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Re: Retrovans MeFusco Beetle Truck Project

Posted: Sun May 05, 2019 8:16 pm
by retrovan
Being Sunday night again, and having battled the whole week and weekend with this gear system,

Its just about there.

As we do not have a floor or tunnel or bulkhead for the peddles, we had to make it in a single unit.

But..

The floor had to go in 1st, and had to be sound proofed before going in.

We once we had all the parts lined up, we went to work.

The number of times I had to take out the tunnel assembly for something else is uncountable. :shock:

So how did you do it I hear you all ask, well the turn around systems will not work, as the gearbox and motor is still in the same direction all be it in the front.So using these other systems would have turned the shifting around...

So a new system had to be brainstormed and parts got to modify to make it work as standard.

Bought a Golf 2 steering knuckles, coupling and cut it to bits. Use one half for the top twist coupling, and build a new VW gearbox coupling but with a spin pin so as to be able to take up the twist needed to go from 1-2 to 3-4 to R.

The length of the shaft was a hit and miss issue as I would either have 1&3 or 2&4&R but not at the same time.

The floor is in, the tunnel assembly is in the gear lever shaft is in, (still needs setting) and now we can get the steering in ....... . :huh:

So now its time to sit on the couch and wait for the next stint in the workshop.

Feet up ... :D

Herman

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Re: Retrovans MeFusco Beetle Truck Project

Posted: Sun May 05, 2019 9:49 pm
by Dawie
Good to see progress.
How easy does it shift forwards/backwards, (as in between 1st and 2nd, or between 3rd and 4th), is the side loading on shift shaft bushing giving issues? At least it should be easy to replace that bushing in your application.
Just thinking...
Seeing that a tunnel is not really necessary. If you use a kombi gearlever, (which is also slightly longer below it's fulcrum point), and mount at floor level.

One could also use a single shift-shaft from below lever directly to your modified kombi coupling on the box. Then also tilt gearlever's mounting (with lockout plate), forwards at same angle as shaft. (Unless there is something in the way, trying to occupy the same space as the shaft). Then just bend gearlever more backwards to compensate for angle.

Re: Retrovans MeFusco Beetle Truck Project

Posted: Sun May 05, 2019 11:15 pm
by retrovan
Thanks Dawie,

Like the way you think, yes that may be an option, only do not have much space towards the seats, as the engine cover takes up a lot of space.

But that said, it may help to get under the peddle intrusion into the tunnel, and reduce the angle into the box.

Can cut the tunnel back to just before the peddles, and fit my blank off cover there.

Then have the kombi floor shift fitted into the floor or even lower down, if I have space.

The shifting is OK, but not as tight as I would like, it may give issues at the wrong time, or when you need accurate shifting to get you out the :bn:

As can be seen, I did open a way for a straight down rout, put the beetle shift will not work at such an angle.

Will try and get a Kombi shift from someone, and test it.

Hell have had this system in and out so often, another try would not matter as long as the shift is tight and positive.

Haha! Watch this space......

Herman

Re: Retrovans MeFusco Beetle Truck Project

Posted: Mon May 06, 2019 5:36 pm
by Tony Z
you need to look at the following website for ideas on your linkage.
http://www.cableshift.com/Website/catalog%20page.html

Re: Retrovans MeFusco Beetle Truck Project

Posted: Mon May 06, 2019 6:15 pm
by retrovan
Tony Z wrote:
Mon May 06, 2019 5:36 pm
you need to look at the following website for ideas on your linkage.
http://www.cableshift.com/Website/catalog%20page.html
Thanks Tony

That has verified the bay gear stick direction.

if you look at the above type 2 setup, you see the push-pull cable comes in just over the gear box,

well when I fit the bus gear lever at an acute angle just passing over the gearbox, I will get the same result with the gear rod.

The left to right movement is not the issue as this is the easy part, as my swivel gearbox couple has shown.

The iffy bit is the push-pull as the angle tends to lift the rod rather then move forward when shifting fast.

I am sure I will get good results from the Bay stick.

Hoping to hear from my good buddy supplier......

Herman

Re: Retrovans MeFusco Beetle Truck Project

Posted: Mon May 06, 2019 9:58 pm
by retrovan
Hold your horses...

Just had a rethink, and as I am trying to keep as much as possible from the Beetle

This whole gear lever system needed a rethink.

So I will take all the good points from all the ideas, and rework the Beetle system but into an angle under system.

This will include a floating tunnel end which will bring the gear lever more into the cab and allow for a more straight gear lever.

So with my trusty grinder we will rebuild it till I am happy.

So the Kombi shift is on hold, and I will re-engineer my Beetle shift.

Will keep you posted.

Herman

Re: Retrovans MeFusco Beetle Truck Project

Posted: Sun May 12, 2019 10:15 pm
by retrovan
If your questions is did this "old Toppie" do any work this week, then the answer is yes.

Build the floating tunnel, and got the gear placement ready for the gear rod bush holding plate ordered from Volkspares.

The old one I had has been hacked up to fit the last attempt with the universals.

Also made center pins, mounting brackets and fixing plates for the handbrake lever.

This had to be done as My tunnel does not run between the seats, but is a short ended tunnel.

Also it is on the door side of the drivers seat, as there is no gap between the two seats for the handbrake.

Also busy with the cut outs of the front fenders, so as to allow the doors to open fully without bumping into the fender.

All these thing have to be done because of the front nose coming back so much that it all interferes with each other.

Doing some investigation in the running of the steering rod as it has to return past 80 deg.

Will probably fit a T3 Bus bevel box to get it to line up.

Watch this space for that final solution......

Will not be posting any photo's this week, as the parts still have to be fitted and signed off.

Well till next week.

Thanks for looking.

Herman

Re: Retrovans MeFusco Beetle Truck Project

Posted: Mon May 13, 2019 3:52 pm
by 73type2
retrovan wrote:
Sun May 12, 2019 10:15 pm

...the parts still have to be fitted and signed off.

So, between you, yourself and Herman, who will be signing off the parts?

Re: Retrovans MeFusco Beetle Truck Project

Posted: Mon May 13, 2019 6:27 pm
by retrovan
Its not that easy,
Me and myself have to do the work....

And I keeps standing around....

When you ask him if all is fine, he says, I

So now we say "have you signed off on these parts".... and he says ... I

Then we can carry on ... :shock:

:lol: :lol: :lol:

Re: Retrovans MeFusco Beetle Truck Project

Posted: Mon May 13, 2019 6:30 pm
by retrovan
Haans wrote:
Tue Apr 23, 2019 7:34 am
Which of the three is the genius !!!😂🤣😆

Regards Haans
When you ask all three.... they all shout Me.

So it must be Me ...

:lol: :lol:

No genius here, but that said... 3 heads are better then 0ne.

Herman

Re: Retrovans MeFusco Beetle Truck Project

Posted: Wed May 15, 2019 3:32 pm
by retrovan
Parts from Volkspares have arrived.

These include Golf Ignition key body, Golf ignition switch, and late beetle indicator cluster.

Yes the golf key and switch fit into the beetle steering hub with a few modifications,

and you have OEM parts at a 1/4 of the price of beetle replacements.

Can now do the steering hub, and get it ready for the steering completion.

How is that going to happen....

Well I have found an type 3 Kombi steering bevel box, just need to collect it in the morning.

"Bevel Box" thats the 90 deg. angle transfer box that sits at the bottom of the T3 Kombi steering rod, and transfers the action at 90 Deg. to the steering rack under the cab.

Post to you again on Sunday...

Herman

Re: Retrovans MeFusco Beetle Truck Project

Posted: Sat May 18, 2019 11:00 am
by Haans
Problems tend to become large when the threeof you have different opinions,....voting on it often ends in a stalemate situation!

Hope " I " have the 'swing' vote!!!

Keepit up!!

Haans

Re: Retrovans MeFusco Beetle Truck Project

Posted: Sun May 19, 2019 10:56 pm
by retrovan
But if we do start swinging, no body gets hurt... :lol: :lol:

OK, so we got into doing some of the "can't be done" things :shock:

As I needed to get the mechanical things right, and working, I have been concentrating on the controls,

Because if they work, then the project will work, so these are the things I got working this week..... :D

Put a lot of effort into the gearshift floating tunnel, and it has paid off.

The gears are positive and the gear lever true. Changes very nice even without the engine running.

Brought the angle in straight from the gear lever to the gearbox hockey stick which has made all the difference.

Even if the tunnel and gear lever is at an acute angle, it still works ,and best of all, its still of Beetle origin.... :wink:

Fitter the master cylinder into its position, but no brake lines as yet.

Managed to find a brand new VW T3 Bus NOS bevel box how nice is that.

Fitted the steering shaft housing and made up the steering shaft to enter the Bevel box with an spline,

Needed to make a nylon bush to centralist the bevel box, into the old steeling housing shroud as I do not have bonnet clearance otherwise.

This meant it had to go into the cab divider wall shroud as deep as possible or crash with the bonnet.

As it is, I only have 2 mm clearance between the bevel box and bonnet.

Having fitted the bevel box so close, I had to hack a hole into the cab wall for the Golf 2 steering universals to pass through.

This we will have to make two angle box covers for to clean up its appearance and stop air blasting into the cab all over.

Did some epoxy repair to the cracked up steering wheel and will smooth it off and paint it when nice and hard.

The hand brake fitment bracket can also be seen between the seat rail and door.

Repaired the rusty floor edge of the cab and welded in some metal, strengthening it and making sure to seal off the cab.

The steering shaft passes very close to the accelerator, but will not be obstructive as it will make a nice foot rest .. :roll:

Will probably be doing the clutch cable and accelerator cable tubes next, but who knows, may go off on a tangent again...

So here are some photo's of what has been done,

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Thanks for looking

Herman

Re: Retrovans MeFusco Beetle Truck Project

Posted: Mon May 20, 2019 7:06 am
by AlanH
Nice one Herman.
It sometimes helps to walk away and let the ideas mull around a bit.
When you then come back everything just falls into place.

Re: Retrovans MeFusco Beetle Truck Project

Posted: Sun May 26, 2019 11:25 pm
by retrovan
Thanks Alan, see you right, but sometimes a person is so dog sure it will be OK, till you do it and then you get the inspiration of "but why did I not do it this way"

But as said, before, this is an experimental build, of known challenges, without solutions and not an strip, clean , reassemble, add replacement brand parts, and say I built a car.

This is a one off, and as the car manufactures need to think out the box when coming up with a totally new model,

so this has to systematically be gone through but not by a team ,

but only by 3 old Toppies with split personalty's..... or wait, .... is it one old Toppie with 3 personality's

Oh darn, I forget... :shock:

:lol: :lol:

So no progress this week, as the kids and their kids came over to please this old man, so week end well spent.. :D :D

Till the work begins next week.

Herman