Restoration Project: '68 VW Beetle (o\ _!_ /o)

[AsadIshaque]

The case halves have been united in these pics. Note use of "Abro Eagle Head gasket Shellac" on the case meeting surfaces. Application has been a bit too liberal, better than the pesky silicone RTV sealant.

[murtaza_murti]

how ever do tell me the parts that I might be needing is the decklid and front bonnet seal and the drain cover thing. So where did u get those ?

What do you need?

[AsadIshaque]

The cylinder heads being given a good scrub.

Before final fit the valves were individually 'lapped' or ground by hand to ensure a perfect sealing seat. An old school practice not followed by 'modran' mechanic bhais.

[AsadIshaque]

The engine core ready to receive the pistons/cylinders/heads.

[AsadIshaque]

A peek though one of the locations for the cylinders to fit.

[murtaza_murti]

The cylinder heads being given a good scrub.

Before final fit the valves were individually 'lapped' or ground by hand to ensure a perfect sealing seat. An old school practice not followed by 'modran' mechanic bhais.

The bare metal is eye-catching.

[murtaza_murti]

Update: The Bug has been sent to Uncle Fredricks workshop where it will be painted by Uncle Fredricks brother Uncle Harry, some stuff has also been moved there for the time being. Will go to the workshop tomorrow with the battery, oil bath air cleaner, flywheel gland nut and other stuff that would need painting like the radio face plate cover, rear license plate light housing, dashboard grills and inspection plates. Will update the thread after I get back from the workshop.

[Xulfiqar]

you should have used the threebond on the cases. unless you have checked the flatness of the cases with a flat (straight) stone the shellac will leak eventually.

and to tighten that gland nut - you will be needing a BF breaker bar to make it gorilla tight

[reezvaan]

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[murtaza_murti]

Knock Knock...Updates buddy?

Well, today I bought the following things:

• Clutch plate
• Pressure plate
• Thrust bearing
• Spark plugs
• Spark plug adapters
• Plug wires with connectors and points
• Condenser point (tall cap)
• Axle boots

Uncle Fredrick opened up the brakes and front suspension today, we found out that the brake drums have lived there lives and they've been worn out pretty badly, secondly there was a gap in between the suspension beam and it's foundation on the left hand side after opening it up and taking it out we found that the beam had been repaired before.

There are two areas in the center of the beam which have been welded and are clearly visible the corners were welded before aswell to give a 'jugari' stiffness for the time being, now we can't fit the same beam back into place. What we'll have to do is to find a clean complete front suspension beam from Shershah with front brake drums, I might plan on going there tomorrow.

In the meantime, uncle Fredrick would start up the engine in a day or two I'll have to go and give him the battery aswell as the motor oil tomorrow so, he can start the engine up ASAP. Wish us good luck!

[reezvaan]

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[NashTrooper]

Well, today I bought the following things:

- Clutch plate
- Pressure plate
- Thrust bearing
- Spark plugs
- Spark plug adapters
- Plug wires with connectors and points
- Condenser point (tall cap)
- Axle boots

Uncle Fredrick opened up the brakes and front suspension today, we found out that the brake drums have lived there lives and they've been worn out pretty badly, secondly there was a gap in between the suspension beam and it's foundation on the left hand side after opening it up and taking it out we found that the beam had been repaired before.

There are two areas in the center of the beam which have been welded and are clearly visible the corners were welded before aswell to give a 'jugari' stiffness for the time being, now we can't fit the same beam back into place. What we'll have to do is to find a clean complete front suspension beam from Shershah with front brake drums, I might plan on going there tomorrow.

In the meantime, uncle Fredrick would start up the engine in a day or two I'll have to go and give him the battery aswell as the motor oil tomorrow so, he can start the engine up ASAP. Wish us good luck!

Good Going MASHA ALLAH!!!
Best of Luck for your project...
Really wish to see the Beetle Deluxe..

[Storm]

The heat exchangers.....

These have been screwed up by some genius. I guess he removed the outer jackets as they may be loose and causing a bit of a racket on the running engine. If you can't fix it, ruin it. Another one of our National Traits.

We may end up reusing these as finding good heat exchangers is a bit of a problem. We will not have running heaters on this bug since for that, a body off is required with heater channel repair.

Scrappers love this part. It yields a lot of 'silver', an alloy you see here with which the fins are made of. This sells for good money.

Rare chance to learn the anatomy of the heat exchanger here with the garments off. A real VW p@rn clip!

i've loved the reading so far, it's clear how frustrated you are getting as each post goes by and how passionate you are buddy.

many people don't know how the heat exchangers work and it's a good chance for them to see the insides in this pic. I was thinking that it might be possible to get the covers stamped out here in PK and possibly be able to make something useable out of what you have left there. i'm guessing as long as it has airflow and is correctly sealed then it might just be possible. but it'd be a major "khuwari".

One of the best parts sourced for this engine......the correct intake manifold. Its not perfect as the heat riser tube has been opened up and welded not so neatly, probably someones attempt at cleaning it. Still I consider myself lucky in having sourced this.

This dual port manifold is correct for the 1300cc DP engine having the smaller flange to accept a 30 or 31 PICT carburetor. The 28 PICT can also be fit if one chooses.

The 1600 DP manifold is the same apart from a bigger flange which accepts the 34 PICT series carb.

The boots seem to be in great shape, hope so as these are hard to find.

This engine can now breathe well. The setup which came off was restricting the inflow and choking it up. Now we can take advantage of those dual port heads!!

i'm a bit confused, the code on the manifold states "AH" at the end which means it should be form a 1600 from 71-76. i thought the manifold for the 30 & 31 carbs was coded "AR" as that is the only 1300 DP i know of.

i'm just asking as i'm new to this compared to you and hoping you could shed some light as i'm also looking for a manifold (jus the centre) as i'm trying to switch my 31 to a 34 in the 1303 and need all the guidance i can get.

Horn button, don't know if its original its pretty faded from the front.

mix a 50 : 50 ratio of compound polish and car polish (or brasso liquid and car polish) and go at the surface with a soft cloth. it'll shine it up in no time.

Good luck with your project murti ... I will start mine as now I m stuck btw a 1303S and a restoration project so I have finance for one of the two

i'd suggest you have a look at my 1303 thread to give you an idea as to what could go wrong. mine was by far the worst 1303 in PK when i bought it but it's abck on the road now, so it'll be a "worst case scenario" guidline to your rebuild.

good luck and i suggest you invest in allot of painkillers:)

[murtaza_murti]

I have a complete beam in my stash...but thats from a 1966. Let me know if that could help...its un-repaired and all.

Wouldn't a '66 front end suspension beam be different? Don't pre '66's have a 5-bolt rim pattern?

[murtaza_murti]

Good Going MASHA ALLAH!!!
Best of Luck for your project...
Really wish to see the Beetle Deluxe..

Thank you :), I hope it gets done ASAP.

[murtaza_murti]

mix a 50 : 50 ratio of compound polish and car polish (or brasso liquid and car polish) and go at the surface with a soft cloth. it'll shine it up in no time.

Would give that a try on the weekend.

[reezvaan]

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[NashTrooper]

Thank you :), I hope it gets done ASAP.

Hmm.., INSHA ALLAH, then I'll also show mine!!(H)

[Xulfiqar]

whatever suspension you put in, please derust and paint it - so it looks like exactly like the VW-werk job

[murtaza_murti]

I thought you said beam and not the whole set up with spindles and drums and all. '66 Beam would do on your bug as far as spindles/back plates go. Drums are definitely different, being 5 lug on '66 and 4 lug on your year, if I am not mistaken. Please confirm from Asad to be certain.

Well, if I do get the beam you have the biggest problem would be transporting it to Karachi. I would however go to Shershah either tomorrow or on Friday in search of a clean front beam and four brake drums. Thanks for your offer though I really appericate it!