1960 VW Beetle - Bagged

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Post by EngineerTEN on Sun Apr 05, 2009 10:29 pm

April 5, 2009 - I worked on the engine more yesterday. I have to still cut more fuel line, install the breather, cut the breather host and install the pulley. After that, the engine come off the stand for the flywheel and clutch install.

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April 5, 2009 - to show where the coil was relocated so that it would not be in the way of the linkage.

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April 5, 2009 - One of the finishing clamps I am toying around with. This one is too big for the fuel line. I'll be using it on the breather tube.

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April 5, 2009 - Carb linkage.

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April 5, 2009 - The right carb.

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April 5, 2009 - The backside and the firewall.

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April 5, 2009 - The dowels.

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April 5, 2009 - The exhaust.

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Post by EngineerTEN on Sun May 03, 2009 1:20 am

Went to prepare the engine bay for the for the seal a couple of week ago in preparation for putting the new engine in. It did not have a seal when I bought the car. The rear apron was BAD! Covered in bondo and the engine seal channel did not match up with the the right shelf. It was about an inch off. I ripped out the rear apron and ordered a new one. In this picture, I am preparing to dismantle the rear end.
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Took this picture to remember where the wires go back for the tail light.
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This is after welding in a new bumper mount, grinding it and putting some filler for a smooth finish. I'll sand it next week.
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A picture of the old bumper mount.
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Another picture of the old bumper mount.
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Drivers side rear quarter panel. Grinded down the welds and put some filler down for a smooth finish.
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Passenger side quarter panel. It will get some attention next. Has a chunk of metal missing. I'll have to weld in a piece of scrap there.
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The passenger side shelf. I should have gotten a before picture to show what it looked like before beating it into shape. I'm going to strip the paint, grind it smooth and give it a smooth finish with some body filler.
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Rust on the driver side rear fender. The picture was taken after I completely stripped the fender of pain and then gave it a coat of etching primer. This is the only spot of rust on it. I'll cut this section out and weld in a new piece.
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Have some cracks and denting on the bottom corner. Also, there is cracking around the bumper mount and overrider holes. I'll be welding those the then smoothing them out with the grinder and body filler.
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The driver side rear fender stripped of paint and covered with etching primer.
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Pictures I took of the air-ride parts for planning purposes. I'll be redesigning the layout and relocating components.

Electric Valves
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Electric Valves
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Tank and compressors.
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Pressure regulator.
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Front air shock.
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Feed from the tank, splitting off to the two rear air bags.
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Driver side rear air valves.
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Rear of the pressure gauge.
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T fitting at the tank.
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Close up of the air compressors.
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Post by EngineerTEN on Tue May 05, 2009 10:37 pm

Thinking about painting my car this color when the body work is done - Candy Red Metallic - with white on the sides:
1960 VW Beetle - Bagged - Page 7 AcrylicUrethanekit4website_CandyAppleRedMetallic
http://www.paintforcars.com/kitu_candyredmetallic.html
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Post by aircooledaddicts on Tue May 05, 2009 11:24 pm

Everything is looking good. Can't wait to see it all done.
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Post by 39coupe on Wed May 06, 2009 7:32 am

EngineerTEN wrote:Thinking about painting my car this color when the body work is done - Candy Red Metallic - with white on the sides:
1960 VW Beetle - Bagged - Page 7 AcrylicUrethanekit4website_CandyAppleRedMetallic
http://www.paintforcars.com/kitu_candyredmetallic.html

I like the color, in fact that is what I was looking at for my '65 when I paint it. I'm thinking more on the lines of a Candy Apple Red Metalic
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Post by EngineerTEN on Wed May 06, 2009 10:31 am

aircooledaddicts wrote:Everything is looking good. Can't wait to see it all done.

Done? LOL Is an old beetle ever done? It will probably be next year before I paint it. It is slooooow going.
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Post by 59suicide on Wed May 06, 2009 11:41 am

I was checking out there metalic black paint a few weeks ago, looks like a pretty good product not a bad price either. That red would look good.
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Post by racecar67 on Wed May 06, 2009 9:25 pm

EngineerTEN wrote:
aircooledaddicts wrote:Everything is looking good. Can't wait to see it all done.

Done? LOL Is an old beetle ever done? It will probably be next year before I paint it. It is slooooow going.

Thats a funny one. I thought I finnished my bug 4 years ago. I'm still changing and refining things. The latest is removing the 1776 and installing a 2186 I love you Twisted Evil and Fuchs
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Post by EngineerTEN on Mon Jun 15, 2009 11:32 am

I almost completed my drivers side upper hinge on Friday.

For a reminder here is what it looked like.
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Here is how it looks now. I still have some finishing to do.
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On Saturday, I got the engine in and started up. It still needs the timing set and the carbs synced and adjusted. I'll do that over the next week.
1960 VW Beetle - Bagged - Page 7 Engine11
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Post by rpm750 on Mon Jun 15, 2009 12:45 pm

Man looking good. That baby will be on the road soon! Keep stickin it to it Jason!
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Post by EngineerTEN on Tue Jun 23, 2009 1:30 pm

I got the car out for a test drive on Saturday although missing the rear fenders and driver side door. The thing has aloooooot of power! I did a couple of nice burnouts. I love it. Anyways - the BAD..... So I had a friend over last night and of course I had to show it off like a total idiot. I decided to do a burnout again and when letting off the clutch, I heard a POP and then thunking sound. We pushed it back up the driveway into the garage and with every revolution of the wheels there was a thunk from the transmission. I got a light under the car and it appears that the side cover on the driver side of the transmission is busted and a lot of transmission fluid was poring from that side. I am hoping that the side cover is the extent of the damage. Unfortunately, I am going to have to pull the transmission out to find out... Sad I guess the 50 yo transmission could not take the torque of the new engine.
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Post by 59suicide on Tue Jun 23, 2009 1:52 pm

Shocked Im only guessing, but I think I too will be having the same project. Do you have a transaxle strap, my bug came with one and it seems to make the whole setup more rigid.
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Post by fearthefat138 on Tue Jun 23, 2009 1:53 pm

did you have it the bags let down when you did the burn out? sounds like a busted fulcrum
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Post by EngineerTEN on Tue Jun 23, 2009 3:49 pm

Yes - I had the air let out... When you say it sounds like a busted fulcrum, do you mean the diff, paddle on the axcle or one of the fulcrum plates? Really won't know for sure until I can get the transmission out and open it up to inspect it...
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Post by EngineerTEN on Tue Jun 23, 2009 11:37 pm

Here is the prognosis - busted the paddle off the axle.

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Post by Bugman114 on Fri Jun 26, 2009 12:41 am

^^ so is it easily repairable, or do you need a new tranny? you said it also broke the side cover, but did also hurt the tranny case at all? good luck with that cheers
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Post by fearthefat138 on Fri Jun 26, 2009 7:26 pm

Laughing camber + hp always end bad
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Post by EngineerTEN on Tue Jun 30, 2009 12:32 pm

well... I took the tranny completely apart and performed an inspection to see what all damage there was. Good thing is that all the gearing is perfect...

Here is the extent of the damage:
- Passenger side axle tube cup is bent.
- Passenger side axle retaining plate is bent - which was causing the fluid to leak.
- The entire axle on the passenger side is trash.
- Dibris in the passenger side diff bearing.

Steve at ProFlow Performance is pulling the parts from on old tranny for me so that I can repair mine...

1960 VW Beetle - Bagged - Page 7 Photo_10

1960 VW Beetle - Bagged - Page 7 Photo_11
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Post by EngineerTEN on Sun Jul 05, 2009 11:38 pm

This is the axle tube retaining plate - the cup end is bent as well. It is bent beyond what I consider reliably repairable. The bend created a big enough gap to allow most of the transmission fluid to poor onto the garage floor.
1960 VW Beetle - Bagged - Page 7 Photo12

This is the replacement axle tube to replace the one with the bent plate. I sourced it from Steve at Pro Flow Performance in Hiram, GA. I need to cut the air bag mount from the old axle tube and weld it to the replacement.
1960 VW Beetle - Bagged - Page 7 Photo13

Two good used replacement axles. One to replace the broken one and the second to replace the other which I found was heavily worn. These came from ProFlow Performance as well.
1960 VW Beetle - Bagged - Page 7 Photo14

The transmission case cleaned, painted and ready for reassembly.
1960 VW Beetle - Bagged - Page 7 Photo15

I purchased a new nose cone. The old one was fine, however it did not allow the installation of the reverse sensor. The 1960 model did not come with a backup light to see behind you when backing up at night. Now I will be able to ad one. The reverse sensor is installed in the threaded hole.
1960 VW Beetle - Bagged - Page 7 Photo16

When doing the transmission inspection, I found that the passenger side diff bearing was going bad. Steve at ProFlow Performance pressed a new German bearing on the differential. The bad bearing is in my hand on the left.
1960 VW Beetle - Bagged - Page 7 Photo17

These are the good used replacement left and right spider gears complete with replacement fulcrum plates to mate the replacement axles to the differential. These came from ProFlow Performance as well.
1960 VW Beetle - Bagged - Page 7 Photo18

All I am waiting on is the gasket kit and then I will be able to begin assembly. Hopefully I will have it tomorrow.
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Post by rpm750 on Mon Jul 06, 2009 7:23 am

I want to know the location of the Ace Hardeware that stocks all those VW parts! Suspect
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Post by EngineerTEN on Mon Jul 06, 2009 10:00 am

Ace is where I find the unique and hard to find hardware. The bag in the picture has stainless allen head door hinge screws for reattaching my doors.
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Post by EngineerTEN on Wed Aug 19, 2009 10:42 pm

Got half way completed with the disk brake conversion. We are hosting a German exchange student this year who I am teaching how to work on beetles. Kind of ironic. He is a great kid!

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Post by EngineerTEN on Thu Sep 03, 2009 7:55 pm

Put this on the family car today...

1960 VW Beetle - Bagged - Page 7 Photo_12
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Post by fearthefat138 on Thu Sep 03, 2009 8:41 pm

man i really like your car
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Post by aircooledaddicts on Thu Sep 03, 2009 9:56 pm

EngineerTEN wrote:Put this on the family car today...

1960 VW Beetle - Bagged - Page 7 Photo_12

Cool! Where did you get those? I want some Smile
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