1965 Volkswagen Type-1 (Beetle) D.I.Y. Project (o\_!_/o)

[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[Xulfiqar]

she looks pretty natural in the sand and besides a fort - there is something about some cars that make them look good in some environments, e.g. a MB W123 serving taxi duty.. a vw bus driven by hippies or a type 1 in an adventure like this.

[agoodfriend]

Soon we broke off the rally track and into the desert. After a kilometer or so of distance, we could find a nice solid plain to park Patina and take a few shots to document as a memory:

.

dont you feel the real wheel caber is +ve from this pic ?

[reezvaan]

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[reezvaan]

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[vickytulla]

Holy FIshhh!!!! Mitti he mitti ...

[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[agoodfriend]

We travelled a total of 254miles ~ 408kms and we consumed 38litres of fuel when we refueled the tank.

The mileage comes out to be 10.75kms/litre which in my personal opinion is pretty good average keeping in view that almost 100kms of our journey were done in either 1st gear or second with countless dead stops at the 30kms patch b/w Ahmedpur East and Derawar. I hope that answers your query. Thanks for your patience.

This mileage is pretty acceptable by my standards as I know what were the driving conditions like, but lets find out what veterans have to say about it.

@Veterans, lets hear about it from you, shall we?

10.75 km/L for a 46 year old 1200 CC car is not a bad average ,,,,,,,,,thats what i guess but i have no experence with VW,,,,,,,,,,,,,,,,
how you have grease all that fround suspension,,,,,,,,,,,,,,,i noticed 3 grease nuts for grease gun,,,,,,,,,,,,,,they look like a break oil bleading nuts but infect there is a bearing ball in it followed by a spring,,,,,,,,,, which act as a one way valve

[Xulfiqar]

grease separating from oil under pressure load is normal - thats how grease works infact, it oozes oil from its soap to keep metal lubricated. Proper intervals will help greatly.

and choose a good quality grease, you can find leads from where you bought the F A G bearings

[AsadIshaque]

Now the thing that really had me surprised is the cracked generator flange. I wonder how could have that happened but it just has.

When I revved Patina up this morning when I was checking the motor and wanted to listen to the sound of the motor to make sure that everything was in order on the motor, I noted that there was some additional rattle that was singing along the motor. Upon close inspection it was sorted out that the noise was coming from the shroud. I immediately cut off the engine and cranked the fan with a spanner on the generator and there was no sound. That was quite a deal. I was inspecting the generator and the fan operation when I accidently happened to look at the flange and here is what I saw:

Having seen that, I knew there would be an additional wobble in the fan belt since the flange was now cracked and it wont hold the generator steady. Just wanted to make sure, I revved patina back up and it was as I had guessed. I captured this video for all of you:

WobblingFanBelt-CrackedGeneratorFlange - YouTube

Now then, we've a cracked flange to take care of before Patina moves otherwise it would not only break off the fan belt but could play more havoc like damaging the generator/fan/fan shroud etc.

I am not worried about the replacement flange because I have one in my stash and it could go on Patina anytime:

But before the replacement could go on I want to find out the reason how could this have happened. Because what has happened is not important rather "how did it happen" is.

Its the root cause I am looking for so that I could nip the evil in the bud to ensure that it never happens again. Could anyone please shed some light on the reasons that might have caused this crack?

I've already checked the torque on the generator strap, its torqued pretty well. But I am not sure about the position of the metal shim/strip that goes b/w strap & generator to provide the filling of the gap b/w the generator and the strap to ensure that generator is all tied up nicely with the flange by this metal strap.

And there is no rubber pad/packing between generator & the flange, could the absence of this pad/packing cause the crack?

Hello,

 I built up courage today to take a peek at this thread today.....was not lookin as I always thought I should have time to go thru the details. Time, free time, we never get, so I thought today and dived in....have lots to see in reverse gear.....:D

 Causes for the broken gen/alt stand??

1. Basically anything 'imbalanced' in the components being spun:

a. The fan. It may be bent, loose, improperly torqued down, imbalanced or damaged. Remedy: replace fan/ proper torque with the right amount of shims and an undamaged nut (hard to find thanks to our chisel wielding ustaads)

b. A bent armature. Remedy: replace armature or whole generator unit.

c. A bent, damaged or loose generator pulley.

1. A loose generator strap (already covered by you).

2. A loose fan belt. In the video posted, the fan belt does have a 'jump' that is there is a bit of jumping motion esp when you rev up the motor. This also places stress on the generator pedestal. In your case, it may be due to a loose or defective fan belt or due to the cracked gen pedestal itself.

3. Maybe Ive forgotten something???

   Btw, you were running an alternator pedestal in the engine. So is the replacement. I am not sure whether this may have contributed to the failure??

   As far as I know, VW engines never had any sort of gasket/packing/rubber in between the pedestal and gen/alt. If everything is in order ie you do not have any bent components in the fan shroud, gen/alt backing hardware, you must have a snug fit when everything is in place before you go on to tighten the gen/alt strap. There most be no rocking motion here in other words.

   Hope this helps.....I may add onto this later......maybe I'm forgetting a point or two.

Best regards.

[AsadIshaque]

With old pop out seals all removed and seal channels on the pop out windows all cleaned up, it was time for the new WCM pop out seals to go on.

It is one of the task that isn't really easy. I have already shared a link on how to restore the pop out seals but then the link rather required too much precision and hassle. I searched the samba for something different and this is the method that I came to read about in one of the posts. The pictures are rather self explanatory so I dont see that I will have to explain anything about how its done, though it requires a lot of patience and is pretty slow a process to mount the pop out seals but has worked for me by far:

As you can see, my tools are pretty basic Please remember that you would need liquid dishwash solution to soak the seals first before you start pinching them into the channel using the "basic tool"

Maybe the 'like' button was insufficient for me to say.....I like that!! :D

[reezvaan]

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[reezvaan]

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