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

[tyrone_40]

Updates 28-9-2012 and 29-9-2012

I got Blue washed yesterday as she was pretty dirty. Now, after I got her cleaned up and since she was running fine I thought to myself that I should take her for a small spin, and wined up going to Defence to pick up my brother from tuition which is in Phase IV. While driving smoothly the brakes failed on me near Kala Pul, there was a dump truck right in front of me and I was coming down a slope. Tried to brake but nothing happened, then I downshifted from 3-2-1 and then switched Blue off. Blue came to a stop nearly a feet away from the dump truck, I was a goner if I had not stopped.

Then after I slowly made my way to my brothers tuition and pick him up and dropped him off at home. On my return to the workshop, Blue's battery gave up near Teen Talwar, Clifton. I called the workshop and told them to send Brendon (son of uncle Harry) he came after 30 minutes and jump started Blue with my March, it started up like a champ on the first try then we slowly slowly made our way to the workshop with me in the March making way for Blue.

I had a doubt on the alternator from the beginning and that's what it turned out to be.

Now, I was suppose to give the alternator for repairing and had to get the brakes fixed up today but due to some other work I couldn't get time to go to the workshop.

Sometimes some stuff comes up that you cannot delay.

Take care next time buddy. Glad you'll were safe. How did the brakes fail???? I thought so too abt the handbrake but.......??????

[murtaza_murti]

Despite your mechanic plotting your killing rather neatly, am glad that you are still among the living.

B/w why there is no mention of using Emergency (hand) Brake which utilizes a totally separate cable setup to coupe up such situations. If you took Blue out without getting the cable emergency brakes set up, you are equally to blame alongwith your mechanic. Never ever take a half baked mechanically restored car on road ever again. If you so wish to conmmit suicide, make sure no VWs are hurt in your suicidal acts in future

The handbrake spring along with the button came out when I lowered it. I know, I should have gotten that fixed up first.

Good you alive & Safe to narrate the accident with us. as said above by Reezvan You shall be made murgha too for being careless. hammer down ur ustaad both ways. why was there is no hand brake? or you just panicked ? did you tried to isolate the reason of brake failure?

Will try to be more careful next time.

Take care next time buddy. Glad you'll were safe. How did the brakes fail???? I thought so too abt the handbrake but.......??????

Don't know, will find out the problem tomorrow.

[murtaza_murti]

Got the following done:

• Got new brake master cylinder gaskets and fitted them as well
• Got the alternator repaired and fixed it

Now I need to get all the brake drum cylinder gaskets. Eight in total, two for each cylinder.

Will test the brakes out once I get the gaskets in place and pour in new brake fluid.

[Xulfiqar]

The car should have never ever rolled out the shop without a brake job in the first place.

[AsadIshaque]

The brake master cylinder was brand new.....

 Generally speaking, VWs (or most old cars) must never be kept parked away for long. The brake components tend to seize up. Im guessing that's what happened here......it had rained too. Rust forms on the brake cylinder inner surfaces with the resultant friction for the brake washers/seals. Brake fluid leaks and disaster!

 While assembling drum brakes, it is crucial that we use brake grease to lubricate and protect the wheel cylinders. This is Castor Oil based and not mineral oil based like most other greases. Does not eat away the rubber components. I bought a tube quite some time ago and now when I searched for it, its no longer available.

 Do look for the grease if you want the brakes to last and remain reliable.

[AsadIshaque]

One more thing......

Never ever mix brake fluids. I do not even mix the same brand from two different sources! Always buy one brand from a single reputable buyer.

If you mix brake fluids, there is a chance of the seals going bad.

[AsadIshaque]

What is the condition of the brake wheel cylinders on the car???

 If the inner bores are pitted, you will have recurring leaking brakes, a headache you want to avoid.

[murtaza_murti]

[QUOTE=AsadIshaque;3576005]The brake master cylinder was brand new.....

 Generally speaking, VWs (or most old cars) must never be kept parked away for long. The brake components tend to seize up. Im guessing that's what happened here......it had rained too. Rust forms on the brake cylinder inner surfaces with the resultant friction for the brake washers/seals. Brake fluid leaks and disaster!

 While assembling drum brakes, it is crucial that we use brake grease to lubricate and protect the wheel cylinders. This is Castor Oil based and not mineral oil based like most other greases. Does not eat away the rubber components. I bought a tube quite some time ago and now when I searched for it, its no longer available.

 Do look for the grease if you want the brakes to last and remain reliable.[/QUOTE]

Yes it was brand new, you got it for me.

Can you recommend any other grease beside Castor?

[QUOTE=AsadIshaque;3576009]One more thing......

Never ever mix brake fluids. I do not even mix the same brand from two different sources! Always buy one brand from a single reputable buyer.

If you mix brake fluids, there is a chance of the seals going bad.[/QUOTE]

Neither do I, I always get Seiken's that too from the same shopkeeper.

[QUOTE=AsadIshaque;3576017]What is the condition of the brake wheel cylinders on the car???

 If the inner bores are pitted, you will have recurring leaking brakes, a headache you want to avoid.[/QUOTE]

One is broken, the others are fine. Will get a new one tomorrow.

[murtaza_murti]

• Brakes are a-OK now, took a load of time to get them fixed but finally got that done.

• The alternator is working fine

• Replaced the gear oil

• Painted all four brake drums

• Got the RHS window pop-out latch installed

In the up-coming days I'll get the carpet installed and then other fittings will follow accordingly.

[Xulfiqar]

for proper brake greases - Marriot road market is your best source, also get a tube of castrol olistamoly or any other thick and tacky type genuine CV joint grease - its used on the parking brake system and also the backs of shoes to eliminate squeaks and seizing.

[margallar]

for proper brake greases - Marriot road market is your best source, also get a tube of castrol olistamoly or any other thick and tacky type genuine CV joint grease - its used on the parking brake system and also the backs of shoes to eliminate squeaks and seizing.

is castrol olistamoly available in pakistan, ill try and ask the local oil store to source some, our car's cv joints need replacement so it is a good time to get this grease, plus what is it's price range and how much do i need for the two cv joints.

[murtaza_murti]

Got all the mechanical tweeks done, was bringing Blue home today but didn't because we finish with the work at around 7PM. Plan on bringing it home tomorrow once I get the carpet done.

[Xulfiqar]

is castrol olistamoly available in pakistan, ill try and ask the local oil store to source some, our car's cv joints need replacement so it is a good time to get this grease, plus what is it's price range and how much do i need for the two cv joints.

200 grams tube of olistamoly would cost you between Rs 800/- to Rs 1000/- today. Similar other CVJ greases are also available. I dont believe your car has rzeppa type CVJs though. - btw which grease did your mechanic use for the wheel bearings and what was his bearing packing technique and adjustment technique.

[margallar]

i dont remember much about the wheel bearings, it was done in i think 2010 and i wasnt with the car at that time. now they have crossed 100k kilometers, i asked my brother, he told that the bearing was installed using a press and i think was prefilled with grease, sorry for being a noob

[Xulfiqar]

^^ oh I was referring to murtuza - as in a VW the wheel bearings need to be repacked everytime the drums are removed.

[margallar]

wesay how long should the bearings last (how many km)?

[murtaza_murti]

She's finally home

[margallar]

thank God you gave her clothes

[lazeez]

what about tail lights etc?

[Xulfiqar]

wesay how long should the bearings last (how many km)?

oldschool taper bearings which can be cleaned and regreased can last nearly forever if taken care of. The newer sealed type are good till lubricant compromise.