Got given a few stickers that i was missing. Washer bottle pressure. Bosch 12V coil one. It should really be yellow as the blue sticker is fitted to a black coil but ho hum. 12V sticker. I got the rest of the brake parts fitted too.
Made some new kunifer brake lines, bent to clear the Z bars drop link. I then realised that i hadn't taken into account the shock absorbers position. Bugger. I also spent a good while looking for the clips that hold the hard line to flexy join to its bracket only to remember i'd used them on my westy a couple of years back when i redid all its brake pipes.
I'm still on the lookout for this filler flap sticker. Its available on the bay window sticker sheet for some reason but not on its own unfortunately.
Realised theres no hole for the brake pipe to run though. Big one has a sleeved grommet with the starter positive cable running through it.
Passengers side rear brake pipe fitted. Misses the shock too. Fitted the rear flexy and handbrake cable. Only managed to get one brake shoe fitted as i'm missing a clip.
Finally got it all built up. Fuzzy picture. Managed to track down the T piece i've been looking for for the past few days. Found the old seized master cylinder too so i could start mocking up the front brake lines. Put the bonnet badge on to keep it out of the way and stop it getting damaged.
Made a few more brake pipes today. Pipe over the nosecone was a PITA to bend to fit properly. The main front to back pipe doesn't actually touch the torsion tube even though it looks like it in the piccy. Front to back pipe was a pig to fit because its 7ft long. Haven't fitted the grommets yet as still not bought a new master cylinder. Drivers side front pipe MK2. Passengers side front pipe. Still needs a little work but i was starting to loose the feeling in my fingers.
Made a mount for the fuel filter (that bolts onto the side of the gearbox) after seeing one for sale for £20 and thinking i'd rather spend £20 on something else more needed. (NOT a stunt hand!)
Inside of new steering box. Pretty sure its supposed to be full of grease. Theres maybe a tea spoon full.
They changed in '63 to grease on the beetle. It's NLGI 00 grade semi fluid grease. A bit like a really thick oil.
Ran into a bit of a problem with my EMPI 8s. Spokes catch the face of the caliper when bolted down. Needs a 3mm spacer to clear. Forgot this was still hung on the shed wall. VIN plate finally found and cleaned up.
Couple of washers fitted behind the caliper mountings and a bit of a grind of the face of the caliper gives me this much clearance. Not a lot of clearance but theres still a mm or so of the Girling logo i can grind off too. The shape of the spokes on the EMPI 8s is really just the wrong shape to clear the caliper. I could grind a smidge off the spokes but theres 8 of them per wheel and 2 sides to each spoke as they are hollow. 32 bits to grind off the 2 wheels or 2 minutes with a grinder on the caliper. Cleaned the majority of the rust off the front bumper too. Still pitted though so i think it'll end up getting rust cured and painted silver.
Seats still appear in OK condition despite sitting in a shed for 15+ years. Hung my bike on the wall which saves me having to move it everytime i need to get to the side of the car.
Bag of grease arrived today so i can fill the steering box. Its one shot grease made for land rover front swivel housings but its the same NLGI00 spec sem filuid grease as VW recommend to fill the steering boxes with. I got a few nuts and bolts though the post too so once its filled i can install the steering box and track rods, the steering damper and the spindles and calipers. I can also fit adjusters on the front beam. I'm using late 80s astra front brake hoses as they're the right length and have M10x1 banjo fitting on one end and m10x1 female fitting on the other. The brake hose exits in the wrong place to use bug hoses as they point straight at the balljoint.
Steering box is ready to be filled. All full and buttoned back up again. Ended up with about 200ml leftover. Box apparently holds 160ml and the grease packet was 375ml so thats about right. Not too bad a job. Fill with grease, turn steering shaft to opposite lock to remove bubbles and airpockets. Add more grease, turn and repeat a couple of times. Then add top and top up through the 2 holes and refit the plugs. Just need to fit it and adjust it now.
This grease is a bit weird. Tip up the bottle and it slowly moves like golden syrup but give it a stir with a screwdriver and its easily pourable.
Adjusted the box and bolted it to the front beam. Still not torqued up but i'm not 100% its in the right place as it can be moved 1/4" each way from where it is. I'll wait until the body is bolted down and the column in to make certain. Added more oil and bled the air out of my 2 trolley jacks too. Worked better than Viagra ever could.
