1303 beetle

[sava001006]

well this is the first time i have ever done anything of this nature, and im doing on a budget. ohh and excuse the ammount of photos

Well as a introduction to this build, I went to insure my Clio with a few modification and as usual the insurance company didn’t like me and quoted me £3000 with modification but £2000 without modifications so I thought I should leave its standard and get something to cure the inch to tinker and modify, so after some thinking I though why not a air cooled beetle the electrics won’t be too hard, I can spray remotely good and I’m sure I can pick up the hand of welding also with choosing a classic beetle is that there is a massive ‘Dub’ scene and parts are very widely available so it won’t be too hard to find the bits that I need for the car.

So the first thing I am trying to get is a pre 1973 beetle so that it will remain tax free, there is a lot of different shapes and that you can get them with many different thing, for example McPherson struts and disc brakes. I have narrowed it down to a ‘gt’ ‘1302s’or a ‘1303s’ because these are the most often, but with this they aren’t the most popular one for the budget I have got, as it stands at the minute I haven’t found one that I want but that hasn’t stopped me getting ready.

06/04/2011
Today I received through the post a 6m x 3m gazebo with attached sides, I think that this will be plenty big enough for the beetle build to take place; it took me 2 or so hours with help from a friend of mine Michael to put the tent up. I suppose the high winds that we had today wasn't the best idea I have had but I wanted to make sure it was be enough. Any ways here are some pics

06/04/2011 by joshsav, on Flickr

06/04/2011 by joshsav, on Flickr

06/04/2011 by joshsav, on Flickr

06/04/2011 by joshsav, on Flickr

06/04/2011 by joshsav, on Flickr

As you can see it is quite substantial in size but I think it may just be big enough! It took 2 hours to put up yeah half of that to put down, I think to be fair it was harder to put it down that put it up and in typical fashion it won’t fit in the boxes but soon I will hopefully putting it because I will have a beetle,

Total cost to date = £147.99

07/04/2011
Continuing with the preparation with the storage of the beetle me and my dad decided to tidy round the back of the shed where we have decide to put the gazebo/tent this may sound easy but we took 2 or so hours to get rid of the crap that was hiding round there, we even managed to find 2 dead birds nice..

07/04/2011 by joshsav, on Flickr

07/04/2011 by joshsav, on Flickr

As you can see from the photos the block have been layout to show where the gazebo will go, also from the photos you can see where all the rubbish was stored because no grass has grown.
Cost to date = £147.99


08/04/2011
Still carrying on with the prep me and my dad put the base down, this does sound easy but as always it isn’t. The piece of garden that I have chosen is behind the shed so it will be sheltered from a lot of the wind. When we initially put the block down they weren’t level so the first job was to sink some of the blocks so that the base was level. Then we construction the gazebo again! And put in onto the base, then bolted it down so that it isn’t going any were.

08/04/2011 by joshsav, on Flickr

08/04/2011 by joshsav, on Flickr

08/04/2011 by joshsav, on Flickr

As you can see from the photos the floor is full of mud so the plant are to get 4 bits of 8” x 4” so that I am working on wood not the grass and mud.

Cost to date = £157.99

11/04/2011
I have good new in the beetle searching part, I have managed to find a beetle that I am happy with and managed to get it nearly within budget £1150 to be exact, the best part is that the guy that I am buying them off will be bringing them 150miles to my house which will save me a lot of time and money, I will be paying for them today and they should be getting to me on Thursday and Friday. It will take two day because there is another benefit about my purchase. There are two beetles and spares. I have been told by the buyer that one of the beetles has a good chassis and the other beetle has a very good body so I will be making one good beetle out of two not so good beetles. It also comes with a lot of spares which is quite handy and could save me a lot of money. it isn’t perfect but it is a good base to start on, also this beetle comes with a 1300 engine, but I may do a engine change at some point. The only bit that I can find wrong is that I will have to sight up to vwoc (vw owners club) for a birth date certificate to prove the dvla that I get free tax.

Cost to date = £1307.99


12/04/2011
When my dad had come home from work he had an early birthday surprise a snap on MIG welder. All I can say is that I am over the moon it some with some steel wire and a boc gas bottle. But still waiting for the delivery of the two cars which should be here in 2 days.

14/04/2011
Well the day is finally here, the beetle has come the red one this is the one where I am getting a engine and gear box from all I can say it that I think its uber cool everything is so basic, must say the chassis and body is shot but this one isn’t the one I have been repairing, anyway here are the pics.

14/04/2011 by joshsav, on Flickr

14/04/2011 by joshsav, on Flickr

Here is how it arrived with a heap load of bits with it took some getting out of the car too.

14/04/2011 by joshsav, on Flickr

14/04/2011 by joshsav, on Flickr

14/04/2011 by joshsav, on Flickr

14/04/2011 by joshsav, on Flickr

14/04/2011 by joshsav, on Flickr


and tips and critism is welcome...

 

[sideways danny]

nice. My first car was a 1303. That car has the incorrect rear valance

 

[MATT BLACK]

Spot on matey - personally i would give it the cal look.

 

[maynard]

Look forward to seeing this progress..... be prepared for a nightmare with the rusty bolts!

 

[Rob]

I can honestly say with absolutely no difficulty - I want one.

I look forward to reading this mate, keep it up with the pics etc

 

[Rob]

I can honestly say with absolutely no difficulty - I want one.

I look forward to reading this mate, keep it up with the pics etc

 

[sava001006]

nice. My first car was a 1303. That car has the incorrect rear valance

i was looking and thinking it was the wrong one but the red one is just for the engine and box, i have another one coming that is in better condition but still a 1303

 

[Gally]

Looking forward to the updates mate, great shelter aswell without building a monster garage.

 

[sava001006]

UPDATE

15/04/2011
Small update today which is good, when I first got the red beetle it had two batteries in it I tried to fire the engine but they were flat so I left one on charge all night. Then this morning I got to the battery I had left on change put it in but it wasn't any good, must be too old. Anyway I took the battery out of my Clio put it in the beetle and it fire and idled for 15 or so seconds but that was good enough for me. So I went for a brew and a ponder, after this me and my dad though to about the taking of the engine out so on we go, it took a lot of jacking up and wood to get the car high enough. Once we had done this outcome the angle grinder to cut the rear clip off so it would be easier.

15/04/2011 by joshsav, on Flickr

15/04/2011 by joshsav, on Flickr

With much heaving and cursing the engine come out.

15/04/2011 by joshsav, on Flickr

15/04/2011 by joshsav, on Flickr

15/04/2011 by joshsav, on Flickr

15/04/2011 by joshsav, on Flickr

The once we had the engine out some more cursing to put the engine on the work bench so I can work on it.

15/04/2011 by joshsav, on Flickr

15/04/2011 by joshsav, on Flickr

Hopefully we will be able to get the gearbox out before Tuesday so the good shell can sit in the shelter. Oh and one more photo as its put away for the night.

15/04/2011 by joshsav, on Flickr

 

[guysy]

Love a good resto thread, will be keeping an eye on this.

 

[sava001006]

16/04/2011
So today I decided to take some parts of the engine to bit ready to clean up and put back together so on we go first the exhaust

16/04/2011 by joshsav, on Flickr

16/04/2011 by joshsav, on Flickr

It was only a couple of bolts but the rust had taken grip so out cam a hammer, it soon moved next it took all the carb, coil, dyno, dizzy and the fan and housing which left me with this

16/04/2011 by joshsav, on Flickr

16/04/2011 by joshsav, on Flickr

16/04/2011 by joshsav, on Flickr

A few bits left to do on the engine but I’m happy with the progress and I’ve took a few random snaps while I was there.

16/04/2011 by joshsav, on Flickr

16/04/2011 by joshsav, on Flickr

All I can say is hopefully my other car will be in better shape!

16/04/2011 by joshsav, on Flickr

I’m happy to say that is full of spare parts such as light, trim and pipe work.

16/04/2011 by joshsav, on Flickr

And of course the photo took before lock up for the day.

 

[Scrooge]

Good little project matey, these can look seriously cool.

 

[sava001006]

17/04/2011
The gear box was on the first thing to do, so I got my tools and me and my dad set about getting it out, we first undid the bolts holding the boots together the 12 nut (6 on each side) were some of the hardest bolts to undo that I’ve come across hitting the bolts with the trusty hammer seemed to free the rust making it that bit easier to undo. Then afterwards I undid the other cables and what not’s. Then it was onto the mount these had plenty of rust so the hammer was out yet again along with some releasing oil to get it going once we had undone them we then put the jack under the gear box and jacket it so that it sat off the mounts and pulled it forward, and that was that it was simple... ish we also managed to get the rest of the tin wear off the engine read to strip it, any way here are some pics

17/04/2011 by joshsav, on Flickr

17/04/2011 by joshsav, on Flickr

Once the gear box was round we then took it off the stand and put the wheels back on it

17/04/2011 by joshsav, on Flickr

17/04/2011 by joshsav, on Flickr

Note on the pictures above the amount of positive camber because there is no wheels on the back, I also moved everything so it was neat and easy to get the red car out and the white one in on Tuesday

17/04/2011 by joshsav, on Flickr

And not for the last shot before locking it up for the night

17/04/2011 by joshsav, on Flickr

 

[Alex H]

Looks an awesome project!

 

[sava001006]

UPDATE

19/04/2011
The day has finally come were my other ‘better’ beetle comes, I was like waiting for Christmas but it eventually come and it is in a lot better shape than the red chassis but it still by no means perfect a quick look of things means that the floor pans look as if they could need some tlc but I think it will make a very good chassis to start upon. And here is a few photos of when it first turned up.

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

As you can see from the photos the body has been braced because the heater channels have been replaced, I also replaced the wheels so it was all a matching set.

19/04/2011 by joshsav, on Flickr

14” steel mini lite wheel look rather odd but they do then job I also unbolted the shell from the chassis read for lifting off when a few of my mates pop down.

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

As you can see from the photos they is more rust but it is all part of the restoration. I managed to rally a few of my mates round to give me a lift with the body so off with the body and on to a stand. Ohh and thanks lads for coming round

19/04/2011 by joshsav, on Flickr

I also got some photos of the rust and the general condition of the shell.

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

As you can see from the photos the body isn’t in a bad condition there are a few areas of rust but nothing too major just a little bit of patching will be needed, now that I had just a chassis on its own it had the best spot in the garden, the gazebo.

19/04/2011 by joshsav, on Flickr

Mean that the red beetle gets the joys of living outside for the time been.

19/04/2011 by joshsav, on Flickr

I also took some photos of the chassis that I will be using, this doesn’t look too bad there is a fair bit of work to be done but I have seen worse brought back to life.

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

19/04/2011 by joshsav, on Flickr

 

[sava001006]

20/04/2011
Not a massive update but I managed to find the owner of beetle before the owner that I bought it off, which was a surprise the guy just happened to comment on build thread I found that he was the one that put 3 Empi 8 wheels on it. He was also the person who braced the shell ready. The guy was also the one that braced the body so he could start work upon it. I also found out that the previous owner was from Coventry, and he called the beetle ‘Ceasar’ so the beetle has a name.

21/04/2011
Did a lot of work today I spent 6 or so hours drilling out the spot weld that held the floor pans in place, this consisted of first chipping away at the tar/bitumen which had been used as seem sealer and sound deadening, this seem to take forever, then we got a wire brush on a angle grinder to get rid of all the crap that was sat on the spot welds then drilled the spot weld with a ¼ drill bit but don’t drill all the way, then swap the drill bit yet again for a special spot welding drill bit, but again this was only to go through the spot weld not to go through the metal underneath otherwise I will have nothing to weld onto when it comes to fitting the floor pans, the was about 70 to 80 or so welds to drill then a lot of hammering to take the pans out but it left us with these

21/04/2011 by joshsav, on Flickr

21/04/2011 by joshsav, on Flickr

21/04/2011 by joshsav, on Flickr

21/04/2011 by joshsav, on Flickr

You can see from the photo that there was a weld ever inch or so, while doing this it uncovered some places that will need some patching up but it’s summat that shouldn’t be too bad to do

21/04/2011 by joshsav, on Flickr

These holes should be too hard to patch up just knock up a bit of metal and weld it in place, also we too the bake line and master cylinder off as well at the rest of the from end, as you can see from the pictures above, while tidying up I also found a good spot for my seat as well

21/04/2011 by joshsav, on Flickr

I some how don’t think that it will catch on!!! And the last shot before I close it up for the day

21/04/2011 by joshsav, on Flickr

 

[Hutchie]

beetles are great fun

 

[BIFCAIDS]

This is brill, ill be having a look every update.

 

[Christopher]

Awesome, they look very easy to work on!

 

[Rob]

Really impressed with the updates, hopefully you keep it up at the same rate - It makes for great reading

 

[Scrooge]

I'm loving reading the updates on this!

 

[sava001006]

Really impressed with the updates, hopefully you keep it up at the same rate - It makes for great reading

i will slow down eventually becuase im sure when i need to buy some stuff my monies will soon dissapear

 

[sava001006]

sorry for not updating this

23/04/2011

Well I’m skint I’ve spent up I decided to get some of the things I needed, got quite a few things such as
Engine Gasket Set
Accelerator cable
Heat Cable
Heat Cable
Clutch Cable
Clutch Cable Conduct
Heat Exchanges Pair
Heat Exchange Fittings, With Aluminium Hose
Exhaust Muffler And Silencer Kit
Floor Pan Left
Floor Pan Right

Most of this should be coming shortly bar the floor pans that will be coming when they come in stock, which is expected in 4 or so weeks but this won’t slow the build down because I still have plenty of things to do in the mean time.

24/04/2011
Not the biggest update but it is still a update, today I started on the de tarring of the chassis, this has got to be the dullest job to do so I only could do it for a couple of hours before boredom kicked in, but I managed to get most of it don’t there is just a little bit left to do on the tunnel but it shouldn’t be too much.

24/04/2011 by joshsav, on Flickr

And hear is the bit that I have got left to do, also in the photo below I scraped some weird glue off my chassis, that hasn’t set it gets everywhere.

24/04/2011 by joshsav, on Flickr

And not forgetting the tar that comes off the car.

24/04/2011 by joshsav, on Flickr

And as a change from the usual last photo I stitched 5 pictures together from a different angle

24/04/2011 by joshsav, on Flickr

25/04/2011
Not much has happened today because I’m just waiting on paint and parts so I started to prep a few bits, all I did was get a wire brush wheel on the angle grinder and took all the surface rust off it I also found that some of the tin ware had a little bend in it that shouldn’t be there so out comes the hammer and it soon looked like the part that it should be.

25/04/2011 by joshsav, on Flickr

25/04/2011 by joshsav, on Flickr

I also took the other two wheels off my chassis and had a good sweep around because the amount of crap that was on the wood was driving me mad, I have also received a email about the order that I placed with machine 7 everything should be here tomorrow apart from the exhaust because that will come Thursday. So I should have some good updates soon.

 

[Laura]

great work! fast progress!! keep it comimng

 

[sava001006]

great work! fast progress!! keep it comimng

cheers

 

[sava001006]

27/04/2011
Well waiting in all day has paid off my parcels have come, that’s right parcels I wasn't expecting the floor pan but it has arrived, the other one should be here within 4 weeks or so, as for my other parcel I now have loads of bits to fit to the engine, I will probably do this later in the week after I have sorted the other bits of the chassis together. Anyway as always here are the pictures

27/04/2011 by joshsav, on Flickr

27/04/2011 by joshsav, on Flickr

27/04/2011 by joshsav, on Flickr

27/04/2011 by joshsav, on Flickr

Cost to date = £1,722.89

28/04/2011
Well today some more parts have come, the exhaust from machine7 which I must say is some of the best service I have had in a long time, I also had some por15 come, and I also went out to get some VHT (very high temperature) paint for the heater exchanges and the exhaust. The colour I have gone for is matt black because its gives that OEM look.
Cost to date = £1,767.00

29/04/2011
Not the biggest of updates again today, but a update none the less I have painted the heater exchanges and the exhaust with the vht paint that I got yesterday must say I am impressed any way I got a few pics


Before

29/04/2011 by joshsav, on Flickr
After

29/04/2011 by joshsav, on Flickr

29/04/2011 by joshsav, on Flickr

when my dad got home we decided to strip the engine read to clean and change all the gaskets. So off with the rocker covers and heads.

29/04/2011 by joshsav, on Flickr

29/04/2011 by joshsav, on Flickr

29/04/2011 by joshsav, on Flickr

All simples really but when I managed to get the heads off in over covered a little problem.

29/04/2011 by joshsav, on Flickr

29/04/2011 by joshsav, on Flickr

Yep a melted piston, this isn’t the exact news that I wanted to see, I think its happened because the piston ring has snapped so it has over heated and melted. Only the one piston has done it. But I will have to find some pistons from somewhere. After I had found this I decided to look at the heads because I know that they are prone to crack so after a look at them I found one has cracked

29/04/2011 by joshsav, on Flickr

Strangely this is the head that was on the other side of the engine, it currently seems to be getting from bad to worse. But it isn’t anything that isn’t fixable. That’s all I got done. Ohh and I managed to get a few last photos before I locked it up for the night.

29/04/2011 by joshsav, on Flickr

29/04/2011 by joshsav, on Flickr

And I also managed to get the last shot before I lock it all up.

29/04/2011 by joshsav, on Flickr

 

[sava001006]

30/04/2011
Not a massive update but it’s getting there; we took the last bit of the old floor pan off ready to fit. We also test fitted the left hand floor pan because I’m waiting for the right hand floor pan to come.

30/04/2011 by joshsav, on Flickr

30/04/2011 by joshsav, on Flickr

30/04/2011 by joshsav, on Flickr

 

[sava001006]

01/05/2011
Well I have good news I have found an engine for cheaper than new pistons barrels and heads. £350 for a 1600 engine with code AB on it so it’s a twin port engine that has just had a clutch change. It also comes with a Webber progressive carb. And they guy say the engine has done around 60,000 miles but I will still take this on to pieces and replace all gaskets. I shall be picking this tomorrow hopefully.
Cost to date = £2,117.00


02/05/2011
Well after 250 miles 4 hours and £350 I now have a 1600 engine with a 2 stage progressive carb, get me not much to say really when I’ve got the time I will break the good engine for parts and then strip this one and change gaskets and clean it up. Anyway I did get some photos but they aren’t the best but everyone knows what a engine looks like

02/05/2011 by joshsav, on Flickr

02/05/2011 by joshsav, on Flickr

02/05/2011 by joshsav, on Flickr

 

[sava001006]

UPDATE

04/05/2011
Well we stripped the new engine and took barrels rockers and heads off and I must say this engine is it lot better nick than the other one, the other bit that I like is that someone has converted it to a sump plug so it makes my life easier instead of doing all of the other bolts. It also had full chrome tin wear but it has seen better days I will remove this because it can cause overheating and I don’t fancy that happening really. I started to clean the heads up and lapping in the valves but then ran out of time so I will continue tomorrow.

04/05/2011 by joshsav, on Flickr

04/05/2011 by joshsav, on Flickr

05/05/2011
Today we started on a bit of a downer really because I looked at the head and the cracks are a little serious, so the gamble with the engine didn’t pay off which is a shame, but on wards and upward. I will order a top end re building kit. I started to warm the pistons up to get the pin out of the piston. Then one this had been done we started to take the head studs out of the engine so that they can be cleaned. Here is a photo on the left before on the right after

04/05/2011 by joshsav, on Flickr

05/05/2011 by joshsav, on Flickr

To clean the stud I carefully put them in a drill at a low speed and use a blade to get crap off then fine sandpaper to get the nice and clean. We then took the flywheel clutch and other gubbings off the engine. Ready to clean the block

05/05/2011 by joshsav, on Flickr

05/05/2011 by joshsav, on Flickr

05/05/2011 by joshsav, on Flickr

One I had done this I de greased it all ready to paint it when I get some paint.

05/05/2011 by joshsav, on Flickr

05/05/2011 by joshsav, on Flickr

05/05/2011 by joshsav, on Flickr

I would have got a photo of the whole workshop but it looks more like a beetle breakers yard at the minute so I didn’t bother.

 

[Addz]

Great read so far keep it up!

 

[sava001006]

06/05/2011
Whey my parts have finally come, really good service from vw heritage, ordered yesterday and they come today. Well I ordered a top end rebuild kit I didn’t realise how many bits it came with.

06/05/2011 by joshsav, on Flickr

Safe to say a few bits came, right now that they are there might as well start building the head. First thing to lay out all the bits I will need to build it up.

06/05/2011 by joshsav, on Flickr

So the first thing to-do was to Lapp the valve, this consists of putting some fin grinding paste on the valve so that they have a really good seal.

06/05/2011 by joshsav, on Flickr

Put some grinding paste, and then make sure the valve has some oil on it then pop in into the head and spin, when its done it should look like this, after I have wiped all the paste off it.

06/05/2011 by joshsav, on Flickr

06/05/2011 by joshsav, on Flickr

All nice. Once all the valves had been done it looked like this.

06/05/2011 by joshsav, on Flickr

Then on with the spings and all the other gubbings

06/05/2011 by joshsav, on Flickr

Once I had got my head round the spring press I ended up with this

06/05/2011 by joshsav, on Flickr

And then when they are all done I ended up with summat like this

06/05/2011 by joshsav, on Flickr

06/05/2011 by joshsav, on Flickr

Total cost to date = £2,554.95

 

[sava001006]

07/05/2011
Still cracking with then we had to first put the piston ring on, but they all have to go a certain way but just look carefully.

07/05/2011 by joshsav, on Flickr

07/05/2011 by joshsav, on Flickr

07/05/2011 by joshsav, on Flickr

Note all the writing on the pistons with all the spec of the piston on it. We then took all the bits down to the workshop; I first had to re seat the barrels so that a good seal was achieved so it don’t piss oil everywhere when its built.

07/05/2011 by joshsav, on Flickr

I did this the same way that I had done the pistons before, by using grinding paste. When this was done it was then onto putting the pistons onto the rods.

07/05/2011 by joshsav, on Flickr

Once this had been done we cleaned the rocker up and cleaned the streigher and the bottom of the sump but I havent got any pictures of this, we then after doing this went on to put the bots in the case, we notice that one went in more that the others, wierd.

07/05/2011 by joshsav, on Flickr

07/05/2011 by joshsav, on Flickr

And I did get one last shot before locking it up.

07/05/2011 by joshsav, on Flickr

 

[fUbAr]

Awesome. Do you plan to sell it when it's done to make quick money, or are you keeping it?

 

[Dunn]

Great progress

keep it up

 

[sava001006]

Awesome. Do you plan to sell it when it's done to make quick money, or are you keeping it?

i will be keeping it, and just enjoying it, and going to the many vw shows about

 

[sava001006]

10/05/11
A little update but not much, we had the piston in as of the other day, we were just checking over them when we notice excess play so we thought it was best to split the block and have a look over it, bad news a lot of wear on the crankshaft so a new one is ordered, also new big end bearings, I did get a few photos so here they are.

10/05/2011 by joshsav, on Flickr

10/05/2011 by joshsav, on Flickr

10/05/2011 by joshsav, on Flickr

10/05/2011 by joshsav, on Flickr

14/05/2011
Not been doing much because I’ve been waiting on many different parts, but now they’re here so I can crack on with the building of the engine, first was to lay out the parts

14/05/2011 by joshsav, on Flickr

14/05/2011 by joshsav, on Flickr

14/05/2011 by joshsav, on Flickr

As you can tell from the photos the block had been cleaned and the crankshaft is a remanufactured to help cut costs down, and after a lot of heat and a little tap of the hammer the gears went onto the crankshaft. Then I had to put the conrods on, we referred to the manual which was a little confusing but we got there.

14/05/2011 by joshsav, on Flickr

Next was to put it in the crankshaft and the cam shaft into one half of the block, and smear the sealant stuff that I decided to use.

14/05/2011 by joshsav, on Flickr

14/05/2011 by joshsav, on Flickr

The stuff that I was using on the block.

14/05/2011 by joshsav, on Flickr

the next bit was a little fiddly because of the cam followers wanted to fall out but a little grease to hold them in a little but we managed it.

14/05/2011 by joshsav, on Flickr

14/05/2011 by joshsav, on Flickr

Total Spent = £2,730.95

 

[Ian_182]

Nice project.

 

[john.med]

Cracking stuff. Good luck!

 

[sava001006]

[FONT=&quot]19/05/2011[/FONT]
[FONT=&quot]Not a massive update but I went to Halfords and got some satin paint to paint the tin wear just to smarten it up. Anyway pics[/FONT]
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[FONT=&quot]19/05/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]Total spent = £2,736.94[/FONT]
[FONT=&quot]20/05/2011[/FONT]
[FONT=&quot]We went to fit the pistons and barrels but when we were fitting the barrels the rods were toot bit for the holes in the barrels so I phoned vw heritage and it turn out that they had sent the wrong ones, and that they were going to send some more tomorrow and take the other ones back. Sorted.[/FONT]
[FONT=&quot]21/05/2011[/FONT]
[FONT=&quot]The parcel has turned up, the best customer service I have had off a website in a long time. I would recommend them to anyone.[/FONT]
[FONT=&quot]25/05/2011[/FONT]
[FONT=&quot]I’ve not had too much time recently with coursework and extra hours at work to help pay for the beetle so I decided to paint the bock just to make it a little easier on the eye I decided I have some VHT matt paint already in so I picked that up and painted the block, once it had dried I didn’t like the finish because it just looked like dried oil, so I will nip Halfords tomorrow and see what they have got.[/FONT]
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[FONT=&quot]25/05/2011 by joshsav, on Flickr [/FONT]
[FONT=&quot]26/05/2011[/FONT]
[FONT=&quot]A very small update, I went to Halfords and the best colour they had in was black so I got the gloss one that will hopefully look better.[/FONT]
[FONT=&quot]Cost to date = £2,742.93[/FONT]
[FONT=&quot]27/05/2011[/FONT]
[FONT=&quot]Managed to paint the block today with the paint that I purchased yesterday and it was tricky because I didn’t want it going into the block, but I soon managed it anyways the picture[/FONT]
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[FONT=&quot]27/05/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]I also started to strip the carb and give it a once over and make sure nothing is broken or blocked so first I laid out the carb ready to clean it up[/FONT]
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[FONT=&quot]27/05/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Then off with the choke and the top half of the carb[/FONT]
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[FONT=&quot]27/05/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]All the other bits and pieces jets floats etc[/FONT]
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[FONT=&quot]27/05/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]27/05/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]We went to put it back together but I ran out of carb cleaner so it will have to wait till tomorrow, also I have bought a few days ago a empi manifold that should fir on the carb, because the only one had holes is it.[/FONT]
[FONT=&quot]Cost to date = £2,792.93[/FONT]
[FONT=&quot]28/05/2011[/FONT]
[FONT=&quot]Today we got a fair bit done, which I was happy with because I can now see things taking shape, first think we did was to put the piston rings on the piston, because the was a different set that the last ones then to squeeze the rings so that the piston would go down the barrels.[/FONT]
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[FONT=&quot]28/05/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]One we had done two we then had to fit the head and pushrod tubes, these is a little trick we did to fit the head so that the pushrod tubes just fit then fit the pushrods to just hole them in place, when made it easier than holding 4 tubes in place.[/FONT]
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[FONT=&quot]28/05/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]28/05/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Then once done I had to torque the heads up in a certain order. And to fit the rocker, once fit the rocker I had to use the feeler gauge to make sure that the rocker is the correct distance[/FONT]
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[FONT=&quot]28/05/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Then on with the rocker cover and the clip, which was really tight because it was brand new[/FONT]
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[FONT=&quot]28/05/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]When I had done this I did the carb because I was late and it took a while to do one side. The carb parts needed cleaning, once done the looked all new[/FONT]
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[FONT=&quot]28/05/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]28/05/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Then once all cleaned back together[/FONT]
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[FONT=&quot]28/05/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]30/05/2011[/FONT]
[FONT=&quot]Well I a bit more work has been done on the engine I’ve managed to complete the other side of the engine, which is great, it is eventually starting to look like an engine. I didn’t bother with loads of pictures because they would just be the same as the other side. Only got a photo of when I had finished building it.[/FONT]
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[FONT=&quot]30/05/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]30/05/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]30/05/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]30/05/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]01/06/2011[/FONT]
[FONT=&quot]Got a lot done today which was great, it is starting to look more and more like a engine, the first thing that we did was to fit 2 pieces of tin where that fitted onto the barrels[/FONT]
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[FONT=&quot]01/06/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]01/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Got some nice shiny screws to do all the tin wear too next was to attach the heater exchanges and the exhaust this was a tricky job because they had to all be shuffled are so that they would fit. Once bolted up the next thing was to use the new fitting kit that I had got to join the exhaust and the heater exchanges. This was very fiddly because there wasn't much space.[/FONT]
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[FONT=&quot]01/06/2011 by joshsav, on FlickrYet not another job that wasn't too easy the manifold this would be easy but I have to glue/seal the manifold pipes, first thing to do was to fit it but not too tight then mark where the pipe goes. Then once this is done take it off and use the sealant to bond the pipes in place then bolt the whole thing down and fit the stabiliser bar. [/FONT]
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[FONT=&quot]01/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Whey more shiny nuts right the fan housing was the next bit that we fit. This was heavy and it didn’t want to fit so a few choice words were said and a quick hit with a hammer it fitted. Once we had done this we left it as it was.[/FONT]
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[FONT=&quot]02/06/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]01/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Total so far = £2,794.93[/FONT]
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[FONT=&quot]02/06/2011[/FONT]
[FONT=&quot]Not a massive update but a update none the lease, a few bits of tin wear fitted along with a new oil pressure switch and a oil filler cap[/FONT]
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[FONT=&quot]02/06/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]02/06/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]02/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Total so far = 2,800.93[/FONT]
[FONT=&quot]03/06/2011[/FONT]
[FONT=&quot]Now that my carb has been overhauled I need to make a gasket for it, I could get one from Webber but at £36 I think I will make one. That and I have never made one so it will be summat new. First thing was to get a piece of cardboard big enough[/FONT]
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[FONT=&quot]03/06/2011 by joshsav, on Flickr [/FONT]
[FONT=&quot]This come from a cereal box next was to lay it on underside of the carb, the side where you want to gasket. Then lightly tap round all the edges with the handle of a screwdriver just enough to mark it.[/FONT]
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[FONT=&quot]03/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Then was the tricky task of cutting it all out very carefully and you end up with this.[/FONT]
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[FONT=&quot]03/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Then to see if it fits all nice[/FONT]
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[FONT=&quot]03/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]And then to bolt it all together.[/FONT]
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[FONT=&quot]03/06/2011 by joshsav, on Flickr[/FONT]
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[FONT=&quot]03/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]09/06/2011[/FONT]
[FONT=&quot]not the biggest update but the workshop was getting a bit messy and it was hard to get to work on the chassis so a quick tidy up.[/FONT]
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[FONT=&quot]09/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]15/06/2011[/FONT]
[FONT=&quot]Cracking on with the chassis a needed to strip the rear of the car down so odff with the trailing arms. This wasn't too hard because someone has had it off before the bolts weren’t too tight.[/FONT]
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[FONT=&quot]15/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]Once these were off it was off with the damper and the driveshaft, I also looked in the drums to see how bad there were. This was easier said than done we took the split pin out so we assumed that it wont be too tight the bolt. We were wrong it was silly tight but we managed to crack the nut so to speak. We then opened the drums to find all new pads and the drums weren’t original because there was no lip. This was good new means I don’t have to but new ones.[/FONT]
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[FONT=&quot]15/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]We put the drum back on so that we didn’t lose the bolt. And cracked on with the rust. It was my first time using a weld and all I had to do was weld a little hole and yeah, I went crazy but it will be ok one I’ve got the angle grinder on it.[/FONT]
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[FONT=&quot]15/06/2011 by joshsav, on Flickr
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[FONT=&quot]I spotted a small hole on the underside of the chassis so I turned it over and wire brushed round the hole to have some nice clean metal to weld to, this is where it goes downhill. It revealed a few more holes[/FONT]
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[FONT=&quot]15/06/2011 by joshsav, on Flickr[/FONT]
[FONT=&quot]This is how I left it because I come to the conclusion to replace the bottom of the frame head, because I think that it takes a lot of strain so I want it to be done proper.[/FONT]
[FONT=&quot]21/06/2011[/FONT]
[FONT=&quot]Not a big update but I’ve pained a few bits suspension arms and roll bar; I’ve also cancelled the order of the floor pan, and ordered it from a different place because they were starting to take the piss. Anyway I didn’t get and photos because I’m sure you will see them later on in the build.[/FONT]
[FONT=&quot]Total so far = £2,862.54[/FONT]

 

[Nickson]

Great looking project mate!
A hell of a lot of time and work has gone into this!
Seems to be shaping up very nicely!

Top work! :approve: