Restoration of VW Thing

[AVRORAXXX]

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[aabirgti]

updates?

[bravo122]

today when i went to painter he had painted the sample paint that i had given him to paint
greenish color looked awful paint code was not matched and also it was making the car look way too dull
but on the other hand white looked great so i went with the white color as final color

[bravo122]

since the block of the thing was badly rusted and was not worth repairing i started the search to look for a perfect engine which will need minor work
engine available with local kabaria were not in good shape all were overhauled 2 to 3 times before hence if i got them this will be their last time.
few days ago i got a call from a local kabria that he had found what i was looking for
a nice clean decent bloock which was still standard and also an untouched crankshaft. according to him he was had all other parts in stock.
before paying i asked him to show the block to kahlid sahab so i can be sure that it is the state which he said
next day when the kabaria arrived with the stuff it was complete crap.
although crank was still on standard but it had to be remade to 50size his block was also ***** and had to be overhauled.
with a heavy heart i left the shop still hopping to find a 1600cc engine which was never overhauled.
since no other 1600 engine was available so ii got a suggestion from kahlid sahab how about using a 1300cc dp in it.but 1300cc will not be fair.
next day when i arrived in the shop and saw nasir uncle there i asked if he had any available
to my luck he had a extra available which according to Khalid ustad was supposed to be used in his one of the beetle was available but was now free available since Khalid sahab repaired the one that came with the vechle
engine arrived in the workshop 2days ago upon inspection came to know it was not the one with the slim studs .instead it had double the size studs which was not good.
after opening came to know that its block was opend before and also had to be repaired .Two of the sides to 25.and also its one of the head was shot .The block was again not what i wanted but was the best available.but the good side of the long block was that its crank shaft,pistons and its selves were perfect.
Khalid sahib then got another long block from nasir uncle and now this block was perfect but its crankshaft and other stuff was not in good shape .kahlid SahaAB asked me to leave every thing to him he merged the two engine parts and now i have perfect block perfect crank shaft and perfect pistons.in short perfect engine.

[bravo122]

i met kahalid sahab some time back for updates on progress. he gave me a list of parts which i had to arrange list included few parts such as the piston pins,piston ring set,engine packing kit,main oil seal,engine dust rubber,spark plugs, points,coil,gear box rubber.i will get all those parts probably tomorrow .
another decision had to be made now which heads shall i use dual port or single port.
vw made basiclly 2 type of 1600cc engine single port which produces 53hp and 1600cc dual port 60hp
but with the increase in power there are some disadvantages such as it will drink more fuel and will not be economical.and 7 more hp will be of no use to me since thing are not meant for racing and also because of reduction gears speed is already limited to 70km/h max .
i was also guided by nasir uncle to use single port rather then dual port some time back as sp are more robust.
so it was crystal clear that i was going to opt for single port and thats what i did.
today i called kahlid sahab again and got the bad news that one of the port of single port head was shot and kahlid sahab did not wanted to put that in the engine.
NOW again i have decision to make whether to take the nice clean dual port heads or the get the damaged one and get it repaired.
what do you guys think?
MEAN WHILE i have also asked kahlid sahab to look for a single port head which is perfect

[NashTrooper]

That's really good,, now sorted two main and tough jobs.

Somebody would be very happy to know about your final color choice..

[aabirgti]

Good choice on the colour hope it turns out ok. try to look for sp if u can give it time though. would love to hear more opinions from senior members

[bravo122]

chassis was again striped down to clean the 15 year old mud on it .
another paint of astar was applied to protect from monsoon rain
currently wrk is being done on the engine side will get the paint on after getting all the mechanical work done

[NashTrooper]

Pictures showing the body work done very well, all the body parts seems pretty straight and clean now.

[aabirgti]

updates?

[bravo122]

hmmm

after alot of cleaning with kerosene oil,wd40, diesel,petrol,dirt removing detergent and also acid (tezab) block was finally clean and was ready to be fitted. final checks were being made to see if every thing was perfect. for the first time after full cleaning block was taken out in the sun light too have a beeter look when came to there was a crack on the top left side and another large crack behind it.upon further inspection came to know that that the crack had gone all the way in.
will see tomorrow if the what can be done

[mybuilt]

I will say that go for (pearl white) colour i will look great on your car and by the way nice thread.....

[AsadIshaque]

hmmm

after alot of cleaning with kerosene oil,wd40, diesel,petrol,dirt removing detergent and also acid (tezab) block was finally clean and was ready to be . final checks were being made to see if every thing was perfect. for the first time after full cleaning block was taken out in the sun too have a beeter look when came to there was a on the top left side and another large crack behind it.upon further inspection came to know that that the crack had gone all the way in.
will see tomorrow if the what can be done

I am quite surprised that you are finding problematic crankcases every time. But then, good 'cases are getting hard to come by. Sorry to hear about this cracked one.

The only thing you can do is to look for another block now since most VW cases cannot be welded. I say most since some type 4 cases are capable of being welded with some special techniques.

One more thing......I do not think cleaning the 'case with acid is advisable at all.....so don't do it again pl...Also the mating surface where the two halves meet must be cleaned very very gently. NO abrasives/wire brushing etc in that area.

Wish you good luck...

[bravo122]

I am quite surprised that you are finding problematic crankcases every time. But then, good 'cases are getting hard to come by. Sorry to hear about this cracked one.

The only thing you can do is to look for another block now since most VW cases cannot be welded. I say most since some type 4 cases are capable of being welded with some special techniques.

One more thing......I do not think cleaning the 'case with acid is advisable at all.....so don't do it again pl...Also the mating surface where the two halves meet must be cleaned very very gently. NO abrasives/wire brushing etc in that area.

Wish you good luck...

block is not repairable it can be tig welded but its way to dangerous and will cost twice the price of ENGINE.
i located few blocks locally but all of them had their mains made to 25 or 50
will still be looking for a block which is on standard and is in pristine condition
thanks for the info on the acid thing will make sure that does not happen again

a

[bravo122]

............after opening came to know that its block was opend before and also had to be repaired .Two of the sides to 25.and also its .......

my mistake turns out that block mains had to made to 50 , 75 hence not worth repairing

[bravo122]

chassis got another wash to make sure that the main beam (qabar) was dirt free.
sent it to the service station twice but beam was not cleaned as it should have been hence the third time i stood on his head to make sure he cleaned it fully
floor will be painted after the chases and body are mated together
here are few pics

[AsadIshaque]

I shall strongly recommend that you get the floor pan painted before the body goes on....

The advantages are endless and I cannot think of a single disadvantage (except from the painter's point of view ;) since he'd have to move his lazy bum some more)

a) You'd get a much better job done with better result. Surface prep can be proper.

b) You can paint the hard/impossible to reach areas.....mating surfaces, underside, nook and crannies, inside the spine/tunnel/'qabar' as you called it.....wonder why??

c) You can inspect each thing in detail and pick out any faults.......prolonging the painters work

  Good, good, good.......all good for you and the VW!

[bravo122]

[QUOTE=AsadIshaque;3513447]I shall strongly recommend that you get the floor pan painted before the body goes on....

The advantages are endless and I cannot think of a single disadvantage (except from the painter's point of view ;) since he'd have to move his lazy bum some more)

a) You'd get a much better job done with better result. Surface prep can be proper.

b) You can paint the hard/impossible to reach areas.....mating surfaces, underside, nook and crannies, inside the spine/tunnel/'qabar' as you called it.....wonder why??

c) You can inspect each thing in detail and pick out any faults.......prolonging the painters work

  Good, good, good.......all good for you and the VW![/QUOTE]

will see if it body is not attached and ask him to paint
i got all the underside painted before
cant think of any way to paint inside the tunnel other then ripping open the chassis thats not gona happen
i called it "qabar" since its the term used by the painters

[chali]

colour options

lotus white vw L282
pastel white vw L90D
Beryl Green VW L478

[bravo122]

few more shades for the thing to chose from
VW Colors (Colours), Volkswagen Paint Chips, Color codes
can chose any shade of white