Chilli, The funky green chillin' machine!

Yeah! It's a 1303 karmann. I've been after a cabriolet for years but have always been skint or in the wrong place when one turned up! Was hoping for an early but with the way prices are going, I jumped on this one when it surfaced...just 4 miles from home! And yes, it's a project!

 

Ive posted a wanted ad for parts needed in the non latebay listings!

 

Ok, so ive been a bit sidetracked with a Cabrio project and chilli has just sat! but in my defence I have extended the workshop too so I haven't been sat on my bum!

Here is the chaos!



And here is the temptress!!!!



and how it's progressing!

 

The reason I got sidetracked was because I was (and still am!) waiting for a few bits and pieces. (anyone got a temp 2 sensor sitting around?)
So where to start? previously id tried to get the handbrake handle off as it was perished and split and also because I had a rather nice shiny bit to go back in its place! It took some effort getting the roll pin out but it did come eventually. I thought it might be an idea to tap the handle and use a set screw so I can remove it easily next time ( i have been thinking its a bit too shiny and a coat of black paint might suit better).



Next was the Just campers dash shelf which needed quite a bit of modification to fit to allow the handbrake switch to work.

Then it was time for a test drive!

 

Before i start the engine i'd like to fit the gauges just to keep an eye on things. After researching on here and the samba i decided that a taco plate for the oil temp and a stainless hose and adaptor for the oil pressure. I picked up a cyl head temp guage too off ebay but not too sure i like the digital readout.




existing taco plate



the nice new taco plate from boatyard buses. really really nice bit of kit!



so today I'm going to run through everything to make sure everything is where it should be and then maybe put some juice in the tank...

 

Fill the engine up with oil



drain the old oil out of the gearbox and fill with nice clean oil. Look at the metal on the magnetic sump plug!!



Ok! A quick run through of everything and fuel in the tank, coil lead off to build up some oil pressure, battery connected and....
turn the key the engine turns over but the oil light doesn't go out..
let go of the key but the starter doesn't stop arrghh!
quickly out of the cab and off with the battery

so after disconnecting the wiring i run a flying lead to the solenoid switch terminal from the battery but still the same so guessing the solenoid is sticking. So much for my plan of saving the starter by replacing the solenoid! So starter out and out with a 12mm tap to remove the bush, and order new starter!!!

 

All is not lost though as i have just enough time to mount my new gauges under the dash!

 

Let me know what you need in regard to FI parts,I will keep an eye out here in Sweden...PM me your list.

 

Ha! Just found what you looking for! Should I get in contact with the seller?

 

Look what he has.

http://boxerville.se/forum/viewtopic.php?id=45381

 

so, new starter motor...



and now its alive! (Click on image for video!)

 

driveshafts greased up and fitted. Bought these ages ago when I first got the camper from one of the major suppliers. Not sure about the quality but they fit up nice and ive already got them! I'll hang onto the original for a while...




the other cv's to the left are genuine vw off my cabrio...look to be so much better!

as well as a new clutch cable and conduit. I'm not sure its right and have added a few washers on the end of the conduit to get any kind of adjustment (and pedal). to be fair the pedal doesn't feel as positive as in a beetle and its a long time since I drove a bay, so might have to revisit this. I'm also not happy with the angle of the flexible conduit and have read the genuine one have a better fit?

 

so, over the weekend ive jacked the bus up and checked all the nuts, bolts and whatever else for tightness, torque and etc etc. Ive fitted split pins where needed, bled and adjusted the brakes...

An MOT is now on the horizon I think...just got to clean and assemble the other jalousie window and muster up enough bottle to drive it to the garage!

 

Fingers crossed

 

i'd take the washers out, you will get a more natural curve i think

 

I've tried with 1,2,3 and 4! And I can only just get enough pedal with 4. With no washer or with 1 or 2 there wasn't enough adjustment on the cable to move the clutch arm when the pedal was pressed and all the slack taken up.
Should the pedal feel like a modern car? It's a long time since I've driven one!

 

Oh I have heard about the phantom long clutch cable that lurks with many suppliers!!

 

you need to put the washers on the cable side between the arm and the wingnut that will effectively shorten the cable an make it possible to tighten up.

 

That would make sense and bring the flexy to a better shape, but the wing nut is shaped to fit inside the arm to stop it undoing isn't it? A nyloc nut run up behind it after adjustment would hold it tho I guess...