der Käfer

The new engine is in the Beetle.  It was a bit of a challenge with a couple of parts needing to be removed to fit under and up in the space.

The next step will be connecting the fuel line and all the new wiring.  Once that's done I'll move it outside under better light for more pics.

Slowly, but surely, der Käfer is coming together.

Getting Close Beetle

Yesterday in preparation for installation of the Beetle engine I installed the insulation tar boards and did the tedious job of threading the engine bay rubber seals in the channels.



These seals are absolutely essential in a VW air cooled engine.  They keep hot air generated by the exhaust and lower engine from getting up to the fan which cools the engine and transmission oil cooler.



As they age the seals wear and crack.  Quite a few times I have seen Beetles with no engine bay seals and the owners are oblivious to the necessity of them.  Without them hot air from the exhaust and lower engine is sucked up into the fan and they wonder why their engine is overheating.

I also installed the clutch throw out bearing - a much less tedious job.



Once the brake line hose I ordered gets here it will be time to replace the brake fluid and bleed the newly installed brakes.  Then comes long awaited installation of the new engine.

It's getting close to being a road worthy Beetle again.

Just one day more...

Beetle Brakes

The brake job on the Beetle was a little more demanding than I anticipated.  In part because it included putting in a new master cylinder.  I still have to connect up all the braided hoses and forgot to order them with the cylinder.

It has been a number of years since the brakes had any attention and the front had nearly reached their limit.

Included in the project was replacing not only the shoes, but the cylinder, bearings, seal and springs.

I was concerned about pulling the rear drums as they are torqued tight on the axle.  My friends had just the remedy in an old drum puller they picked up at an auction.  Rather than beat on the drum to get it off, the puller made the job much easier.



While they didn't have as much wear as the front, the rear brakes were in need of just as much attention.



All new parts added there too.



It was great to get the brakes finished and the freshly painted wheels and new tires back on the car. The last thing left to do is putting the new engine in the car.



I can see light at the end of the tunnel and it feels good to being close to finishing the Beetle.

Just one day more...

It's Back To The Beetle

The Beetle is back from getting a wiring harness and headliner put in.  Two projects that are above my skill level.

For those unfamiliar with my Beetle project, it is the restoration of a 1970 VW Beetle I started some 5 months ago.

Today I worked on the defroster box and hoses.



It was a little tricky working around the wiring. 



The Beetle heater system runs off the manifold up to the front of the cabin in the rocker panels and ends up in the defroster box.  As anyone who has driven a classic Beetle knows, "heater system" can be sketchy depending on the hoses.  Good reason why I replaced them all with new.  A day long job I'm glad to be finished.



Tomorrow my friends and I will replace the brakes master cylinder, brake cylinders and brake shoes.

After that the only other major job is installation of the engine.  

It's back to the Beetle project and getting closer to completion.

Just one day more...