Happy Campers New 67' Bug Barn Find

[Happy Camper]

I found a nice thread about how to take them apart, with pics!
www.thesamba.com/vw/forum/viewtopic.php?t=432132&highlight=

This is where I got the info about the grease.
www.thesamba.com/vw/forum/viewtopic.php?t=450569&highlight=steering+box+grease

I am not sure either of these boxes would hold oil! Both had grease in them, and it looked really old. Both my original box and the box off the 69' I got from Brian have the two plastic hole plugs, I can only assume it was filled with grease.

Not sure now though.

[ghiastein]

Ok you got me now.

I do know that I have a steering gear from my old 1970 bus sitting on the floor and it is leaking gear oil all over the place. I also have a old steering gear here from a 1969 Ghia that is rough to turn but it does not leak.

Someone have a Bentley handy?

[tarrich]

www.scribd.com/doc/31973060/VW-Workshop-Manual-1200-Type-11-14-15-Part-6-of-14

160cc (5.4 oz) Liquid Transmission Grease is what my 70-79 Beetle Bently manual says for roller boxes.

[Happy Camper]

Ahh, the joys of building a custom car!

Just when you think you have it ready, you have to take it back apart and make changes. I had the beam back on the pan (for the third time!) and I was all excited to mount the shinny new steering box and I discovered the steering box now sits right over the Zerk fitting on the top tube. Now I need to weld up the old hole and drill and tap a new one. I remember reading this on a thread on the Samba, but I couldn't figure out what it meant, I think I know now

[Ruffuss]

Feb 16, 2011 20:37:39 GMT -5 Happy Camper said:

Ahh, the joys of building a custom car!

Just when you think you have it ready, you have to take it back apart and make changes. I had the beam back on the pan (for the third time!) and I was all excited to mount the shinny new steering box and I discovered the steering box now sits right over the Zerk fitting on the top tube. Now I need to weld up the old hole and drill and tap a new one.

Why not just plug it? and drill and tap? so you don't mess with that pretty paint?

[Happy Camper]

Talked me right into it! I think I will just put a pipe plug in there nice and tight, grind it off flush, and do a bit of touch up on the paint. The beam is getting messed up a bit with all the handling anyway.
Good idea, thanks.

Steering box update
Box filled with moly grease and is smooth as silk. Filling the box was a very messy job.

[Happy Camper]

Old hole filled and a new one 1" outboard is complete.

I stopped by and picked up a pipe plug on the way home. I threaded it in as tight as I dare turn it. I then cut it off close to the beam and ground it pretty close to flush with the tube. I then peened the edges of the plug with a ball peen hammer to help make it flush and to lock it in the tube.





Next I drilled and taped the hole for the Zerk fitting.



Next I sanded the old paint, added a shot of etch primer, and painted the beam. I threaded the Zerk back in and it's ready to go, again!

[bren]

Nice solution! I just removed my zirc and put the box over it .
I need to do this upgrade someday.

[Happy Camper]

Today found me in the garage with a few hours to work, a good day for sure. I started out by cutting the torsion springs to length. 1 1/2" off each end so I could keep the center dimple in the center!



Next I drilled a small pilot hole .35" from the end of the springs for the end dimples. One on the same side as the center dimple, and the other on the opposite side. After the pilot hole was drilled, I formed the dimple using a standard counter sink. I opened the dimple to match the originals. The trick it to go nice and slow and use a fair amount of TapMagic. The springs will drill easily. Note the bevel ground on the end of the springs. This is to ease the insertion through the center tube block.







After the springs were done, I assembled the beam and installed the swing arms. Lots more grease. I inserted the springs into one of the swing arms. I tightened the set screw to hold everything in place. On the end that I inserted into the beam, I wrapped the spring leaves with a zip tie about 1" from the end. This held the leaves in place while I slid the springs in. Once the spring passed through the center block, I continued to push and the zip tie just slid down the springs. Worked great.



On to the sway bar. I cut the sway bar in the middle and installed the two ends into the swing arms. I then clamped them in the middle and marked my cut. I cut the ends and ground a pretty steep bevel onto the ends for the weld.





I welded the sway bar in the center and peened the weld joint many times to relieve any heat induced stresses. I mounted the bar in the vice and stuck a piece of pipe on the end of the sway bar and twisted the sway bar back and forth, I made sure I was swinging it past the farthest twist it would see in use. No problem, the weld was fine. I then cleaned the weld up, primed and painted the sway bar. Enough for one day. I am waiting for my drop spindles now. They should be here next week.

[dunedudex4]

Nice work. Thanks Dave T

[Happy Camper]

Blah, Blah, Blah
It suddenly occurred to me that you guys might be sick and tired of all my blah, blah, blah. I have been posting almost everything I have done to this car. If you want me to shut up, just say so. I don't want to be posting stuff no one wants to read.
Camper

[dunedudex4]

Scott, if you stopped posting progress then I would have to stop posting parts for sale. NOT GOING TO HAPPEN ;D Keep the posts coming. Thanks Dave T

[dansam]

Keep the updates comming. Not only is it a cool jurnal that you can look at later but it helps others that will do the same thing in the future. Thats why I keep an update on Ally.

[VDub63 ( Steven )]

Feb 20, 2011 9:26:00 GMT -5 Happy Camper said:

Blah, Blah, Blah
It suddenly occurred to me that you guys might be sick and tired of all my blah, blah, blah. I have been posting almost everything I have done to this car. If you want me to shut up, just say so. I don't want to be posting stuff no one wants to read.
Camper

If you stop posting updates we will make someone else come over and do it.

[dubfreak1]

WHAT? Heck no don't stop.

Your postings are my best relief from hibernation.