VR members from all over Malaysia got together in the Historic city of Melaka last February.
View the slide below or click the link below for tumbnails....
Tumbnail link...
http://picasaweb.google.com/geraldmohan/VDubsInMelakaFeb09#
Monday, July 20, 2009
Sunday, May 17, 2009
The Case is Finally Splitteded!!!!
The past two Saturdays i've been working on the engine.... ....
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The pistons come off by first removing the circlips... one on each side of the wrist pin...
Then put a socket on a long extention and slot it into and against the wrist pin.... then with a piece of wood i struck it to drive the pin out.... just enuff too remove the piston from the con rod..
After i removed all the pistons .... i noticed that one of pistons isnt the same as the rest.... hmmm it didnt have the same hump on the top.... (is that a bad thing) .... it didnt have the same arrow markings that point to the flywheel either.......
Ok.... well its decided then.... i will have to get new pistons......
Now to remove the pulley...... Slot a big screw driver thru the pulley holds and brace it on the case.... then removed the bolt....
Only after removing the pulley can screws securing the pulley cowl be accesed....
After removing the pistons and wrapping the con rods with lots of paper...... i was confident enuff to carry the engine and turn it over upsidedown... This is so that i can remove the Pressure Relief Valve and Control Valve.... having the engine upsidedown also helped me to get finally remove those pesky screws that are securing the side cowling....
The Oil pressure sensor was easy and simple to remove....
So was the Oil Pump cover plate........
Check the oil pump and cover plate for ware.... if its heavily wore out ..... just add it to your growing list of parts to buy.
To remove the whole oil pump assembly you will need a specialized tool.... Otherwise you will just need to split the case slightly before wiggling off the for studs.... for now just remove the the oil pump gears.....
I better put a photo (as shown below) of where the Oil Pressure Relief Valve and Control Valve are........
Ok .... now to unbolt and remove all the Crankcase nuts...... then strike the case with a piece of wood and mallot till it splits at the Flywheel side.... This is when you can wiggle the Oil pump assembly off the studs....
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The pistons come off by first removing the circlips... one on each side of the wrist pin...
Then put a socket on a long extention and slot it into and against the wrist pin.... then with a piece of wood i struck it to drive the pin out.... just enuff too remove the piston from the con rod..
Ok.... well its decided then.... i will have to get new pistons......
.
.
Now to remove the pulley...... Slot a big screw driver thru the pulley holds and brace it on the case.... then removed the bolt....
Only after removing the pulley can screws securing the pulley cowl be accesed....
After removing the pistons and wrapping the con rods with lots of paper...... i was confident enuff to carry the engine and turn it over upsidedown... This is so that i can remove the Pressure Relief Valve and Control Valve.... having the engine upsidedown also helped me to get finally remove those pesky screws that are securing the side cowling....
The Oil pressure sensor was easy and simple to remove....
So was the Oil Pump cover plate........
Check the oil pump and cover plate for ware.... if its heavily wore out ..... just add it to your growing list of parts to buy.
I better put a photo (as shown below) of where the Oil Pressure Relief Valve and Control Valve are........
Ok .... now to unbolt and remove all the Crankcase nuts...... then strike the case with a piece of wood and mallot till it splits at the Flywheel side.... This is when you can wiggle the Oil pump assembly off the studs....
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After that tilt the case on to the left side and wiggle the right side off.... if it still doesnt give.... un-tilt the engine and strike it again... tilt it and wiggle again.... for the love of money dont use a sharp object or place anything on the seams of the engine casing.... cos you will muck up your engine and you might as well trow it out and scrap it....
When you are taking the right side off .... four peices of errrrrr... #^&*(!!... i forgot the name lah... hmmm any if you see the photo below you can see 4 small round things will fall out.... so slowly do it so it does not fall out hard..... anyway i will update the correct name of those things later....
When you are taking the right side off .... four peices of errrrrr... #^&*(!!... i forgot the name lah... hmmm any if you see the photo below you can see 4 small round things will fall out.... so slowly do it so it does not fall out hard..... anyway i will update the correct name of those things later....
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TBC
Saturday, April 04, 2009
Coin Box or Ashtray....
I managed to find this Coin Box before the car was painted.... Bought it from Ah Pin who is an excellent vw mechanic and has a workshop in Old Klang Road. He has a alot of vw treasure in his shop....
Been searching for this for almost a year.... luckily i have the volksriders forum for help....
Bumpers
I was so excited about the car's paint job being completed that i didnt post a few things that happened before that, like the bumpers...
The bumpers as they looked before restoration....
Close up of the rusted back bumper......
If you noticed.... the front bumper bolts are not original... the past owner for some reason replaced them with regular bolts...
..... i took one of the rear bolts out and managed to get a couple of bolts that match except the rounded top part of the bolt which was a lot bigger.... So i sent them to a machinist to be reshaped....
below is the finished bumpers with the reshaped bolts....
Now for the bad news..... the shop did not knock out the rear bumpers far enough.... once it was fitted to the car the engine lid couldnt be opened.... those #%^%* had it on for days and just convinently did not tell me and actually thought i wouldnt notice..... dumb F#$^@........
All i had to do was look at the rear bumper from the top and see that the center of the bumper is too flat.... the whole bumper needs to be more curved.... dang it!!!!.... $$&()(<>^&*(*(*()!!!!!!
The front looks fine.... but im not too pleased with the way the bumper brackets fit in the braket holes.....
the bumpers arent the only thing i wasnt pleased with..... The fenders were tightened too tightly till the fender beading pinched into the paint.....sigh!!..... anyway the car is safely back home.... i will deal with the bumpers later as i want to concentrate on the engine.....
The bumpers as they looked before restoration....
Close up of the rusted back bumper......
If you noticed.... the front bumper bolts are not original... the past owner for some reason replaced them with regular bolts...
..... i took one of the rear bolts out and managed to get a couple of bolts that match except the rounded top part of the bolt which was a lot bigger.... So i sent them to a machinist to be reshaped....
below is the finished bumpers with the reshaped bolts....
Now for the bad news..... the shop did not knock out the rear bumpers far enough.... once it was fitted to the car the engine lid couldnt be opened.... those #%^%* had it on for days and just convinently did not tell me and actually thought i wouldnt notice..... dumb F#$^@........
All i had to do was look at the rear bumper from the top and see that the center of the bumper is too flat.... the whole bumper needs to be more curved.... dang it!!!!.... $$&()(<>^&*(*(*()!!!!!!
The front looks fine.... but im not too pleased with the way the bumper brackets fit in the braket holes.....
the bumpers arent the only thing i wasnt pleased with..... The fenders were tightened too tightly till the fender beading pinched into the paint.....sigh!!..... anyway the car is safely back home.... i will deal with the bumpers later as i want to concentrate on the engine.....
Thursday, March 19, 2009
Paint Part 'Its done!!!'
Went to the shop yesterday cos Luew Yow said he would be done.... but found that he was not happy with a few spots and was tackling it when i got there,,.... you can see by the patches on the bonet and engine lid.....
oooo... check out Knight Rider (the making of).....
Yow said he will be done today and i must say WOW..... i didnt think the colour would be this dark but i like it..... i cant stop smiling....
now to put all the bits together again......... sigh... wish i had a running engine....
Monday, March 16, 2009
Paint Part 10
Black Base Coat........
This is the fenders with one coat of the dark green paint......... cant see the difference :) if you see below ...the inside of the bonet is the black base coat.....
The back is still in black.....
Below.... Mics parts with a single coat of green paint after the black base coat....... Still cant see the green???...... see the last photo .... the rear light housing has two coats of green....
The Green!!! a little more obvious after two coats.... ...... 3 more coats and it will be down..... oh wait theres colour sanding........
Saturday, March 14, 2009
Paint Part 9
The guys primered the car and gave it a coat of gloss to highlight the imperfections. Too bad i wasnt free to take photos of the car after they primered the car...... The gloss coated primer made it look like it was ready to roll out.......... sigh!! ..... its not long now....
More shaping and sanding..... more sanding!!!!
The light well is also being dealt with.....
ooooooooooooo...... so smooth and clean..........
The hood.......
Engine lid.........
Engine bay ...... so clean........... sweet.........
Interior............ im the 'standard interior' is coming along ready nicely.....
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TBC
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