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Old 08-11-2018, 08:49 PM   #231
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Well as good as that rear panel looks, the rest of it is causing some bother. Still being left with scratches and swirl marks in enough places to upset me.

I flatted the boot lid right back once again. I expect its my last chance before I get through to primer!



Then after some time gently massaging it was G3 and then G10





The reflection is more than good enough for what I wanted to achieve, but take a look on the left there around the house roof, and then to the right near the tree.

Bit of a spoiler that! But as id not got it that good before Ive left it alone and decided to work on the bonnet so I can get that refitted. Im acutely aware the longer the panels sit in the garage the higher the chance ill scratch/dent/chip one.

So the same as above, 1200/1500/2000 on blocks, spray bottle of water and a bucket of water. A hose pipe for washing off. I flatted it right back to dull and seemingly smooth, unfortunately the light was fading by this point, but none the less i polished it with G3 and it again looked half decent.



But once id taken it in the garage it really didn't look half as smart, id seemingly made it worse!



At this point I was feeling rather demoralized, it was time to stop adding brush strokes and know when to stop.

The paints had 4-6 weeks to cure nice and warm for the first two weeks, and averaging around 8 for the remaining. I will chalk this up to experience and assume the paint simply is still too soft at the minute, I have started to bake one panel at a time in front of my IR heater. I am going to leave the colour sanding for, well probably until next year. Giving the paint as much time as it needs to settle.

Wanting to recover some garage space and reduce the likely hood of bumping into a painted panel ive decided the gearbox and engine need to go home.

This meant the first job was to install the wiring loom and then any of the other bits and bobs which sit on the underside of the boot floor.

To quote Kirsty Wark "More on that story later"
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Old 11-11-2018, 12:13 PM   #232
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Shall we have a change of pace then, I know I need one.

I dragged the rats nest out of the loft.



It has all sort of splices and joins along with horrible modern connectors. I wanted all this nonsense removed, I have planed to simple cut trim and solder it all healthy.



Back in august danny lord put a box of wiring loom up for sale. It was a bit of an unknown with out getting my hands on it, I couldn't and just had to go on the photos. I thought I might get something useful and it was about 20 from memory. Once id unpacked it all I worked out it as for an injection engine late type 3. A good starting point, the wires seem supple and nothing looks heat/fire damaged. The section which runs from the fuse box to the regulator and then all the way to the engine bay and rear lights was all there and in unfettled condition.



The only fault I found was the diagnostic socket, its clip on cover had broken off. My original loom has this.





Before I got any more involved I sat and worked out if both looms had the same number of wires in the right places with the right colours.



With it confirmed that new and old were all but the same, I removed the socket from my old loom and cleaned it, the carefully marked out this pin diagram to make sure when I fitted this socket to my new loom it was wired up correctly. Ignoring the fact it will almost certainly never get used

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Old 16-11-2018, 10:01 PM   #233
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Such is my way, lets jump about between jobs.

Dug out the rubber grommets to feed the loom through the engine bay and through under the rear seat. I cleaned them up installed them and fed the loom through. Following this I was going to complete the routing in the bay. It was at this point it was brought to my attention that I had missed a couple of repairs, some of the small tabs which retain the wiring loom had broken off and needed welding back on. With these three fellas reattached I also noticed I had someone managed to miss a great lump of painting. So i cleaned the area up on the inner back panel and painted that body colour.

Yet another job I was reminded of before the loom could be installed was the requirement to de waxoyl the rear wing air intakes and the rear panel air box. I spent a couple of hours with a scraper and petrol soaked rags to removed it. Then I filled the rear panel cavity with dinatrol cavity wax and inside the side airboxes with a black harder waxier dinatrol. Its not had a few days of curing so tomorrow I should get the chance to feed some wires through!

In other news, remember all that work I did on the rain deflector under the scuttle panel? Well what I didnt tell you was that although it was a good fit and sealed up, when I installed the wiper mechanism, the motor mounting tab was about 10mm to far south west. I had considered removing hte bracket and welding it in to the right place. But In the end I had pulled this panel back out for some adjustment later on.

While I was avoiding doing this job, this came up on ebay. at 35 I was left with no option but to hit Buy It Now





The leading edge was shot, but as this was the bit which needed reworking on the old panel, it was something id have to make anyway.

I hot footed down to the blasters and prayed id still have something to show for my 35. Pleasingly only 1 hole appeared and its not to bad to repair.





Sticking with the spirit of this, I havent done any more with that, but I got my spare set of stock wheels blasted and powder coated so that ive got some wheels to fit to the car while I work out what im going to do with my sprint stars.



And there you go, you thought you were going to read more about my wiring loom, oh how wrong you were!
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Old 05-12-2018, 10:26 PM   #234
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The paint just isnt ready and I havent returned to it yet. But I have been pottering away

I cleaned out the rear wing and rear valence cavities and then reprotected with dinatrol 4942 and 1000 for the cavity.





With the continued fear of bumping into a painted panel, I made the decision it was time to recover to fighting room, so the gearbox was refitted. With a new nose cone mount.



And then the biggest space hog needed some love, this dusty bugger ran fairly rough and leaked like me after 10 pints.



The plan being, I know the engine was mechanically fine, it just needed a full regasket and all the tin needed a smarten. I measured the end float and its well with in spec. The firs fight of many was the exhaust, I believe I have joined a rather small club these days of people who have undone the primary heater boxes from the main silencer box. And without the use of an angle grinder.

Over the course of two weeks these 46mm buggers were given liberal gulps of super crank and WD40.



I spent quite a bit of time with it clamped in a vice and swinging from a huge spanner. But all I managed to do was turn the work bench around. So at that point I fired up the burning gear and went red hot. Then still took me pre loading the spanner and then some hefty thumps with a hyde face to crack off and finally undo.



I have much more for you and I will give you what you are after later this week
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Old 06-12-2018, 09:53 PM   #235
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Right ive been up to my eye balls for weeks now and putting this off. So sod it lets have at it and do you a proper update. Im just going to stick the kettle on and make a brew first. Id do the same yourself, its a fair size. See you in 5...............

With the box jobbys undone I got on with the rest of the engine knocked down. And I really went to town. Fan flaps out.





Helpfully some yeas ago a friend made me this handy spanner to hold the dynamo pulley, its pretty similar to the VW original too and works a treat.



I seem to remember this was a runaway saturday afternoon, but if im honest I really cant place this on any particular day, other than to say it happened in November 2018. I seem to have developed a muscle memory with these engines and before i realized it was in pieces with out having paid any attention.





Then light enough for me to lift into the stand and take the heads off. Note the very black oil below, and that isnt from the tray. I shall explain in a matter of some photos time.



Other matters are pressing, that oil leak I told you about, and youve have since forgotten. Well I didnt want to split the block, but I made myself do it. It was so very well stuck together which is a shame, but the lower front corner had this delight. The oil had breech the liquid gasket due to the over heating incident.

xv9G28MxpsLRhLzbNA-V1DjDBfy5mvAr8x9M5GphVIfn44v9SuVa4vbqAxXT_NHgy8-jqmnARwnA?width=1600&height=899&cropmode=none[/img]

So worth while splitting the block, even if it had taken up more time I dont really have. ANd after a suitbale clean up, yet again notice the very black much in the sump.

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Old 06-12-2018, 09:56 PM   #236
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I rebuilt the engine up to short block and then added the barrels and pistons. That big pile of tinware brackets clips pipes ect all went of to the powder coaters, I took all of the exhaust system too, but just for sand blasting. This is an original system but I had just thrown it on the car without ever looking at its condition. Turns out it was a little bit sick. The small boxes should have a decent chunk of copper in there to seal it to the muffler, this had all but vanished, along with dodge joints to the heat exchanger and last but not least the piss poor job someone had done welding on an original tail pipe into some old beetle smaller diameter exhaust. If youve stuck with me, the reason for explaining that is, I set up my engine with a carb balancer and CO meter, needles to say I had it running way over rich as the tail pipe was the last place to be emitting and gas. It had long since buggered off before it stood a chance of making its way that far through the system. End result coked pistons and heads, and the very grotty oil. To that end I had to do something about it, the type 3 had a bespoke tail pipe diameter so there was no way I was going to be able to borrow from the parts bin to make good. Not wanting to was years on a simple fix, I found this perfectly diametered exhaust repair section on ebay for four of our queens finest pounds.



Roughly a foot long wit ha 2 inch flared end I could make a sliding tail pipe. With not a moment to waste, out with the tube cutter.



I cleaned up the face on the silencer and with rough measurements.







Not as VW intended, but a quick and serviceable repair, once fitted to the car I will clamp the sleeve to seal it up.

The heat exchangers were a less pretty site, though ive yet to do anything about these yet.



And just because I went to the effort of taking photos.





Dont tell the missus, but i sat in front of the stove and masked off the black areas ready for the silver.



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Old 06-12-2018, 09:57 PM   #237
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At some point during all this waffle I got a phone call to say my wallet needed emptying and I got this box of shrink wrap.



There has been much debate on these fellas (if you want me to waffle on about them do ask, but otherwise I will spare you), anyway my question wasnt to fit or not. It was regarding orientation. Those of you who can count will have noticed the 4 cylinders, and these chaps only have three wings.



My logic suggested to me this was the correct way around. Number 2 being well cooled if not best cooled. Closely followed by No.1



Where as 3 and 4 also share with the oil cooler, 3 being well know as the worst cooled. The little wing should direct a little more air flow around the head just to help a few degrees. Rational to my thoughts?

Added goodies from VWHeritage.



Suddenly a long block.



Ive grown tired of typing this evening, I will finish the story tomorrow.
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Old 07-12-2018, 09:45 AM   #238
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Feeling a little more awake then. The fan housing needed building back up, but as it was nice and clean, this was a joy to do.



With the flaps and linkage reinstated.



And rehomed with a few of its other friends. Were racing through it now.



I continued the build up fairly slowly, making sure everything was properly aligned and every fitting suitably lubed to help me undo it when the day finally came, and to keep the fan flaps moving as they should.



A friend of mine recent visited California and said he could pop into ISP west if i needed any bits, as I want to revive the original heating system (hence the efforts with an original muffler ect) I had managed to collect all the parts required other than the two small diameter hoses which carry the cool air to the top of the mixer boxes behind the rear seat. I couldn't find a single UK supplier, but ISP stocked some so he brought me these back.



One happy chap!



Some hours later I got to this.



I had painted the coil the closest blue I had kicking around in the garage, its too dark but it will do for now and I even bought some cheesey stickers just because.



In pursuit of the heater system I had these mixer boxes cleaned up and blasted. I stripped the thermostats out and get them a few coats of stove paint.



And tested the thermostats on the stove, both of which open and close smoothly.

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Old 07-12-2018, 09:46 AM   #239
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With that complete i rebuilt them, setting the correct pre load on the thermostat of 1mm. I just need to go fetch the gaskets Ive had made and they're ready to go on. Then there wont be much stopping me fitting the engine.





ANd so I fear we have caught up, well just about. I feel rather pleased with how its all gone. Though with an exam looming next week I can see progress coming to a stop for 4 or 5 days.
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Old 11-12-2018, 05:20 PM   #240
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Looks really good mate
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