_114548.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG5BczFgZhCRWd-DiRD93iEGU8KKQn_v8WMQjTyMQemMjL25uTeH00PGBNDiue5wxdMBSrCJq_Ypu2Zbizj39H29XnoiNp-H8hdAezeo0k6FoH_Psj18cS7npQXXhdZV6bEAGqhnUBMPx0/w640-h480/IMG_20210102_114548.jpg" width="640" /></a></div><p>There was also a screw driver for the tiny screws and a little "tool box" of cardboard, to store the small items during the build phase. (Not shown in the picture)<br /></p><p>Maybe for the die-hard VW beetle enthusiast nothing really new to learn, but it was a funny experience, even though some of the "gimmicky" presents were a little lame...</p><p><br /></p><p>The model itself is a Welly VW beetle, with a solid body, no doors or hood to open. <br /></p><p><br /></p>Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-25318088144125801032020-12-15T17:33:00.001+01:002020-12-15T17:35:57.400+01:00Franzis Adventkalender VW Käfer: kein Ton? No sound on Franzis Advent calender VW beetle?<p></p><p> My lovely wife gave me the Franzis Advent calendar for this year's pre-Christmas time.</p><p>Today,
the button for the sound module was the "gift of the day" and it was
supposed to start the sound module. Unfortunately, it didn't do
anything! So a little analysis showed that the battery box prevents one
of the battery contacts to actually get contact! </p><p>But don't worry, here is the solution to the problem: Remove the battery box from the base plate and flip it over, like so:<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqA8O3PwYy20QRFY__yoCxuom2JJhuxk88_yGWxes-22i5d-P6C6vtm3y8bzD4IqwVe-aiNryTgaEmv5ew98h5_RFwW54FdAkffdjh7hEz8RyRPW4ue2C3MRUw9XsjVqeCBw1cnXLVDKo/s2048/IMG_20201215_165516.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqA8O3PwYy20QRFY__yoCxuom2JJhuxk88_yGWxes-22i5d-P6C6vtm3y8bzD4IqwVe-aiNryTgaEmv5ew98h5_RFwW54FdAkffdjh7hEz8RyRPW4ue2C3MRUw9XsjVqeCBw1cnXLVDKo/s320/IMG_20201215_165516.jpg" /></a></div><br /><br /><p>Then, carefully pry off the cover of the battery contacts:</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi4YYL6r0EZ7GPkP7_Slk6b5uXovdNMuwmjURT3I1a7ME5yoAJOg-HUZNOjShzP3zMqKzUDAcBMT7jykEQM2Tn_ZrUBlc-knIxAuLWHNDTqmNGgBUbVHjWCYjj4LYxCz113WRze8yADqM/s2048/IMG_20201215_165502.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi4YYL6r0EZ7GPkP7_Slk6b5uXovdNMuwmjURT3I1a7ME5yoAJOg-HUZNOjShzP3zMqKzUDAcBMT7jykEQM2Tn_ZrUBlc-knIxAuLWHNDTqmNGgBUbVHjWCYjj4LYxCz113WRze8yADqM/s320/IMG_20201215_165502.jpg" /></a></div><p>Then remove material with a file in these areas:</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH9Ls8MipibMCoYfcX3GhA63agjvSvenuC3KnZMQdiJTH-xSK1yaH8GzXlJbWtWYIitX0oFxcaLSTkXDR1o6EY1Ium-J1Q7-QoXr9grtlnVcZrZ3S3127dJn1E1YVpXSM7hnwp0J_O6rM/s388/Batt2.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="188" data-original-width="388" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH9Ls8MipibMCoYfcX3GhA63agjvSvenuC3KnZMQdiJTH-xSK1yaH8GzXlJbWtWYIitX0oFxcaLSTkXDR1o6EY1Ium-J1Q7-QoXr9grtlnVcZrZ3S3127dJn1E1YVpXSM7hnwp0J_O6rM/s320/Batt2.JPG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgW-TJIliFO0N07xe3TkP6J71P6_wdWQ6AlT-uJnL4V-eNluO5M6tIOGJ2IpQIGUT3En4OMbHEs_eqK8HAPfsSrrpncLIq4mpH6ik3cadv9dm1iNIr8Vu0lEF471blApEpTMLTYBdKgV8g/s412/batt+1.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="228" data-original-width="412" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgW-TJIliFO0N07xe3TkP6J71P6_wdWQ6AlT-uJnL4V-eNluO5M6tIOGJ2IpQIGUT3En4OMbHEs_eqK8HAPfsSrrpncLIq4mpH6ik3cadv9dm1iNIr8Vu0lEF471blApEpTMLTYBdKgV8g/s320/batt+1.JPG" width="320" /></a></div>Depending on the type of battery you use, the dimensions might be a little different, but the general idea is, to remove material to allow contact of the "+" side of the battery box.<br /><p>Assembly in
reverse order of assembly and your sound module should sound like a
beetle!</p><p>On December 24th I will post the complete project!<br /></p><p><br /><br /></p>Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-66583798617233445792020-04-29T22:47:00.000+02:002020-04-29T22:52:24.738+02:00Oil cooler project finally finished!After lots of angle grinding, hole drilling and thread cutting, it is finished!<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgY4F97gWr3RW9WtynRPEPgp6bFi_0Kls4386AsST3DXeAVLCQhimORMpUysm-WCNEBi-z79mlYWHNYNybdn3NkK-g92GZlGmUapFPUo1D-zzrBQ9X7bEJCFmpMXYCkgcO7RS4R77u7jgS9/s1600/IMG_20200425_190424.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgY4F97gWr3RW9WtynRPEPgp6bFi_0Kls4386AsST3DXeAVLCQhimORMpUysm-WCNEBi-z79mlYWHNYNybdn3NkK-g92GZlGmUapFPUo1D-zzrBQ9X7bEJCFmpMXYCkgcO7RS4R77u7jgS9/s640/IMG_20200425_190424.jpg" width="640" /></a></div>
Some details of the 3mm steel plates I used for the brackets (again, captive nuts were used)<br />
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Here is the cooler already fitted, the oil lines are not finished yet in this pic (another set of 6 captive nuts in hindsight of a cover with vents, to be mounted later)<br />
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And a view from the side:<br />
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And the finished article, plumbed and oil tight!<br />
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Currently I am designing a metal shield with cooling fins to improve the already good airflow even more!<br />
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Besides the improved cooling abilities, I also wanted to get rid of the "chaos" in the engine bay, I think it worked out well:<br />
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before:<br />
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after:<br />
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(Yes, I know, the vent hoses looks like garden hose, but it was supplied by CB performance, with the Type 3 specific vent housing. It will be replaced with "proper" hose soon!)<br />
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all of this cluttered mess is gone:<br />
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Here are a few shots of the creating, fabricating and assembly process:<br />
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This is the initial sketch - for me, most of it still makes sense, even though, I changed a lot of details along the way... <br />
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I also added another piece of sheet metal to improve air flow on the 3/4 cooling tin. There is a rectangular opening to release the hot air, after it passed the oil cooler, here is a pic of such an original cooling tin:<br />
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This opening could be closed, now that there is no oil cooler any more, it will improve the cooling of cylinder 3/4 as more air volume will flow over the cylinders now.<br />
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Here is the metal cover, I used a simple tab on one side and an existing thread on the other side, thus I could slip the cover onto the already mounted tin:<br />
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This is a mock up of the final assembly set up: <br />
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(Of course, the cooling tins on my engine are not that messed up and rusty!) Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com1tag:blogger.com,1999:blog-5820824994634285571.post-22210653389603322012020-04-21T21:22:00.002+02:002020-04-21T21:22:37.399+02:00The first cut is the deepestThe oil needs to travel from the adapter to the oil filter, behind the firewall. A hole in the fire wall is a first step. (A lick of rust protective primer hopefully prevents rust on the cut line). To make this mess a whole neater, another aluminium cover, painted in black wrinkle finish, equipped with proper rubber grommets to protect the oil lines was fabricated. M6 Captive nuts allow for a neat installation of the cover:<br />
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-30724121834379065362020-04-21T21:13:00.001+02:002020-04-21T21:13:26.843+02:00Major Tom to ground control"Ground" is the key word here. After final assembly of the oil filter / adapter, the oil temperature / warning light sensor had no ground. So, the oil pressure showed a constant 10 bar and the "idiot light" did not come on. An update in the ground connection was necessary - but how? The sender unit only has 2 contact prongs, one for pressure and one for warning light. The M10x1 thread for attachment to the oil line is conical, so, no way to attach a ground strap...<br />
The solution was to ground the housing itself!<br />
Today shown a little different - In a short photo story:<br />
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(forgive my booger welds)<br />
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a little zinc spray to avoid corrosion<br />
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Ground strap attached! The sender is fully functional again<br />
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com1tag:blogger.com,1999:blog-5820824994634285571.post-71915958856846294442020-04-17T15:06:00.000+02:002020-04-17T15:06:35.046+02:00Peter Kramer's California Käfer Shop / Stage FrightRecently I mentioned Peter Kramers "California Käfer Shop" in one of my posts. When he was still located in Dortmund, basically on a scrap yard, this guy had it all, one piece windows, Baja bug kits, cheap taiwanese chrome parts, performance exhausts - you name it. A good amount of my monthly wage in the late 80ies was regularly brought to his shop. I still see the guy from time to time on the Maikäfertreffen or selling Hot
Wheels and neon signs in the Techno Classica Fair in Essen, but this
shop was the only source for rad Cal look parts since the mid 80ies.
Also he sold the American "Hot VW's and Dune Buggies" and "VW Trends" magazines for 5 DM
instead of the 12 DM you could buy it for at the book store of the main
train station in Essen.Well, he was - and probably is still - a special
character, but also thanks to his engagement and his shop, I became the
VW nut I am today - and since the mid 80ies!<br />
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Here is a key ring I still own, with the image of his "promotion vehicle" at the time, which he later sold to Helge Ohmes, the famous VW Dragster Bug "Stage Fright" - originally built in Bakersfield CA by Michael Irvin<br />
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-1560599025737073772020-04-17T15:05:00.001+02:002020-04-21T20:45:30.820+02:00The Spaghetti IncidentYes, another album title, but here it is all about the relocation of the ignition coil and cables, to remove as many cables from visibility:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipEFzaJ1GshZ125Jh2nocY-CDwkHbeXPmORBkdwnMHUjKNAdM9az2ObHbVeGJ8rMNRZMCmg0qcJt3TIo-96RB43p3OyyG-UOcfPwh1xHojERMjzTXsxtTcj5zAfOjh3qcqNSJ68omaJLI5/s1600/IMG_20200416_180530.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipEFzaJ1GshZ125Jh2nocY-CDwkHbeXPmORBkdwnMHUjKNAdM9az2ObHbVeGJ8rMNRZMCmg0qcJt3TIo-96RB43p3OyyG-UOcfPwh1xHojERMjzTXsxtTcj5zAfOjh3qcqNSJ68omaJLI5/s640/IMG_20200416_180530.jpg" width="640" /></a></div>
This lot of wires could be removed <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIb8fn_NDrR1HrKAS5UWbQ1niBRFbPIIfxMYPoTAsa3BhZt-Upa1Sp_CVhJqFDaccA3FJOwOJ5yk9uyK-cukbakvGW8WgshfMOlbfuDSMT5D9Mvh4jtXhX-kY1P9zvn3qggEvcqU-JpG5X/s1600/IMG_20200416_180546.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIb8fn_NDrR1HrKAS5UWbQ1niBRFbPIIfxMYPoTAsa3BhZt-Upa1Sp_CVhJqFDaccA3FJOwOJ5yk9uyK-cukbakvGW8WgshfMOlbfuDSMT5D9Mvh4jtXhX-kY1P9zvn3qggEvcqU-JpG5X/s640/IMG_20200416_180546.jpg" width="640" /></a></div>
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The coil is relocated to the left side of the engine compartment. Almost all wires are invisible now. It will only become apparent after final assembly, but if you compare this to the "before" status, you get the idea: Especially around the oil cooler and coil area, all sorts of wires strewn around</div>
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Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-70726670752167007232020-04-17T14:06:00.002+02:002020-04-21T20:45:46.884+02:00electric fuel pump installation finalizedThis is the final set up of the fuel pump:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQFVSApotA-VWB8NyPtSVLP_RgXLuplD9nCwkulCctlApEakgxO_bzQwJPZEeQIthEkhXNr8K4pcl-1t2mUgtAWWoH7YEn7lqzvkAB_RZjLrEqkwxHGLEIFShLMzefsTP_NYK1AJU7m9g-/s1600/IMG_20200417_125313.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQFVSApotA-VWB8NyPtSVLP_RgXLuplD9nCwkulCctlApEakgxO_bzQwJPZEeQIthEkhXNr8K4pcl-1t2mUgtAWWoH7YEn7lqzvkAB_RZjLrEqkwxHGLEIFShLMzefsTP_NYK1AJU7m9g-/s640/IMG_20200417_125313.jpg" width="640" /></a></div>
The bulkhead cover, fuel pump, filter and fuel line as well as the electrical connections, all in their final position, ready to run!<br />
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Here is a view from below, the routing of the complete systemcan be seen here:<br />
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2 rubber damped clamps lead the fuel line into the perfect contour Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-520435158023618322020-04-13T14:02:00.001+02:002020-04-21T20:47:11.961+02:00old school cool!With the mechanical fuel pump deleted, I had to cap off the mounting hole for it in the engine block.<br />
I knew I had such a block off plate since years somewhere in my parts stash. I must have bought in the early 90ies in a shop, known to every VW nut in Germany at that time, Peter Kramer's <b>California Käfer Shop</b> located in Dortmund, later moved to Schwerte. <br />
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Here it is, a CB performance cover in the old style packaging:<br />
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It is a perfect match to the new breather housing: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikDW-jT0qU9gmUmDI4z-Zb40fYNrgS7VYUleSD0vSx6Ft9XJTyfO1m9MmSxVx0ooOjuDKuPpkyVCHWYbgqPnCGk-wsX-zLGf2c9wsXmB8EvlNqQWizDgqqOX4w8RwTrxsxtjlymVcDYXzT/s1600/IMG_20200328_161940.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikDW-jT0qU9gmUmDI4z-Zb40fYNrgS7VYUleSD0vSx6Ft9XJTyfO1m9MmSxVx0ooOjuDKuPpkyVCHWYbgqPnCGk-wsX-zLGf2c9wsXmB8EvlNqQWizDgqqOX4w8RwTrxsxtjlymVcDYXzT/s640/IMG_20200328_161940.jpg" width="640" /></a></div>
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-38347244904569127182020-04-13T13:18:00.001+02:002020-04-21T20:47:24.170+02:00breathe easy and keep your cool!A friend of mine offers an upgrade kit for the IDF 40 Weber carbs, allowing to increase the Venturi size from original 28 mm to 34 mm. Also, the spray bar is a completely different design with a more even spray pattern. I purchased this kit already 3 years ago, but never had the itch to mount it. But with the car now in pieces anyways, it was a good time to install the kit:<br />
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left side: og spraybar and 28mm venturi (2-pc design) right side: one piece 34 mm venturi with incoporated spray bar<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhO4aqhyG60KBFNDirjvpUtDilwLo66ud4IS1Qfutezi9NGzZ2HUyzimFz0X9EmJAkhU3ecjcAIsI-PeMo56ItvKoNXrPQHvzVpaCabzbQuEZzGO8wEdTQtKdnSfQC8rpW8lq3483zd86J5/s1600/IMG_20200405_182014.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhO4aqhyG60KBFNDirjvpUtDilwLo66ud4IS1Qfutezi9NGzZ2HUyzimFz0X9EmJAkhU3ecjcAIsI-PeMo56ItvKoNXrPQHvzVpaCabzbQuEZzGO8wEdTQtKdnSfQC8rpW8lq3483zd86J5/s640/IMG_20200405_182014.jpg" width="640" /></a></div>
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and this is one of the finished carbies, with both new venturies assembled:<br />
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When everything will be assembled, I'll also add another heat barrier under the Webers, original VW "Pertinax" seals, of course with enlarged inner diameter to fit to the ported heads:<br />
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-62283623527004030742020-04-13T13:02:00.001+02:002020-04-21T20:54:24.047+02:00Packaging the oil filter and thermostat housingThis was an epic challenge. As you probably know, the old air cooled Volkswagens were not equipped with an oil filter, which might be o.k. for a stock engine, but with the added displacement and performance, I wanted to add an oil filter with the external oil cooler. The filter shall be mounted in a way allowing to service it, but not block the access of heater cables, fuel lines, clutch cable etc.<br />
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After hours of playing with mounting locations and options how to possibly mount it, I came up with a solution which shall allow to mount it, but also be able to replace it easily. In the left rear area behind the wheel well:<br />
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This time I will start with a picture of the final article, but the way to get here wasn't that easy!<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2NXef9ppKt9KtOJVlFopB00AE0itNM_KkRNVjimS8lgXqdavHoEAnQ7WT_oZDtekcAjPhEPn9iPVc93seqxWPIRKkUtgcKYevq79a5pufijdMKmzL9tv1r_29RRNaONlUM5RXUC9WYkXX/s1600/IMG_20200411_162913+-+Kopie.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2NXef9ppKt9KtOJVlFopB00AE0itNM_KkRNVjimS8lgXqdavHoEAnQ7WT_oZDtekcAjPhEPn9iPVc93seqxWPIRKkUtgcKYevq79a5pufijdMKmzL9tv1r_29RRNaONlUM5RXUC9WYkXX/s640/IMG_20200411_162913+-+Kopie.jpg" width="480" /></a></div>
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With the decision of the location finalized, I had to find a way to mount it here. A bracket of 5 mm thick mild steel was the solution.<br />
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It is basically "L"-shaped, following the contour of the filter housing with a 2nd plate welded on, to accept the fixation points of the housing.<br />
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and this is the designated position of the bracket (positioned with my fingers only):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQCpGCpgPruZfAmuTIZtsuWj7QP81J3BELC4wqtor7GYyt9OzQ4eUcSc2APsI-Ph-rXz-jg-ydvVBAfomsarVUBVgQhNkM6NykXjw-bmDeR9unrgXHrV3CvDDIH-Z7VmTCE-p7w4mGQMXP/s1600/IMG_20200409_195010.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQCpGCpgPruZfAmuTIZtsuWj7QP81J3BELC4wqtor7GYyt9OzQ4eUcSc2APsI-Ph-rXz-jg-ydvVBAfomsarVUBVgQhNkM6NykXjw-bmDeR9unrgXHrV3CvDDIH-Z7VmTCE-p7w4mGQMXP/s640/IMG_20200409_195010.jpg" width="480" /></a></div>
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With 3 M8 screws attaching the filter to the bracket, it seemed only logical to use more than 3 bolts to mount the whole assembly to the body. So I used 4 M8 captive nuts to for a strong attachment set up:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwvYfnaEgR9655W3pd-Vm3vY5-dl8NfSyj7dmdFtacL2X65twPFuCY6zubFjuPd5Ky1J0jkmJ5q4W6Hcg0xSWwq_xyusbfnMK7ufBLtP-j7Ml7uLIuKNqNieyiurFN-krXX4jeppXRbErV/s1600/IMG_20200411_135515.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwvYfnaEgR9655W3pd-Vm3vY5-dl8NfSyj7dmdFtacL2X65twPFuCY6zubFjuPd5Ky1J0jkmJ5q4W6Hcg0xSWwq_xyusbfnMK7ufBLtP-j7Ml7uLIuKNqNieyiurFN-krXX4jeppXRbErV/s640/IMG_20200411_135515.jpg" width="480" /></a></div>
(Yes, there is a fifth hole, but it wasn't usable, as it is located
exactly in a depression of the beam. I used it to fill the beam with
fluid film cavity protection and capped it off with a rubber plug) <br />
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Here is the sub-assembly of the bracket and filter housing, already attached with lock nuts:<br />
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and another picture of the final assembly, mounted into the vehicle:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhROIfX15Z4if5sw-xNWMjjkw6BbXEt6pHSYp46NN1g_3t4l9B9eMqpG-gtaK-x-e_UUAjXh5mc4jjOxdHcxnUOhyphenhypheng6eDnB0ZqLC2m90rXpRXMwuvlS5ioLgmIW-IUSHTfun7GOmi8_rTIE/s1600/IMG_20200411_162913.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhROIfX15Z4if5sw-xNWMjjkw6BbXEt6pHSYp46NN1g_3t4l9B9eMqpG-gtaK-x-e_UUAjXh5mc4jjOxdHcxnUOhyphenhypheng6eDnB0ZqLC2m90rXpRXMwuvlS5ioLgmIW-IUSHTfun7GOmi8_rTIE/s640/IMG_20200411_162913.jpg" width="480" /></a></div>
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The oil pressure and warning light sender is also installed here, making the engine compartment a little neater with less cables. Oil hose routing is the next challenge!Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-35401813100317375592020-04-13T12:36:00.000+02:002020-04-21T20:55:29.089+02:00electric fuel pumpIn an effort to get the engine compartment a little cleaner with as much clutter removed as possible, I will change from a mechanical to an electric fuel pump. It will be attached to the front bulk head. There is a cover already, which I will replace with a self made aluminium one, with incorporated captive nuts for fuel pump attachment.<br />
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top is the original bulk head cover, bottom is the aluminium replacement. The og cover has a raised section, which takes away some precious space, so the new one is flat: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsGJ7yCAxndSnu6_8u9V1aabaDL2DQnAyeqMCE6qVrC6hhoXdOg1gtUv3aEeQCaTZd5N_V_gSIljha3dLduHzQNcPv7RPcDVCLfkgrqarzL8965MEnucW73ezgVZkmiUG4epr37lXm9Q_a/s1600/IMG_20200402_154434.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsGJ7yCAxndSnu6_8u9V1aabaDL2DQnAyeqMCE6qVrC6hhoXdOg1gtUv3aEeQCaTZd5N_V_gSIljha3dLduHzQNcPv7RPcDVCLfkgrqarzL8965MEnucW73ezgVZkmiUG4epr37lXm9Q_a/s640/IMG_20200402_154434.jpg" width="640" /></a></div>
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I am a big fan of wrinkle finish paint, so I painted this cover with it:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgr0-bs6a2gO_5ccyd0Y1J4rJRm2oCyxXfO0x_Y89131L7_QkccPHAJtp6A7YHUpSgj0JbQ7ERkZpqaEynFhbQl9NT_IEg35STSV_ozmZgvh91SDngLxTMov_zTseMM5eo7zikJCUWQQKYJ/s1600/IMG_20200402_162308.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgr0-bs6a2gO_5ccyd0Y1J4rJRm2oCyxXfO0x_Y89131L7_QkccPHAJtp6A7YHUpSgj0JbQ7ERkZpqaEynFhbQl9NT_IEg35STSV_ozmZgvh91SDngLxTMov_zTseMM5eo7zikJCUWQQKYJ/s640/IMG_20200402_162308.jpg" width="640" /></a></div>
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This is the assembled status, with two rubber lined mounting brackets for a robust attachement, but also some noise reduction:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5QEM-fF0ZGXuuONkJKolm_hQdiEWvkL3MqGv6LPiwS4s_4TKO60-qx-pQcFIPBiagn0870wUBUpv6irGQEFFCIegePNBIOonxcUihADE5h2uu02pn9FJvyj2QeHFl2mGuDgtoIbSO73-G/s1600/IMG_20200402_165803.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5QEM-fF0ZGXuuONkJKolm_hQdiEWvkL3MqGv6LPiwS4s_4TKO60-qx-pQcFIPBiagn0870wUBUpv6irGQEFFCIegePNBIOonxcUihADE5h2uu02pn9FJvyj2QeHFl2mGuDgtoIbSO73-G/s640/IMG_20200402_165803.jpg" width="640" /></a></div>
( I marked the direction of flow and also the positive and negative terminal to make sure everything will be assembled flawlessly)<br />
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New plate already mounted in the Fastback's bulk head: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcujgOBYxd6brkdbyL_CGUiyg1kjXgEMGr6WkICTFOSG7WZuOeG69tCAJJmKa0L-aFJbuoPsXLfDXO5V3xQCC0s0qJiEftsDztnz1H_d8_oom8KQKCe2P5IU_0R8eUBujma_GUzBemaVU0/s1600/IMG_20200402_171209.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcujgOBYxd6brkdbyL_CGUiyg1kjXgEMGr6WkICTFOSG7WZuOeG69tCAJJmKa0L-aFJbuoPsXLfDXO5V3xQCC0s0qJiEftsDztnz1H_d8_oom8KQKCe2P5IU_0R8eUBujma_GUzBemaVU0/s640/IMG_20200402_171209.jpg" width="640" /></a></div>
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The fuel pump has differently sized electrical attachment points, to avoid malfuncton or having the pump running in the wrong direction, so I had to enlarge one of the crimps accordingly:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig8HaWZ1uuzz6dJoAuSfo67iKsDwtdQUD9LfvHgOVV5LOV0bvX3EimBGupUBYOY2bHEv65U5WlE8rUfeKhVOdnLq1aF-9rdSDnbqTRy1mQ4Q_Aj1MshEYxQjCtPBbAQb0dwVfI19TDhS20/s1600/IMG_20200403_121952.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig8HaWZ1uuzz6dJoAuSfo67iKsDwtdQUD9LfvHgOVV5LOV0bvX3EimBGupUBYOY2bHEv65U5WlE8rUfeKhVOdnLq1aF-9rdSDnbqTRy1mQ4Q_Aj1MshEYxQjCtPBbAQb0dwVfI19TDhS20/s640/IMG_20200403_121952.jpg" width="480" /></a></div>
A picture of the final assembly will follow soon!Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-70845880685187870332020-03-29T13:13:00.000+02:002020-04-21T21:00:29.859+02:00re-routing the air flowWhen the original type 3 oil cooler is removed, the engine tin needs to be modified. There is a gaping hole left when the external adapter is installed instead of the cooler. The viably important flow of air for the engine would be lost, resulting in even hotter engine temps and possible fatal engine failure.<br />
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To avoid that, the cooling tin needs a block-off plate in the former oil cooler area. So, in order to "fabricoble" such a plate, the exact set-up needs to be assembled to measure all dimensions needed.<br />
<br />
The
first obstacle was the M8/M6 threaded bolt for the oil cooler fixation. I
vividly remember the problems I had on the 1776 Streaker engine I
assembled some years ago:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigpgWqG-XISc0oiATF4KqMTkhgv8li8SDxd24fBuqdJVjm5YHU5T3trQ6aMX6qX9d2TzFDyfiV4ZSETebbPUuaak801yvHk3mSVMrkbOwSIfM8PjOkmqTBr77P0VL_V12zs2r3WEp0Tt1f/s1600/GEDC0870.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigpgWqG-XISc0oiATF4KqMTkhgv8li8SDxd24fBuqdJVjm5YHU5T3trQ6aMX6qX9d2TzFDyfiV4ZSETebbPUuaak801yvHk3mSVMrkbOwSIfM8PjOkmqTBr77P0VL_V12zs2r3WEp0Tt1f/s640/GEDC0870.JPG" width="640" /></a></div>
Here is the hole story:<br />
<a href="https://volksstreaker.blogspot.com/2014/04/cylinders-heads-and-oil-pump-and-some.html">https://volksstreaker.blogspot.com/2014/04/cylinders-heads-and-oil-pump-and-some.html</a><br />
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This time I was more clever, soaked the thread bolt over night in penetration oil and used grip pliers on the bottom of the pin, to minimze the risk of stripping the bolt. (less flex, less chance of breaking):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVCBhgEvxJQmvNNq701iOlsKfqW4xoYXsqdeh18Ulry8U8IuLWnQZIGBLqumR7BnL3qydzjLv_YqlDgADeY-687ndE-Msqm25ol0VYwRhkbIwql6Z_Tfe_cSfQhGPNNHpsrzYalvumdwW2/s1600/IMG_20200328_131416.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVCBhgEvxJQmvNNq701iOlsKfqW4xoYXsqdeh18Ulry8U8IuLWnQZIGBLqumR7BnL3qydzjLv_YqlDgADeY-687ndE-Msqm25ol0VYwRhkbIwql6Z_Tfe_cSfQhGPNNHpsrzYalvumdwW2/s640/IMG_20200328_131416.jpg" width="480" /></a></div>
Luckily, this time it worked just fine and I was left with a perfect M8 threaded hole.<br />
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It is always a good idea to use brand new seals whenever you assemble things, these silicone oil cooler seals are confirmed to be bullet prove in my last builts, so a new pair was installed:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8qnIPeP2q-Z4ceRr3n687ZSVixPiYtKZQHOb7xne30dqXPO84LLqtPe-6pbSl-qFbRaGX5pclJwDn0JaYoko3Il6pVqLEC6y827vTPFNwfcmhyphenhyphen1GFVIrPyiSv6PGbumdwzhXfZYTrOAou/s1600/IMG_20200328_132914.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8qnIPeP2q-Z4ceRr3n687ZSVixPiYtKZQHOb7xne30dqXPO84LLqtPe-6pbSl-qFbRaGX5pclJwDn0JaYoko3Il6pVqLEC6y827vTPFNwfcmhyphenhyphen1GFVIrPyiSv6PGbumdwzhXfZYTrOAou/s640/IMG_20200328_132914.jpg" width="480" /></a></div>
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The adapter was the next part to be installed and fixed properly:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjl6fVqI_7t86TzwLkQrMwQHfTSlH_VbGQotd7fFqQr3IlMgHA8d2-iMR0cJoKn2Ee6ddWqwkqzE6OPKf7kBN3mMAdRXChqP5-0_ZO99hGTaGRaA9VZvvqtxy8rREFe2rz-0GSjkfCgndix/s1600/IMG_20200328_133309.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjl6fVqI_7t86TzwLkQrMwQHfTSlH_VbGQotd7fFqQr3IlMgHA8d2-iMR0cJoKn2Ee6ddWqwkqzE6OPKf7kBN3mMAdRXChqP5-0_ZO99hGTaGRaA9VZvvqtxy8rREFe2rz-0GSjkfCgndix/s640/IMG_20200328_133309.jpg" width="480" /></a></div>
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Paper or card board is usually the first step for every template I make:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibgC-DjBdUhki-mScXCiYNauSF9-BZiwhsqzg1hXDoNxLgrmtPA6ORMfl9cOqgU8zS-SCKIDP0UoQe7lZm5CHaFsu4qql-MvwQAWTQuV4u-NXHBV-ZgXatlGTRQenC3vZW5ql2zRxGSbGK/s1600/IMG_20200327_205415.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibgC-DjBdUhki-mScXCiYNauSF9-BZiwhsqzg1hXDoNxLgrmtPA6ORMfl9cOqgU8zS-SCKIDP0UoQe7lZm5CHaFsu4qql-MvwQAWTQuV4u-NXHBV-ZgXatlGTRQenC3vZW5ql2zRxGSbGK/s640/IMG_20200327_205415.jpg" width="640" /></a></div>
<br />
transfer to a piece of sheet metal is the next step:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWEcjlanrtQ2bzfW6jrBRNtZ7xAX40EvH3Twq8EGW1GCVrQLxYQXcRlKqZKdSL8PURYgsK4pi_y5wfj7D2c7VljZ-yQ0ts6UEjRZcZOVyr2A3Xx63lJip4WLHvOzmS3vd5P2MPWiusAmjm/s1600/IMG_20200327_211335.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWEcjlanrtQ2bzfW6jrBRNtZ7xAX40EvH3Twq8EGW1GCVrQLxYQXcRlKqZKdSL8PURYgsK4pi_y5wfj7D2c7VljZ-yQ0ts6UEjRZcZOVyr2A3Xx63lJip4WLHvOzmS3vd5P2MPWiusAmjm/s640/IMG_20200327_211335.jpg" width="640" /></a></div>
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Here is the block-off plate in its initial shape:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipzTPUpSoHKkDEHiRtUuhj2APUUYrhVXLNFyixYPitdIVwv2Y6q3qiA2aRMm-LuNrh_AA8IBteVNKZTTk8-q8Ruz1olXlvyLrAX1qlHlOFsoi3FTnRATEl4MxeSwteW5YL5T3Tdniueq0r/s1600/IMG_20200327_214959.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipzTPUpSoHKkDEHiRtUuhj2APUUYrhVXLNFyixYPitdIVwv2Y6q3qiA2aRMm-LuNrh_AA8IBteVNKZTTk8-q8Ruz1olXlvyLrAX1qlHlOFsoi3FTnRATEl4MxeSwteW5YL5T3Tdniueq0r/s640/IMG_20200327_214959.jpg" width="480" /></a></div>
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After fine tuning the fitment, the sheet metal shall be crimped onto the cooling tin<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiv8nSzSIuTTLTjfjNVrYihN123Dijn4z6gVmsKZd-u8uLQ3SahtPdPqL4KeDy-FFZiJpXAcPgJInk5qhhSRq_lAt-56JjXsA3yeXng9I05qYaaSZyJtX3mkKU9nKgbAGQW0_7oxbDcmrqg/s1600/IMG_20200327_220831.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiv8nSzSIuTTLTjfjNVrYihN123Dijn4z6gVmsKZd-u8uLQ3SahtPdPqL4KeDy-FFZiJpXAcPgJInk5qhhSRq_lAt-56JjXsA3yeXng9I05qYaaSZyJtX3mkKU9nKgbAGQW0_7oxbDcmrqg/s640/IMG_20200327_220831.jpg" width="480" /></a></div>
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Here you can also notice the other block off plate in the ignition lead clip area:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijRuT_wyPBTwva28HxrzUZz_XnV4CJdw_ualiSs3w5A9f5oI0mIixraSYmczTYKMpSTXy8sO-ACcYxD1EwvMECbU3ghXG-eHEciln7tPpFG_FbUssUW1kPAycisHScMI9qSD1FY6i722RZ/s1600/IMG_20200327_221348.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijRuT_wyPBTwva28HxrzUZz_XnV4CJdw_ualiSs3w5A9f5oI0mIixraSYmczTYKMpSTXy8sO-ACcYxD1EwvMECbU3ghXG-eHEciln7tPpFG_FbUssUW1kPAycisHScMI9qSD1FY6i722RZ/s640/IMG_20200327_221348.jpg" width="480" /></a></div>
T<br />
he small plate in detail, maybe total overkill to use 4 captive nuts, but where else can you ever use M3 captive nuts?!<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFXv_-_eI-jWY-3MxF37y2tkTuBFoE_2hyHiiNTTMj2VXboL8ZHvs6CiKMXoXKqJRKG1qxsUV3sMKVNUJMcA9vzNBbVCA2KppUUpJWwvSx5QO3B-JjzheChL4ilPY8occtLFhnQ_FgsC8d/s1600/IMG_20200327_192256.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFXv_-_eI-jWY-3MxF37y2tkTuBFoE_2hyHiiNTTMj2VXboL8ZHvs6CiKMXoXKqJRKG1qxsUV3sMKVNUJMcA9vzNBbVCA2KppUUpJWwvSx5QO3B-JjzheChL4ilPY8occtLFhnQ_FgsC8d/s640/IMG_20200327_192256.jpg" width="640" /></a></div>
<br />
Almost finished, card board template vs. finished article<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibGEoIhDtll9arpk6jSP5e-eiEl31ft_N0zsDvFvQA-tab1ZzwPJU0L7gwMPg7wNcJWg9s449oU8nSGSlTjfRDYYwqwCWHr_2vZACg4BIonT5h4OUcwXQCuJEj6x6WqGS1586xpvYjvRtR/s1600/IMG_20200328_162136.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibGEoIhDtll9arpk6jSP5e-eiEl31ft_N0zsDvFvQA-tab1ZzwPJU0L7gwMPg7wNcJWg9s449oU8nSGSlTjfRDYYwqwCWHr_2vZACg4BIonT5h4OUcwXQCuJEj6x6WqGS1586xpvYjvRtR/s640/IMG_20200328_162136.jpg" width="480" /></a></div>
<br />
and finally, everything installed with a small rubber seal on the bottom to avoid rattle and air flow:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxnb61U4jLTbDGtq-iSHFNufEOm2_Ms7jR7sXbqJm9vToPVGDfod3eNwA3zqKt-sYigkDTWkiMi0uXTLQwRI-LVIc_LfkuYriUhljWzfqqfEPcp8QZqBoyyjCPBkBYKP_jv18foLJjwdAM/s1600/IMG_20200328_163624.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxnb61U4jLTbDGtq-iSHFNufEOm2_Ms7jR7sXbqJm9vToPVGDfod3eNwA3zqKt-sYigkDTWkiMi0uXTLQwRI-LVIc_LfkuYriUhljWzfqqfEPcp8QZqBoyyjCPBkBYKP_jv18foLJjwdAM/s640/IMG_20200328_163624.jpg" width="640" /></a></div>
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-9123613958216583912020-03-29T13:10:00.001+02:002020-04-21T21:00:49.860+02:00Let the work begin!As with every modification / repair / improvement, dismantling is always the first step, so I removed the generator, Weber carbs with the (selfmade) linkage, the 123 Distributor and countless wires and lines and also test fitted the breather box and engine case breather / mechanical fuel pump delete:<br />
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-33269132473508108732020-03-29T11:48:00.001+02:002020-04-21T21:31:42.193+02:00Always check new parts carefully!After I received all the new stuff, I started to check them in detail. There were quite some things to improve:<br />
the oil cooler adapter had some burrs in the flow passage of the oil: <br />
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with a little action of the Dremel, I removed those burrs in no time (sorry for the blurry pic): <br />
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As mentioned in my previous post, the fittings of the adaptor looked strange somehow - but only after I tried to assemble a hose fitting. It just didn't work. I measured inner and outer thread diameter as well as thread pitch, all seemed fine<br />
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Upon closer look, it dawned on me that the thread is LH (left handed), so it was no wonder the hose fitting didn't fit!<br />
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-50042971105204231892020-03-29T10:52:00.001+02:002020-04-21T21:32:06.147+02:00New year - new project!Hi to all my Blog visitors - I have to admit, my attempt to blog more in 2019 failed miserably!<br />
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This year I try my best to improve! With the ongoing Corona virus I guess there will be plenty of time to do updates and new stories. <br />
The biggest modification for the Volksback is an improved oil cooling system. Especially on those hot summer days, the oil temperature raised - and in parallel - the oil pressure dropped to levels which are not healthy. 130°C oil temp @ 0,2 bar oil pressure even triggered the oil pressure indicator light, which makes me nervous every time!<br />
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The plan for this season is a vast improvement in the oil cooling. After countless hours of reading forums like thesamba.com (for me, still <i>the</i> source of great info!), checking Google for pictures and talking to friends and "experts", I made my own plan. It involves better cooling, but without the hassle a full flow system brings along, like a special oil pump, routing the oil line between engine block and the fan - which is tricky on the type 3 engine - and so on.<br />
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Here are some parts involved:<br />
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A huge oil cooler with electric fan, numerous AN8 fittings, an external oil filter, hose clamps, an adapter for the external cooler and another adapter block, to connect all this stuff to the original oil cooler passages on the engine block.<br />
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After I knew what I wanted, I started ordering parts (mostly on ebay and from Hoffmann Speedster). Which sounds easy, but actually wasn't. The external cooler adapter came with the wrong fittings (LH threaded) and after the seller sent new ones, which was actually no big deal, he admitted to have sent wrong parts and send "correct" ones free of charge. Unfortunatelly, the new fittings were really rough in the threads and not usable. So, I had to order some more black anodized fittings from another supplier. Also, the package with fittings and braided line got lost by DPD and it took almost 2 weeks before I finally had those parts on my work bench! There is also a new breather box, especially for the type 3 "pancake" engine, just for looks.<br />
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Talking about looks, the engine is running great, but currently, the looks of it leave a lot to be desired. It is a bloody mess of wires and lines - more like a snake pit:<br />
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During the oil cooler modification, I will also upgrade to an electric fuel pump, for even cleaner looks in the engine compartment.<br />
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... more to come, soon <br />
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-49824460028056761572019-05-01T20:55:00.000+02:002019-05-01T20:55:07.062+02:00May Cruise Madness + MKT Hannover 2019<div class="separator" style="clear: both; text-align: center;">
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I just arrived back home after the yearly trip to Hannover. This year we were very lucky, as the weather was perfect!<br />
Here are some impressions from the May Cruise Madness at the Burger King in Hannover Laatzen:<br />
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An exceptional rare sight, the Australian equivalent to the VW 181 / Kübel:<br />
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As always, some very nice water pumpers were to be seen, too:<br />
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... and finally, this shirt made me laugh, because it is so true:<br />
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as nowadays 80% of all aircooled VW's wear Fuchs wheels - including mine!<br />
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Today, the Maikäfertreffen started with a cloudy sky, but it got better by the minute:<br />
I took only very few pics, but this car might look familiar to some folks: <br />
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As every year, I had to buy some stuff as well: A new engine sealing kit, a 123 Ignition distributor for the Fasty, a VDO sensor for the fuel gauge and a very special copy of one of the best books ever released: Bodengruppentherapie from Author Helmut Horn. He was kind enough to sign and autograph my personal copy... <br />
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In the lower right corner are NOS screws for the domed rear lights - a super rare item which I found on the desk of the fifths Ludolf - I guess we all know who I am talking about ;-)<br />
Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-9590576557630107452019-04-28T13:12:00.002+02:002019-04-28T13:12:39.945+02:00spring cleaning - Frühjahrsputz!In 2011, when I installed the carpet, I was in a bit of a rush and I didn't pay enough attention to the details.<br />
Lately, some edges became lose and the interior also started to wear out. So, it was time for some spring cleaning. The blinker lever was really ugly and look at the carpet in the drivers foot well: <br />
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I repainted the lever and fixed the carpet, also note that the regulator lever is installed as well! <br />
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and just for the fun of it, another picture in bright sunlight:</div>
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-20077169359667193612019-04-28T13:01:00.000+02:002019-04-28T13:01:19.289+02:00the heat is onSince the new engine and exhaust were installed, there has always been a problem with engine compartment temperatures. The reason are the CSP headers for the Python exhaust. The heat radiates into the compartment and the Webers were sucking in the hot air - not good - especially for the oil temperature. So, I wrapped the headers with heat insulation:<br />
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before: <br />
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and after insulation wrap:<br />
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I only had the chance for a short test drive, but my impression is that the engine comparment is cooler. The trip to Hannover will show if it really works... </div>
Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-47073887150012796822019-04-14T17:18:00.001+02:002019-04-14T17:18:22.679+02:00Back on the Blog...Hi all, after almost 1 year I am relaunching my Blog and show some updates to the Volksback. Just like in former years, I am also planning on some reports of meetings I attend and other Volkswagen related stuff.<br />
Also, I will of course visit the MKT in Hannover to meet friends and enthusiasts of our beloved old aircooled Volkswagens. See you there! If you still like to visit my Blog, drop me a comment!<br />
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-90690299363454954002018-05-01T20:45:00.005+02:002018-08-16T16:18:26.135+02:00Hannover MKT 2018 + DFL May Cruise NightI just came home from this years MKT Event in Hannover, it was actually the 35. official Maikäfertreffen and I had a blast. I met many friends had some great discussions and - for the first time - I didn't take the Volksback!<br />
Some random snap shots from the DFL Meeting yesterday - I was too busy for nice pictures...<br />
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The Hazard Streaker was the "weapon of choice" this year. One of the reasons is, that I want to sell it. Too many projects - not enough time! But, back to the Volksback. I noticed some increased pressure in the crank case, so it needs some relief. I bought some stuff to make it happen:<br />
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A breather adaptor, replacing the stock mechanical fuel pump, a CB breather box and - in the middle of the pic: most important - a new fuel tank sender. Hopefully I will never run out of fuel again...<br />
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And finally the only pic I took today: My friend Olli's "Autohaus Nordstadt Käfer" on stage:<br />
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-9942803172299803762018-04-22T16:08:00.001+02:002018-04-22T16:30:59.979+02:00Running out of gas is only what happens to losers, right?Well, unfortunately not exclusively... Today it happened to me - for the first time ever! I took the Fastback for a spin in bright sunshine and as I <i>usually</i> allways fill up the tank <i>before</i> I park it in the garage, I didn't pay any attention to the gas gauge... Well, 20 kilometers later I ran out of fuel on a hill of a country road without a hard shoulder...<br />
I just stopped and switched the hazard lights on, when the first car stopped right behind me - I didn't expected that. A very old lady - my guess is around 80 years old - offered help right away. She gave me a 4 km ride in her black Mercedes to the next gas station, so I could buy a gas can and some gas. The way back I had to walk in bright sunshine, which was o.k. About half the way back, another car stopped and the driver asked: "Hey, is this your vintage VW down the road?" Maybe the gas can in my hand was a clue to him... Yes, it is. So, hop on in, I will give you a ride back to your car! Wow, another super friendly guy who was willing to help. During the drive, the guy explained that the same thing happened to him last year on his vacation in France when his old baywindow bus also got stuck without fuel!<br />
What can I say, about 30 mins. after the car stopped I could fill up the tank and was able to continue my journey. Not right away, as the weak battery wasn't able to turn the engine long enough to pump gas via the mechanical fuel pump into the empty Webers, so I switched into reverse and used gravity to roll down the hill backwards with an engaged clutch. It was a bumpy ride, but eventually, the Webers got enough "juice" to fire the engine up again!<br />
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A big thank you to both of my helpers - you collected good karma today! I will try to do so the next time, when I see somebody in need (- which I almost always do anyway)!<br />
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Also, I was super lucky that the car was still undamaged as the "parking spot" was less than ideal...Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com1tag:blogger.com,1999:blog-5820824994634285571.post-22451512833353196542017-12-28T10:54:00.000+01:002017-12-28T10:54:58.587+01:00HibernationThe Fasty is parking in the garage, awaiting better days. To keep the tyres round, I bought those blocks, they are very light and consist of a special "foam", but are super sturdy:<br />
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The body is covered with the indoor soft cover, which I purchased years ago from Mario @ <a href="http://type3headquarter.de/">http://type3headquarter.de/</a><br />
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<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-6788293025423478172017-09-23T11:55:00.001+02:002017-09-23T11:55:08.032+02:00small updateThe Volksback is still going strong. The adjustment and jetting of the Weber carbs helped a lot, the engine is running cooler and more responsive. The front end is a little too low, especially with 2 passengers in the front seats, so I will re-adjust it a bit.<br />
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On my latest trip to the US I bought some more tools at harbor freight for the garage:<br />
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A set of picks to remove O-rings, a breaker bar to loosen those real tight screws, a wire stripper and some shrink tubing, as it really cheap and works well. <br />
<br />Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0tag:blogger.com,1999:blog-5820824994634285571.post-20434878939044465872017-07-18T19:41:00.002+02:002017-07-18T19:42:48.776+02:00New throttle linkage and a job for an expertLast week my friend Uwe (a big Thank You from here!) helped me machining my new throttle linkage. The former one was made of aluminium and due the angle it was mounted, I could not reach WOT (wide open throttle).<br />
The new one has a slightly different set up and is made of hexagonal steel, so the thermal expansion should be reduced as well.<br />
old:<br />
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During the movement the left linkage touched the cylinder shroud, so it was always hard stopped before it did the full throw<br />
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vs. new:<br />
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The initial angle is different and now it works perfect.The linkages have M5 left hand thread on one end and M5 right hand thread on the other other end + a jam nut on both ends. This makes tuning of the length really easy.<br />
Then I checked the valves once more and made sure all is well...<br />
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As I delivered the Volksback today to a well known expert to optimize the Weber carb's jetting and set up:<br />
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I hope he will find some more HP in this engine - even though, I can't complain! I always felt it ran a bit lean and I didn't want to risk a blown engine due to overheating issues. The trip to Spa will show how it runs...Volkswrencherhttp://www.blogger.com/profile/03558501978179773996noreply@blogger.com0