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NOT A MIATA - I've made a terrible mistake
WARNING: This thread may contain one or more of the following:
So we'll start out on the question I'm sure no one cares has been thinking... "So EO2k, you've been gone for a while, what have you been up to?" I got a new job, I moved, there was a fire, and I still have 4 cats an a Miata. Go me. But you didn't come here to hear about me, you came here to see what terrible mistakes I've made. Well partner, we're going for a ride... IN MY 1965 VOLKSWAGEN BAJA BEETLE! https://cimg6.ibsrv.net/gimg/www.mia...8ef4c06a22.jpg So these are the first 3 pics I snapped of the car when I found it in the owners yard. https://cimg7.ibsrv.net/gimg/www.mia...6eee9f38c7.jpg These pics are from back in November or December of last year. https://cimg9.ibsrv.net/gimg/www.mia...d9cbc8ccae.jpg The keen eyed amongst you will notice the background looks a little ...sepia tone. Well, that's not a filter. These pics were taken in Paradise, California shortly after the Camp Fire. This vehicle was sitting in my in-laws neighbors driveway when the whole neighborhood burned to the ground. Most of the cars in Paradise look something like this: https://cimg3.ibsrv.net/gimg/www.mia...b22497fe0f.jpg I even found a Miata for you to gawk at: https://cimg4.ibsrv.net/gimg/www.mia...2c5ce10f22.jpg https://cimg6.ibsrv.net/gimg/www.mia...0e0e12f876.jpg And most peoples houses look like this: https://cimg1.ibsrv.net/gimg/www.mia...f85b63d75c.jpg https://cimg4.ibsrv.net/gimg/www.mia...7630fa66f2.jpg https://cimg6.ibsrv.net/gimg/www.mia...d9b45dc0bb.jpg This is just one house. There are 13,500 more homes EXACTLY like this in Paradise. I don't have the correct grasp of language to express this on a level that can be understood unless its something you've experienced directly, so I'm not even going to try. To quote Dr. Ellie Arroway from Carl Sagan's book Contact: "No words. They should have sent a poet." https://cimg3.ibsrv.net/gimg/www.mia...843648819a.jpg How that stupid VW survived with the pile of oak leaves under it is a mystery to me. The car next to it burned to the ground, the house and trailer next to it burned to the ground, but the car survived. Totally random. |
I spent the next couple months trying to chase down the previous owner (PO) who I'll call "PO Ken" who clearly also lost his house, but eventually we made the connection. For the princely sum of $400 I bought this car, not running, and hauled it over to my father in laws burned out lot.
I can hear the commentary already "You paid $400 for that piece of shit?" Yeah, I did. Because it has a clean title in the POs name, and was on current non-op. For those of you who don't understand the pain of California vehicle registration, that's a HUGE deal. If you fail to pay registration for just 2 years, its a minimum of around $550 and at least 2 trips to the DMV to sort it out. That means taking time off work and dealing with The Central Bureaucracy, and ain't nobody got time for that. If the owner doesn't have a title in their name, you're talking another $100+ and several more trips just to get the title shitshow sorted out. Take it from someone who has played the game several times, if you live in California DO NOT buy a car with a missing or incomplete title history. The juice is almost never worth the squeeze. But back to VW things. For those not familiar with a Baja Bug, you basically take a perfectly good (or perfectly terrible) old air cooled volkswagen and you gut it, then cut off the nose, rear end, front and rear fenders, and anything else that gets in your way and you replace it with poorly made fiberglass parts. You then put big wheels on it and go run around in the dirt/sand/ocean/desert/whatever and give zero fucks. Sounds like my kind of project! Meeting up with "PO Ken" I got a little history on the car, and snapped some more pics: https://cimg1.ibsrv.net/gimg/www.mia...5b4eb06398.jpg The interior is what you might say "cosmetically challenged" https://cimg4.ibsrv.net/gimg/www.mia...1636032618.jpg https://cimg3.ibsrv.net/gimg/www.mia...5127548752.jpg https://cimg4.ibsrv.net/gimg/www.mia...72d9577914.jpg He bought the tub without an engine (quite common for air cooled VWs, check craigslist if you don't believe me) and a pile of used Baja fiberglass and slapped the car together. And I do mean slapped it together. He stuffed a post '71 1600 dual port in it and called it good to go. He drove it around for a while until he had a heart attack (probably unrelated) and now he can't work on cars anymore. It sat in his driveway for about 5 years until his house burned down, and then it was in the way, so he decided to get rid of it.\ The wiring is pretty fucking frighting https://cimg1.ibsrv.net/gimg/www.mia...81b789f02d.jpg https://cimg3.ibsrv.net/gimg/www.mia...df851bfec7.jpg https://cimg5.ibsrv.net/gimg/www.mia...524131532a.jpg https://cimg7.ibsrv.net/gimg/www.mia...450a710f2d.jpg He said used words like "Ran when parked" and "just needs a fresh battery" and "no time to work on it myself" so it was like talking to a walking, breathing version of a Craigslist used car post. He also indicated that the transaxle was leaking lube, but it probably "just needed a gasket somewhere." Riiiight. I was told that he started it and "got it up to temp every 3 months" until the fire, and it wouldn't take much work to get it road worthy. And that was great news, because I plan on driving it all over the place this summer. Why? Because I make more terrible decisions and have fantastic friends who support me in these endeavours: https://cimg1.ibsrv.net/gimg/www.mia...71d9db5734.jpg https://24hoursoflemons.com/lemons-r...monterey-2019/ That's right bitches, I'm going to take a $400 Baja Bug on a Lemons Rally. :party: |
First order of business is to make sure this thing'll start and run, and try not to ruin it in the process.
I picked up some straight 30 weight oil from the Tractor Supply on the recommendation of a very VW knowledgeable friend and changed the oil. https://cimg8.ibsrv.net/gimg/www.mia...37c779392.jpeg I also replaced the oil screen in the engine, as one does with a VW. The oil was dirty and nasty, but wasn't full of sparkly bits. Probably a good sign? The transaxle got topped off with the only GL4 in existence, as ordered from Amazon: https://cimg8.ibsrv.net/gimg/www.mia...366854846a.jpg Words cannot describe my loathing for the stench of gear oil. Topping off the transaxle seemed to go fine, thank goodness and had done my research and already had a 17mm allen key to get the drain and fill plugs loose. Fluids sorted, time to get it to start. Step 2, why the fuck doesn't it crank? Well, that's because the battery was dead. The car had been converted to an electric fuel pump but the battery was stone dead and clearly had issues. Well, issues beyond falling through the floor. As there is no power in Paradise, I had to haul it back to my place in Chico to put it on a charger. Precautions were taken: https://cimg7.ibsrv.net/gimg/www.mia...8d7ed716ce.jpg The damn thing refused to take a charge, so I added some distilled water: https://cimg8.ibsrv.net/gimg/www.mia...5ae5428300.jpg It took half a gallon of distilled water. Well, this battery is clearly fuckered. Well kids, this is what happens when you leave a battery connected to a charger for like, a year. Good thing I've got a spare. I charged up my spare battery and several days later headed back up to Paradise. I hooked up the battery, turned the key, and was greeted by the saddest fuel pump noise I think I've ever heard in my life, along with the sound of dripping and spraying. thatsprobablynotgood.gif Turned off the key and went back to check the engine and I was immediately greeted by a smell that rivaled old gear oil. It was old fuel. And it was leaking EVERYWHERE. https://cimg2.ibsrv.net/gimg/www.mia...b372328ae4.jpg Well, this isn't right. I started pulling the hoses off the regulator and they pretty much disintegrated in my hands. https://cimg4.ibsrv.net/gimg/www.mia...d9fd82f935.jpg Sure PO Ken, I bet it ran just fine like 4-5 months ago :facepalm: Looks like I need some fuel hose. /sigh Gave up for the day and drove the 30 min back to Chico to pick up hose so I can try again another day. |
I should note at this point some of the challenges of working on this project:
https://cimg1.ibsrv.net/gimg/www.mia...0d6820633d.jpg From where I work to where the car was stored at the time, its a 30min drive. Paradise is still under curfew for non-residents, and you are supposed to be off the roads by I think 8:00PM. It is HEAVILY patrolled by both the Butte County Sheriffs Department and the California Highway Patrol and because these guys are working in what is essentially a burned out apocalypse so they have zero sense of humor and no time for shenanigans. I've got a window of about 2.5h in the evening to get from work to Paradise, get shit done, and GTFO in the evenings after work. My weekends were packed up with other commitments so getting this thing running was getting to be a challenge. I'm also working in the dirt/gravel, and that's cause for a few more challenges: Damn I hate gravel. |
Very entertaining.
Where are you working now? What kind os business? IIRC, in the past, you worked IT for a produce grower. |
I should talk about the engine real quick:
https://cimg0.ibsrv.net/gimg/www.mia...863efd7dd3.jpg Rather than the stock 35hp or whatever 1200 or 1300cc engine that the car originally came with, this one has been swapped out for a 1600cc dual port motor out of a 71+ Super Beetle. Much like the Millennium Falcon, the PO had clearly also made some "special modifications" as well. The stock single PICT-whatever carb setup has been replaced with dual Kadron Solex H40/44 EIS kit, somewhat reminiscent to what was originally on a Porsche 356 back in the before times. The distributor appears to be a points unit of the "SVDA" variety (single vacuum, dual advance) and one of the carbs was specifically modified for the distributor, and the exhaust is a typical Baja buggy "extractor" exhaust with what is colloquially known as a "quiet pack" muffler. It was converted from generator to alternator (thank goodness) and an internally regulated alternator at that. Oil fill neck on the alternator stand is some sort of fancy billet piece with a breather. The heater boxes were removed in favor of a set of "J pipes" so at least I know I won't die from carbon monoxide poisoning. For those unfamiliar, the Beetle heater worked by stealing engine cooling air and driving it through a jacket in a double walled heat exchanger that was tied into the exhaust and feeding it into the cabin. They had a tendency to rust out and pump exhaust into the cabin over time. If that's not Kraft durch Freude, I don't know what is! The "high powered" genuine Bosch "Blue" coil rounds out the ensemblé. Here is some more random engine and exhaust pics: https://cimg8.ibsrv.net/gimg/www.mia...a1a1d808a8.jpg https://cimg1.ibsrv.net/gimg/www.mia...94eb0c7eac.jpg https://cimg4.ibsrv.net/gimg/www.mia...22090ffa12.jpg https://cimg5.ibsrv.net/gimg/www.mia...7ee23a3d56.jpg https://cimg9.ibsrv.net/gimg/www.mia...832f721a4d.jpg https://cimg0.ibsrv.net/gimg/www.mia...f4dfafd17b.jpg The aluminum crank pulley (who needs a fucking damper, bunch of pansies I swear!) with all the degree markings will come in handy I'm sure. https://cimg0.ibsrv.net/gimg/www.mia...03f3e295c1.jpg |
Originally Posted by DNMakinson
(Post 1536385)
Very entertaining.
Where are you working now? What kind os business? IIRC, in the past, you worked IT for a produce grower. I'm working for the university here in Chico, still doing tech. The produce company was a good job, but after not really having a boss for 7 of the almost 10 years I worked there, I got a new boss and it suddenly became clear that I wasn't going to be moving forward. I put in a lot of work and effort to "pay my dues" and try to move up, but that wasn't happening unless someone else died or left, so it was time for me to go. Cost of living was too damn high, and my job was never going to afford me the opportunity to "get ahead" of my situation. I should have seen that years ago, but I had some personal stuff I was struggling with over the last couple years that blinded me to it, so it was just a "head down, grind it out, it'll probably get better" situation. Northern California is pretty cool, but I'm still adapting. It'll be a process. |
If you want to megasquirt it, this guy sells a bunch of gear. He's a pretty cool guy, and I'm sure he will steer you right if you have questions:
Fuel Injection Parts and Accessories for Air Cooled Volkswagen - The Dub Shop The other hack I remember from my VW days is that the valve lash is supposed to be set at 0° C, so you can fill a Ziploc bag with ice cubes to make it happen. Also, please name this something something pheonix/dumpster fire, etc. |
Originally Posted by wackbards
(Post 1536394)
If you want to megasquirt it...
(Spoiler alert: I've already been in touch with Mario :cool:) |
While dealing with the apocalyptically leaky fuel system, I came to the realization that the aftermarket fuel pressure regulator was no plumbed correctly. Dafaq?!
It's a super basic Holley non-vacuum referenced adjustable fuel pressure regulator, adjustment range is 1-4psi. No, that's not a typo. Holley PN 12-804 https://cimg4.ibsrv.net/gimg/www.mia...fa61f37caa.jpg The inlet is in the center (on the bottom in the above pic) outlets to the sides, and its generally used to plumb the fuel bowls in a 4 barrel setup, something like this: https://cimg0.ibsrv.net/gimg/www.mia...9644880604.jpg So clearly one of my carbs was getting full, unregulated flow from the pump and the other was getting ... nothing? Alarm bells are ringing. The carbs are happy with 1.75-2psi (again, not a typo) so clearly the needle and seat assembly in one of the carbs is being completely overrun. I bought all new modern fuel hose, filters, clamps and replaced everything. I also decided at that point it was time to do something about the rancid fuel. Good thing the little electric fuel pump was working, because methinks its time to drain the tank and put some fresh fuel in it (without a hint of foreshadowing...) JUST BE GLAD THIS ISN'T SMELL-O-VISION. :barf: |
This was ... bad. This fuel needed to go away as quickly as possible. I generally don't have problems with automotive fluids, but the stink here was indescribable.
https://cimg5.ibsrv.net/gimg/www.mia...99317cce47.jpg https://cimg6.ibsrv.net/gimg/www.mia...23bb217cb5.jpg And yeah, that's rust. FML |
So with the tank empty, I removed it and hauled it back to the house in Chico for cleanup.
https://cimg7.ibsrv.net/gimg/www.mia...e277aef3f3.jpg https://cimg1.ibsrv.net/gimg/www.mia...d5359329c8.jpg https://cimg3.ibsrv.net/gimg/www.mia...a3e472bcee.jpg Ewwwwwwwwww. I put some diesel in it, along with a generous handful of nuts and bolts, and a length of chain, and started shaking. and I shook and I shook and I shook some more. After 3-4 cycles of shaking, diesel rinse, and more shaking, I flushed it with acetone and let it sit for a couple days to completely dry. I came back, upended the tank, whomped it with a chunk of 2x4 and this is what came out: https://cimg8.ibsrv.net/gimg/www.mia...e3f3dc4092.jpg https://cimg3.ibsrv.net/gimg/www.mia...2e756c55ca.jpg Nah, fuck this, I'm out. |
So I did what any logical human being should do, I ordered a new tank:
https://cimg0.ibsrv.net/gimg/www.mia...a69ffb4f2c.jpg https://cimg1.ibsrv.net/gimg/www.mia...c330bd6dd9.jpg Lol, Amazon Prime fuel tank for a 1965 Volkswagen. It came with gasket and outlet nipple thing, but no tank screen. At just under $100 I wasn't going to complain. I got a new screen from a local air cooled VW shop and installed this bish. https://cimg7.ibsrv.net/gimg/www.mia...40bf32353f.jpg Errmergerd! Original fuel cap fits! https://cimg8.ibsrv.net/gimg/www.mia...d6a67f2dfc.jpg I also re-plumbed all the stuff under the tank, and added an additional fuel filter. https://cimg4.ibsrv.net/gimg/www.mia...1e3f1fb512.jpg I also added another filter to the rear, right after the factory hardline. |
I was up in Paradise and didn't have any other fuel, so I decided to make due and get this thing rolling.
Sacrifices were made. https://cimg4.ibsrv.net/gimg/www.mia...1c0fc5ed6e.jpg In order to prime the carbs, I made a little funnely thing to fill the fuel bowls directly through the vents. https://cimg2.ibsrv.net/gimg/www.mia...768545a07e.jpg #cantstopwontstop #necessityisthemotherofinvention #irsmrt |
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It was at this point I realized one carb wasn't getting fuel at all, and the accelerator pump wasn't working in the one carb it was running on. Bugger. Tapping on the top of the carb with a large wrench to knock the needle and seat loose accomplished exactly nothing. Dammit.
https://cimg7.ibsrv.net/gimg/www.mia...da0d0e4fa6.jpg https://cimg7.ibsrv.net/gimg/www.mia...397b5916be.jpg One carb completely dry https://cimg5.ibsrv.net/gimg/www.mia...721a6dac87.jpg The other had fuel coming out of it all over the place. /sigh. Time for some carb rebuilds! I ripped the carbs off the motor, packed up and headed home. |
I got online and I ordered a couple carb rebuild kits from the guys at The Kaddie Shack in Pasadena. For being in SoCal, they seemed like ok dudes, but shipping was like, 4 days? Amazon has completely spoiled me.
In the mean time, I started working on the carbs. https://cimg7.ibsrv.net/gimg/www.mia...1c97cb6954.jpg https://cimg4.ibsrv.net/gimg/www.mia...dce827f120.jpg https://cimg6.ibsrv.net/gimg/www.mia...0cdb38b3f3.jpg https://cimg9.ibsrv.net/gimg/www.mia...7cfde9af46.jpg It was about this time I realized this rabbit hole was going to get deep. https://cimg7.ibsrv.net/gimg/www.mia...82d0f7ac8c.jpg https://cimg9.ibsrv.net/gimg/www.mia...7e510be29e.jpg https://cimg3.ibsrv.net/gimg/www.mia...070e81aac0.jpg Unghhhhh :barf: |
Time for full disassembly.
https://cimg3.ibsrv.net/gimg/www.mia...9deb74e8e0.jpg Why do one at a time when you can do them both and mix up all the parts?! I cleaned what I could with the smallest things I had available, but I still couldn't get carb cleaner through the passages of the accelerator pump. Fffffffuuuuuuuuuuuu :vash: https://cimg0.ibsrv.net/gimg/www.mia...9c2044a9dd.jpg lol handy carb cleaning tools There is a tiny plastic plunger underneath a brass plug in the carb body that was obviously stuck, and a tiny ball bearing check on the output nozzle tube thingaso. Both need to come out. https://cimg2.ibsrv.net/gimg/www.mia...a75602d1b4.jpg https://cimg3.ibsrv.net/gimg/www.mia...cd5459b31c.jpg Carefuling.... https://cimg9.ibsrv.net/gimg/www.mia...31f14823bb.jpg Tiny check ball extracted! Time to break out the big guns |
I then broke down ordered up something I've wanted for years:
https://cimg9.ibsrv.net/gimg/www.mia...96e5529ed9.jpg Aww yiss. And then I filled it with probably a gallon and a half of this stuff: https://cimg1.ibsrv.net/gimg/www.mia...f48bf89f2.jpeg I set it to 35°C and let'er rip. Outside. Away from most flammable things. Lol. https://cimg6.ibsrv.net/gimg/www.mia...da7015445f.jpg For the record, I would NOT recommend filling an ultrasonic cleaner with carb dip :giggle: |
But holy shit does it work great.
https://cimg2.ibsrv.net/gimg/www.mia...e167aef8cc.jpg Most of the parts look damn near brand spanking new. I opted to order new internal filters for the carbs, along with new floats. https://cimg4.ibsrv.net/gimg/www.mia...2cfb263664.jpg Carbs went together super fast, I almost didn't get a chance to finish my beer. :party: ALWAYS KEEP THE OLD PARTS AND THE GASKETS! You never know when you'll need the dammed things, and an old gasket is better than no gasket when you are miles from home. #carblyfe #justvwthings #reliability |
One of the more iconic things about a Baja is the goofy tire sizes. Usually its something giant in the rear, and tiny up front. This car is no exception.
https://cimg2.ibsrv.net/gimg/www.mia...c9292a35e2.jpg P195/75R14 in the front https://cimg4.ibsrv.net/gimg/www.mia...76933e71c3.jpg P205/75R15 in the rear Because fuck me, who needs a spare tire? https://cimg1.ibsrv.net/gimg/www.mia...241731f31d.jpg I've been told these are some sort of oldschool steel rim generally referred to as "Appliance rims" but I've got two different sizes, a 14x...whatever in the front, and a 15x8 in the rear (I think, maybe 15x8.5?) I don't like the staggered sizes because I can't carry a spare, so the goal is to find another pair of at least 15s to match the rear. BTW, the lug pattern is what the airheads call a "Wide 5" its 5 lugs on 205mm and it interchanges with ... nothing. Lo and behold, local VW shop has exactly what I need stacked in the bowels of his warehouse: https://cimg1.ibsrv.net/gimg/www.mia...d348479034.jpg Awwww, fuckyeah. :cool: They are 15x6 and have a completely different offset from the ones I've got in the rear, but at least now I have a chance in hell of carrying a spare. Now I need to find some new tires. |
If they ship this to Cali, buy some. Just be advised that it causes cancer in all 50 states
Berkebile Oil 2 + 2 B101 Instant Gum Cutter - 13 oz. |
In reading about off-road Beetle things, I discovered Baja Class 11 cars. These are basically stock Beetles with the biggest tires you can fit under the stock fenders, plus a cage and some other safty gear. I'm not going to run Baja, but the look is a fantastic inspiration. The local VW shop had this sitting in their lot, and for whatever reason, I really like it.
https://cimg8.ibsrv.net/gimg/www.mia...4a176f5ce0.jpg It's more of a "Class 11" look-alike thing going on, but I totally dig the fitment. The tires are Deestone D503 7.00-15 It's an 8 ply D range light truck tire for ... vintage military things and farm implements maybe? https://cimg9.ibsrv.net/gimg/www.mia...27b329b89c.jpg https://cimg3.ibsrv.net/gimg/www.mia...32154e0a94.jpg https://cimg2.ibsrv.net/gimg/www.mia...9181fbc82a.jpg They are sold under the Deestone, Eldorado, PowerKing, Jetzon and TBCBrands, etc for about $90/ea if you catch them on sale. Unfortunately that's about as much as I paid for the car, so that seems ridiculous. Talking to the owner of the shop, the owner of this vehicle loves the tires and with the stock engine and trans, he can do 65 on the highway no problem, but sometimes has to downshift for hills depending on speed. I believe he said its got a healthy stock single port 1600 with single carb under the deck. Interesting note about the Deestone: https://cimg9.ibsrv.net/gimg/www.mia...bdd440984d.jpg That's a 30" diameter tire. I've got a much lighter vehicle by nature due to stripped out Baja, so I feel like as long as I stay under 30" I should probably be OK. Digging around on TheSamba in the off-road section, I discovered there are a bunch of guys running 28" to 30" diameter tires on the stock drivetrain without a lot of issues, provided you don't get TOO crazy on the rear traction tires. Swampers and big chunky mud tires need not apply. Hell, the sand guys actually install paddles in the rear backwards to help preserve the transaxle. I focused on a LT235/75-R15 as my target size because they run about 28-29" diameter and seem to be incredibly common among a certain segment of the Jeep population. I wanted an A/T tire rather than an M/T tire, and I figured I could find a cheap set on Craigslist and be done with it. Well, after weeks of searching, I gave up. Apparently nobody is selling used tires on Craiglist anymore. I almost broke down an bought a set of General Grabber AT2 when I found these beauties: https://cimg3.ibsrv.net/gimg/www.mia...d09f344b8b.jpg The Definity is a Pep Boys house brand tire made by I think Cooper, and the Dakota A/T2 is currently being discontinued. It's a 6 ply Light Truck tire with a 104/101 R service rating (1984 lbs per axle & 106 mph, lol) At the time they were listed at $65 and I could only add 2x to my cart. I called the Pep Boys and asked if I could get 3 more. He said if I really wanted them, he'd give them to me for $40/ea and he would try to get 3 more. There were none left in warehouse stock anywhere so he had to pull them from shelf stock singles from 2 other Pep Boys stores in NorCal, and one out of Reno. lol Looks like they are on sale for $48.68 now, but good luck trying to get a full set. Price doesn't matter though, because I got a full set of tires and they didn't cost more than the car :D https://cimg1.ibsrv.net/gimg/www.mia...31332d6b7e.jpg https://cimg2.ibsrv.net/gimg/www.mia...f9caf31bee.jpg BEEFFFFF! Now I just need to get them mounted and balanced and I should be good to go. The balancing part may be tricky though, because nobody I've called says they can do a VW Wide 5. About the only place I haven't tried, and the last place someone recommended to me, was the Les Schwab so I'll give them a ring on Tuesday. No idea if they'll balance something that wasn't purchased from them, but I guess I'll find out. I also need a 5th rim, but it looks like there are a few singles on TheSamba, or I'll try to hit a swap meet somewhere. |
Originally Posted by wackbards
(Post 1536415)
If they ship this to Cali, buy some. Just be advised that it causes cancer in all 50 states
Berkebile Oil 2 + 2 B101 Instant Gum Cutter - 13 oz. https://www.amazon.com/dp/B000CII6JM..._Cle7Cb5M0VZ19 I've got the carbs pretty well squared away at this point, but I appreciate the advice! I'm kinda catching things up, as it were. I've got plenty of other stuff to de-grease though, so I'm not going to dismiss it out of hand. Plus, I got Amazon Rewards points to spend. :cool: I didn't start this thread earlier because it was draaaaaaaaagging aaaaaaaaaasssssssssssssssss to get this project moving. With only a couple hours a week to work on it, and working on it remotely with no tools, no power, no running water, no parts stores, etc really ate up time. The above happened over a period of MONTHS. It's probably the most frustrating thing I've taken on in quite a while. :/ |
And during those long periods of time waiting for parts and not making progress, I get bored and my mind starts wandering.
I want to figure out how to get an O2 sensor on this thing, because I don't trust the "classic" methods of getting a pair of carbs synced. Yes, I own a uni-sync and know how to use it, but that doesn't mean I like it. Without thinking about it too hard, I ordered up one of these: https://cimg5.ibsrv.net/gimg/www.mia...029f55137d.jpg https://cimg8.ibsrv.net/gimg/www.mia...2d09951df4.jpg I don't have a welder so this seems like it would be the easy button, right? Well, unfortunately because my project is not in my driveway and I can't walk outside and measure it, I didn't realize the 3 bolt flange on my exhaust is bigger. WAY bigger. https://cimg1.ibsrv.net/gimg/www.mia...b91c93fc9b.jpg Crap. Oh well, good thing it was cheap. But while stumbling around the internet trying to figure out what else uses this bolt pattern, I found something delightful. It turns out the Suzuki Hayabusa GSX1300R muffler from 99-07 uses the same bolt pattern. Sweet. Off to eBay I go... https://cimg8.ibsrv.net/gimg/www.mia...33f3038820.jpg That's the VW gasket on the Hayabusa midpipe, lol https://cimg3.ibsrv.net/gimg/www.mia...6c816d6524.jpg The Hayabusa uses a completely different sealing system, but since when has that ever stopped me from doing something stupid? https://cimg3.ibsrv.net/gimg/www.mia...4e2b05552f.jpg Now I've got two of the things, who KNOWS what stupid things I can do?! https://cimg3.ibsrv.net/gimg/www.mia...8554559884.jpg Fits like a fuckin' glove! |
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Before the muffler went on, I got the carbs back on, synched them up, fought the carb linkage, set the timing and put about 2g of fuel in it. Lo and behold, the mechanical fuel gauge works! I'm not joking when I say I'm shocked. It also starts and runs fantastically! I took it on a blast around the neighborhood and it did great! No bogging, no stalling, no stupidity (also no video :mad: ) just noise and go. Brakes definitely need to be adjusted though :D
It was about this time I decided I needed to take a look at the leak in the transmission and I noticed this: https://cimg3.ibsrv.net/gimg/www.mia...24cf1d4605.jpg Goddammit, that's gear oil. The axle seal is leaking :vash: :vash: :vash: I was hoping it was brake fluid, and that maybe I had left the bleeder open when my incredibly tolerant and patient wife helped me bleed the brakes, but no, one whiff confirmed axle seal. Now I get to fight the axle nut. For those not familiar with VW rear swingaxle nuts, the brake drum is splined and held to the axle shaft with a gianormous 36mm nut, torqued to 217-250 ft/lbs. That is not a typo. To get it off, you need to break that nut loose. I should mention at this point that the rear brake shoes were full of oil, and that drum was completely inoperable. I should also mention that the car has no ebrake. https://cimg1.ibsrv.net/gimg/www.mia...7f242552a8.jpg https://cimg5.ibsrv.net/gimg/www.mia...280d362bd7.jpg https://cimg3.ibsrv.net/gimg/www.mia...b634d2873c.jpg I'm not sure who's bright idea it was to remove the ebrake, but there you have it. So I pretty much gave up trying to get that nut loose. With the breaker bar and a 4' cheater, all I manged to do was slip it in the gravel, or turn the engine over with the car in gear. You know what? Time to get this thing home where I have a driveway and air tools. |
Seeing as how @MiataMan00 is a dick and stole @afm's trailer, then pulled it out to the middle of some godforsaken flyover state, refused to bring it back, and abandoned it in a field, now I can't steal afm's trailer to move the Baja. :vash:
My father in law graciously volunteered his truck and trailer to move the VW off his property (was probably just worried about the hazmat implications) so we fired it up and tossed it on the trailer. https://cimg5.ibsrv.net/gimg/www.mia...f7b571ec54.jpg https://cimg6.ibsrv.net/gimg/www.mia...48aeb73ced.jpg I drove it up onto the trailer, but it was a struggle. The car would barely idle and it was super down on power. I was very concerned as I could barely keep it running. The car had run absolutely great before this, and it was a huge disappointment for me. Also, the damn fuel gauge had stopped working :mad: https://cimg3.ibsrv.net/gimg/www.mia...47dad0b935.jpg We got it down to my 'hood and I could barely get it started. It rolled back off the trailer and idled OK, but as soon as I would touch the throttle it would stutter and cough and try to die. Fuck! I ended up driving it 2 blocks to my house, stalling it about 6 times in the process and barely able to get it to run above idle. Each time it died I assumed I'd have to get out and push but somehow I made it to the house and up the driveway, slipping the clutch and feathering the throttle the whole time. But the car is home now, and it somewhere I can actually work on it when time is available. So I got that going for me, which is nice. |
I checked the timing, I checked the carbs, I checked the fuel pump, I checked the distributor, cap, rotor, plugs condenser, points, every goddamn thing. Engines are pretty damn simple: fuel, air, spark. As long as you've got those the rest is just details. I could not for the life of me figure out what was wrong with this thing, but it was really pissing me off. I had to walk away and not think about it for a while. My wife tried to help, but I think it just added more frustration. "Is the battery charged?" Yes, I just charged it. "Does it have gas?" Yes, I just replaced the whole fuel system, put 1.5g of fresh gas in it (granted, its 2 stroke gas but 50:1 should be fine) and its making pressure. "Does it have oil?" Yes, its full of oil, I just changed it. Bless her heart.
After sleeping on it for a day or so, it occurred to me that while I had put fuel in it and it was making pressure, I never checked to see if it actually had fuel in it. Well, guess what? Yeah, that's right. :facepalm: That's when I remembered from some days ago I came up to Paradise and found the fiberglass Baja hood unlatched. I had been bleeding the brakes several days before so I thought nothing of it, I probably just forgot to button it up. Looking back, its fairly obvious that someone siphoned the gas out of the car. :asshole: I mean, I get it. Paradise is seriously a post apocalyptic wasteland right now. I'm sure for some of the people living up there is gotta be like Mad Max, roving the wastes attempting to find fuel, but that's still a fairly shitty thing to do. I hope that 50:1 leftover 2 stroke gas does wonderful things to their modern fuel injected vehicle. I put 3g of fresh gas in it at the house, ran the pump for a minute to fill the bowls on the carbs and guess what? Now it fires right up and runs like a scalded dog. I took a victory lap around the neighborhood and did my best to run over the frightened children who insist on playing in the street. I failed to hit any of them, but the car still ran great regardless. |
Now its at the house, taking up space in my driveway and leaking gear oil all over everything.
I got out the compressor and air impact and the nut came off with no issues, thank goodness for air tools. The drum also came free with no issues. https://cimg6.ibsrv.net/gimg/www.mia...bd92083a7a.jpg https://cimg7.ibsrv.net/gimg/www.mia...558829e2b1.jpg This thing has clearly been leaking for a while. The shoes are completely soaked in gear oil, and there is a film of death and disgusting behind all the brake hardware. Damn. I guess I get to pull this hub completely apart. https://cimg2.ibsrv.net/gimg/www.mia...fd0ec14908.jpg Nothing to it but to do it, I guess. Have I mentioned I hate gear oil? I hate gear oil. :( |
I have had a few air cooled VW's and lol'd a few times in this saga. Sounds so familiar.
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Originally Posted by sixshooter
(Post 1536451)
I have had a few air cooled VW's and lol'd a few times in this saga. Sounds so familiar.
Its been fun, actually. Heaps of nostalgia for me. My first car was a 1973 Super Beetle that I bought with all my summer job money back when I was 16, in the 90s. I didn't have my drivers license yet but that didn't stop me from buying the car! My Dad and I spent a LOT of time working on it, and that's basically where I learned to turn wrenches. My first trip to a junkyard to find parts, my first stripped bolts, the first time I changed a set of spark plugs, or used a timing light. That poor old Super taught me a lot of things. Eventually my parents divorce resulted in my Dad not having a car, and because I still didn't have a drivers license and it was in his name, it became his daily. It eventually spawned a Porsche Monza exhaust (probably designed for a 356) and I vividly remember it setting off car alarms in parking lots. What a riot! Then it exploded, lol |
Loving this thread. Were you able to take it for a spin after rebuilding the carbs yet? looks fun.
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So that kinda brings us to where I am now.
https://cimg2.ibsrv.net/gimg/www.mia...797fbe0bb9.jpg I got the brake assembly mostly stripped down, and started cleaning up the backing plate. You see that part "#8 - Sealing Ring" in the old timey exploded parts diagram I posted earlier? That thing was nowhere to be found. What I DID find was that someone glued the bearing and seal carrier (#14) to the backing plate, and did't bother with the o-ring, or even cleaning off the old paper gasket. Surprisingly enough, even though this is an unholy pain in the ass to clean up, it wasn't actually my the cause of my leak. The PO Ken told me that the brakes "should be great" and that he "just recently had the hubs serviced" and he was right. The white lithium grease they used on everything was still white, and the shoes had plenty of meat. Unfortunately whomever replaced the axle seal made a bit of a boo-boo. https://cimg0.ibsrv.net/gimg/www.mia...4293ed5c38.jpg See the little tension spring behind the seal? Notice how its NOT totally behind the seal? Thars yer prablem. Just like a Miata crankshaft seal, the spring is important. https://cimg2.ibsrv.net/gimg/www.mia...444d679291.jpg This is how its supposed to look, but the sealing lips are creased and worn, so its done. Good thing replacements are readily available. https://cimg3.ibsrv.net/gimg/www.mia...6e270cf91d.jpg I bought two, because they were cheap and I have two axles. Whoda thunk it? It appears the second paper gasket goes between the back of the backing plate and the axle tube, so I'll be removing the wheel cylinder and pulling the entire backing plate at some point as well. It's going to be quite the trick not getting junk in that bearing or in the axle tube. :ugh: The brake shoes are soaked. https://cimg6.ibsrv.net/gimg/www.mia...a5aecc5da7.jpg https://cimg8.ibsrv.net/gimg/www.mia...32a6ac49e1.jpg No way I'm going to reuse these. I'm a cheap bastard, but $17 for an axle set of rear shoes sounds like cheap insurance to me. ZEE CHERMAN ENGINEERS who designed this thing were pretty clever, check this shit out: https://cimg1.ibsrv.net/gimg/www.mia...0bcdba316e.jpg When the seal is pressed into the carrier, it doesn't go all the way to the face, it stops on a shoulder. The shoulder then has a relief cut, and then this clever hole drilled in it. If the seal were to fail, oil that found its way past the axle would end up behind flung outward or dripped down that inside shoulder, and then drain down to that hole. I've highlighted the hole here by jamming a brake cleaner straw through it. There is a corresponding hole in the paper gasket and in the backing plate as well. So instead of that leaking gear oil getting into the drum and ruining the shoes/causing a brake failure condition, it drains harmlessly out the back of the backing plate and onto the ground where hopefully you eventually notice the drops of foul smelling gear oil on your driveway. Neat! As a recovering machinist and "car guy" I can really appreciate this sort of attention to detail, it really makes me smile to know that someone actually thought this out, and came up with a simple solution that wasn't "value engineered" out of the final product to save in production costs. The only catch here of course, is that much like your toilet, it only works properly when the drain is clear. If you jam it up with RTV then you end up with shit all over your bathroom. Or gear oil all over you brakes. :facepalm: Just another thing to correct I guess. The car is so damn simple, its shocking that stuff like this was straight up overlooked. |
Originally Posted by Fireindc
(Post 1536459)
Loving this thread. Were you able to take it for a spin after rebuilding the carbs yet? looks fun.
I'll have to see if I can find the Go-Pro and get an in-cabin video for you guys. It makes amazingly terrible noises, and I love it. |
Speaking of being a cheap bastard... the Miata community ain't got nothing on the Old Guy© VW crew. This actually brings me to an interesting point.
https://cimg9.ibsrv.net/gimg/www.mia...8ca57554f3.jpg You are going to see a LOT more of this familiar blue/yellow/orange packaging as this thread goes on, as pretty much the only vendor left in the VW space is EMPI. VW owners are so cheap, they'll buy the lowest cost part they can find, regardless of quality. This has caused a "race to the bottom" for price and quality and EMPI has surely won. Or maybe VW owners lost. Regardless, EMPI has driven a lot of the other global parts suppliers out of business and for certain parts, there is no competition. They CAN make good stuff, but you need to be REALLY careful and make sure the things you are buying fit correctly and that the quality and materials are a good fit. Trust, but verify. I try to support small vendors when I can (like the Kadron carbs guys over at The Kaddie Shack) but its getting harder to find small shops that make quality products and actually know what the hell they are talking about. That leads me to these guys: https://cimg4.ibsrv.net/gimg/www.mia...5377a2dece.jpg Nobody, and I mean nobody, bothers to make an ebrake base except for these guys over at airkewld.com out of Texas. Its not something that generally disappears out of a car, so I think these are specifically made for offroad buggies and "volksrod" customs. But I don't care why they make it, I'm just glad that they do! I'm not a big fan of the star, but this is all about function over form for now. I just need to get my hands on a welder so I can get my ebrake back. Siq. Of course, EMPI makes a replacement ebrake handle assembly, as seen in the top right corner of my pile of parts :rolleyes: Like I say, you just can't avoid them for some stuff. Now that I got the car home, I've had a chance to go through a few more things and I'm getting ready to shotgun a parts order at this thing. :burncash: |
Ugh. I got to do a brake job twice once because I didn't realize it was the wheel axle seal.
Air cooled engines just kind of lose power when they overheat. Maybe an oil temp sensor would be a good investment. I used to carry around a roll of quarters and some aluminum friendly degreaser. About once a week I'd roll up to a diy carwash and pressure wash & degrease all the cooling fins. |
In for glorious, abject fuckery and general malaise
|
I.....don't even know what's happening
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Originally Posted by 18psi
(Post 1536471)
I.....don't even know what's happening
|
My favorite part is still the wood mounted killswitch with a cable running through a hole with no grommet :D
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Originally Posted by EO2K
(Post 1536423)
(video)
--Ian |
In it for the sheer VW-ness!!
My very first car was a '61 Bug with a '66 engine in it (eventually with Big Barrels, and dual carbs), so I'm re-living my youth through this thread. Brings back fond memories of terrorizing the North Campus of Univ of Mich in the mid '70s with my pseudo Baja Bug (I didn't have the money for the "real" kit, so I improvised). |
That battery photo reminds me of the time I was one of four in the back of a bug when the seat spring made a connection between both terminals. It went something like: odor, heat, smoke, fire. Old VWs are always an adventure.
|
"Always an adventure" is an under-statement!
I was transporting a car-load of ladies to a party in East Lansing when one of the pistons decided to perforate (due to my misunderstanding of the need for proper cooling ducting around the cylinders), and begin pumping oil all over the highway. My John Travolta-like, Saturday Night Fever white suit was not happy - and neither were those ladies. |
I had a Manx dune buggy, a 66 Microbus, a 65 21 window Microbus, and a hunter green Fastback at various times. All were an adventure. You know your rotted fuel lines? When they are on a bus and the tank lives right above the engine they do not stop feeding fuel until the tank is empty, regardless of whether the engine is on fire or not. RIP 21 window bus.
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i remember empi fondly. my 2nd car was a 1965 karmann ghia that i installed an empi exhaust on. then i had a 1967 bug, then a 1955 porsche (sorta a vw at that point), then a 1965 bus. the last two were when i was in the army in germany. with the bus i never-ever saw the left lane on the autobahn. brought home a 1971 squareback, then we bought my daughter a 1977 (i think) jetta. i'm enjoying this thread and i think you should get extra points for saving this survivor of the camp fire.
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You lost and gained me at "carburetors"
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In for a user report on the mega impressive radiator ducting in the front bonnet ...
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when is ms3 and efr going in
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When is an EJ257 going in?
|
This entire thread is making me happier and helping me feel that I made the right decision selling my 69 VW Bus earlier this month. I had many of the same problems you have faced so far except I ran out of love for it.
Regarding tires. I had great luck with my general grabber at/2s on my bus and they fit my stock wide 5 wheels pretty well. |
Originally Posted by 18psi
(Post 1536614)
when is the Subaru boxer engine going in
|
Learned to drive in a 69 1500. My dad and I removed the engine to swap in a rebuilt one, at the time we were pretty broke and didn't have a trolley jack. We used a vw jack on one side and a scissor jack from a 1979 mazda 626 the other, a lot of 2x4s and lifted the rear of the car off anr over the engine wIth a ratcheting come-along.
This brings back many memories, both good and repressed. Subscribed. |
Originally Posted by msmola2002
(Post 1536681)
Learned to drive in a 69 1500. My dad and I removed the engine to swap in a rebuilt one, at the time we were pretty broke and didn't have a trolley jack. We used a vw jack on one side and a scissor jack from a 1979 mazda 626 the other, a lot of 2x4s and lifted the rear of the car off anr over the engine wIth a ratcheting come-along.
This brings back many memories, both good and repressed. Subscribed. |
Honestly, this is incredible.
But I cannot ignore that rather than trailering this thing to your driveway from the get-go you traveled 30 minutes one way to work on it for what was probably weeks?????? |
Holy CRAP you guys! I was not expecting this kind of response, hah! I'm not sure if I should be flattered or frightened.
I guess I need to make an effort to keep this updated, thanks errybody :bigtu: |
Subbed. This is silly.
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http://aircooled.fi/data/doc/ke/kenn...yfjys6ewvf.pdf
Page 8, top of right list... just sayin :party: |
Ok, deeeeeep breath...
Originally Posted by wackbards
(Post 1536468)
Ugh. I got to do a brake job twice once because I didn't realize it was the wheel axle seal.
Air cooled engines just kind of lose power when they overheat. Maybe an oil temp sensor would be a good investment. I used to carry around a roll of quarters and some aluminum friendly degreaser. About once a week I'd roll up to a diy carwash and pressure wash & degrease all the cooling fins. I've got an AccuTech SMi oil pressure and oil temperature gauges that are known good and were previously mounted in the Miata. My plan is to come off the case at the location of the original oil pressure warning light with a piece of braided stainless or other appropriate hose, and then T the end so that I can continue to use the stock pressure warning light AND the pressure sender for the AccuTech. Oil temp is a bit harder. The 1600 is a dual relief AS41 so if I don't end up doing the "full flow" mods to the case (more on this in another post for non ACVW people) I'll probably put the sender in one of the pressure relief plugs in the bottom of the case. This seems to be the "go to" location for the gianormous VDO temp senders that the VW people love, so an adapter to 1/8"NPT will need to be found. I think the plug is the same thread size as the one in my Subaru, so shouldn't be hard to find. But yeah, I *NEED* instrumentation. Dakota Digital Cylinder Head Temp gauge is absolutely happening as well. Like, not even an option at this point. And a tachometer. Also, any hints on aluminum/magnesium safe degreaser? She's a dirty girl and needs a good pressure wash. As always, I appreciate the feedback! :bigtu:
Originally Posted by Savington
(Post 1536470)
In for glorious, abject fuckery and general malaise
Originally Posted by 18psi
(Post 1536471)
I.....don't even know what's happening
Originally Posted by Scaxx
(Post 1536473)
My favorite part is still the wood mounted killswitch with a cable running through a hole with no grommet :D
https://cimg6.ibsrv.net/gimg/www.mia...3c8154d1fc.gif
Originally Posted by codrus
(Post 1536474)
I spy a Miata at 0:11!
Originally Posted by rwyatt365
(Post 1536485)
In it for the sheer VW-ness!!
My very first car was a '61 Bug with a '66 engine in it (eventually with Big Barrels, and dual carbs), so I'm re-living my youth through this thread. Brings back fond memories of terrorizing the North Campus of Univ of Mich in the mid '70s with my pseudo Baja Bug (I didn't have the money for the "real" kit, so I improvised).
Originally Posted by m2cupcar
(Post 1536504)
That battery photo reminds me of the time I was one of four in the back of a bug when the seat spring made a connection between both terminals. It went something like: odor, heat, smoke, fire. Old VWs are always an adventure.
Originally Posted by rwyatt365
(Post 1536508)
"Always an adventure" is an under-statement!
I was transporting a car-load of ladies to a party in East Lansing when one of the pistons decided to perforate (due to my misunderstanding of the need for proper cooling ducting around the cylinders), and begin pumping oil all over the highway. My John Travolta-like, Saturday Night Fever white suit was not happy - and neither were those ladies.
Originally Posted by sixshooter
(Post 1536519)
I had a Manx dune buggy, a 66 Microbus, a 65 21 window Microbus, and a hunter green Fastback at various times. All were an adventure. You know your rotted fuel lines? When they are on a bus and the tank lives right above the engine they do not stop feeding fuel until the tank is empty, regardless of whether the engine is on fire or not. RIP 21 window bus.
Originally Posted by portabull
(Post 1536533)
i remember empi fondly. my 2nd car was a 1965 karmann ghia that i installed an empi exhaust on. then i had a 1967 bug, then a 1955 porsche (sorta a vw at that point), then a 1965 bus. the last two were when i was in the army in germany. with the bus i never-ever saw the left lane on the autobahn. brought home a 1971 squareback, then we bought my daughter a 1977 (i think) jetta. i'm enjoying this thread and i think you should get extra points for saving this survivor of the camp fire.
Originally Posted by Midtenn
(Post 1536536)
You lost and gained me at "carburetors"
Originally Posted by Gee Emm
(Post 1536589)
In for a user report on the mega impressive radiator ducting in the front bonnet ...
Originally Posted by 18psi
(Post 1536614)
when is ms3 and efr going in
Originally Posted by wackbards
(Post 1536621)
When is an EJ257 going in?
Originally Posted by andym
(Post 1536673)
This entire thread is making me happier and helping me feel that I made the right decision selling my 69 VW Bus earlier this month. I had many of the same problems you have faced so far except I ran out of love for it.
Regarding tires. I had great luck with my general grabber at/2s on my bus and they fit my stock wide 5 wheels pretty well. And yes, dammit, I wanted Grabber AT/2s but couldn't justify the expense. Maybe if I put Forester suspension and top hat spacers in the WRX I can fit some AT/2s in the wheel wells...
Originally Posted by 99mx5
(Post 1536676)
FTFY
Originally Posted by msmola2002
(Post 1536681)
Learned to drive in a 69 1500. My dad and I removed the engine to swap in a rebuilt one, at the time we were pretty broke and didn't have a trolley jack. We used a vw jack on one side and a scissor jack from a 1979 mazda 626 the other, a lot of 2x4s and lifted the rear of the car off anr over the engine wIth a ratcheting come-along.
This brings back many memories, both good and repressed. Subscribed.
Originally Posted by turbofan
(Post 1536749)
Subbed. This is silly.
Originally Posted by gesso
(Post 1536770)
http://aircooled.fi/data/doc/ke/kenn...yfjys6ewvf.pdf
Page 8, top of right list... just sayin :party: |
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