RetroVans's "Fugly Braziliamba" Project

[retrovan]

Hi guys,

Got me a 1977 Brazilia Kombi, had to get away from the Capetonians, man they hide everything....

She is aged, this can bee seen by the thickness of her make-up.

Rather thick in places.

Just to set the record strait from the start, I have no intention of restoring this bus as of now.

Will be fixing the mechanicals, and making her drive.

Have near got the paperwork sorted, so I will be bunging in a Type 4 motor (love the 2lt), and using it during the restore of the split Fleetline Panel Van.

So here is a pic of when I got her...





What I have found is that the steering in totality is worn and needs replacement.

The Master cylinder is a "Once off", even for Brazilian VW being the 211 611 111, and finding parts was near impossible.
Have today found a very dusty box, in a very dusty store, which had a few sets, took 3. ..

Have cleaned up the Steering box, fitted new seals, and filled it up with Bardahl.
Found some tie rod ends, fitted them, and found some strange truck tie rods, which fit the Drag Link ends, and fitted them.
Now the only thing is the Swivel link pin, May have to make that one with the bushes. ??

Well till next time,

Herman

[ST Man]

Congrads and enjoy
Seems she didnt leave the road to long ago with EC number plate... the bottom one

[retrovan]

Thanks,

Had to go to CT to get her back home... EC number...

Will not take much to get her through RW, and then later, to make it look like yours...

Herman

[Golfmad]

I like these, very much!!! Its like a bay with many many windows

Congrats

[retrovan]

Thanks Guys...

Got the brake kit in and started bleeding, One silly little bleed screw had to break off.
So that now goes onto the "To Do" list,
Breaks feel firm, tie rods and Drag line are painted and ready to go back on.
Have Ordered the Damper and Swivel link pin from our GOOD aircooled service provider, Grand Slam, and this should be getting here in the next month or so,due to the Transport strike, NO!! not Es, she had it packed before the phone went down...

Santa Clause also dropped off a NICE dash, so that's sorted....

Now a few small parts, (like Engine... ) and we can drive...

No, I will have to fix the Bleed nipple, and open the drums, just to make sure all is well.

Till then

Herman

[retrovan]

So the parts from Grand Slam, arrived today.
So now that I have striped out the steering, I find the Knuckle pins and link pins are also shot....

The Link pin bushes came out very nicely after I made a nice Drift tool(tool # 1), but the upper Knuckle pins refuses to come out.

Now, we make tool number two(tool # 2), to extract the Knuckle pins.

Also made me a set of "Bush puller Inners" (tool #3) for the Swivel pin bushes.

Have also made a steering wheel extractor tool (tool # 4)

Awaiting the quotes for Link pin bearings, and Knuckle pins bushes.

Let you know how they come out...

Herman

[jolas]

Herman, what does the interior cabin light look like, I never took note of this the last time I sat in one of these busses. Is is the same as a split bus or the type fitted into the baywindow busses ? If it's the same as a split, do you need the lens only ? Cheers

[retrovan]

Thanks Paul, As it is not always clear what is Bay and what is Split, in this bus, I will take a photo of it, and post it here.
Will then list all with photo, as every time I think it is one or the other, I find that it is NEITHER.......
Man is this one mixed up bus. do not believe the folk law, that the front is bay, and the back is Split.
This only applies to the skin, after that its a "free for all"

Herman

[Warwick-Lowlight]

We do all like pictures evn if it is a bit mixed up with the splitt vs the bay
would also like to see tool # 1 -2 -3 -4 -5 etc

[retrovan]

We do all like pictures evn if it is a bit mixed up with the splitt vs the bay
would also like to see tool # 1 -2 -3 -4 -5 etc

You got it,
Will do this weekend.

Herman

[retrovan]

After looking long and hard, I could not get Link pins, or needle bearings, seals and king pin bushes anywhere.

So I ordered a set of Link pins complete set, with seals, bearings, bolt,spacers, and all.
As well as 4 king pin, or as some books call them, knuckle pins.
As well as the assembly 12 seals from http://www.bustoration.com
Total cost $127.45
Well at least now I will be able to keep the wheels on the ground, and all facing the same way..
Now we wait for them to get here.
Think I will clean up some parts so long.
Till then
Herman

[retrovan]

OK, so I now go to fit the Swivel Pin for the drag link, cleaned it all out and pulled the bushes home with my "Bush puller Inner" tool, and even remembered to leave the top bush sticking out by approx. 1.1 mm ( ) as the Germans will have it, test fitted the Pin, got it half home, and it got stuck.

Had to heat the pin to expand it, to open up the bush, let it cool over night, and managed to get the pin out....
I will have to skim the inner of the top bush to get it to fit loose but snug, just have to remember not to push it in with so much gusto when testing...

Opened the front hub to find the shoes are not bad, even the drum would appear to have little wear, bearings are sound, so this weekend, it would be a clean and paint, and replace...

Herman

[hitlers revenge]

Squire

Now that you've done all the hard work in searching for parts, can you please send me all the part numbers.

There's a good chap!

Thanks

[retrovan]

Well as promised, here are some pic's



The reconditioned Steering box, filled, new seals, and ready...



Just an other view of the steering box



Serviced Master cylinder.... Unknown parts number 211 611 111



Before pic of king/ link pins and drum



After pic of swing arms ready to fit the link & king pins..



bits ready for installation..



Rebuilt Swing arm Pin with home made dust cover.( original one lets the road dirt in )



Weird type of steering wheel with insert, already extracted off the steering shaft



My "Tools" to make the job easer,
The top one is the Oil pump skimming adaptor to fit the oil pump to the lath to reduce/ flat cut it.
The bottom centre is my Steering wheel extractor.
Next to it(bottom right) is my Knuckle extractor, the outer "U" presses down on the stub axle, the small "U" fits over the knuckle pin hole, where the link pin fits, and a 14 mm bar passes through the hole, through the knuckle, and the bolt pulls it out.
The centre line from left to right,My sand paper flapper rod, to clear the inner part of a bush to size, Next my Bush puller inner, Then my bush drift, to knock out bushes. the small brass one does the same.
THe last one is a bush line up tool, and /or knock in tool.




Better view of the steering wheel extractor tool, and the Knuckle pin (king pin, upper & lower) extractor
You will note the Steering wheel remover has a swivel on the two half cups, so that they may hook in under the wheel, to spread the pulling load fully around the base of the steering wheel so that you do not get damage.
You then turn the top bolt and the bottom of that bolt presses on the flush nut and steering rod.

Not very pretty, but they work a treat, Look Ma no more bleeding hands......

Herman

[retrovan]

Many may ask, why are the serviced areas nice and clean and painted, and the rest still all rusty and dirty.?

Well as mentioned on the top of the tread, I want to leave the Fugly as is, with all "warts and pimple" but the mechanics must be 100% restored, for reliability and safety.

Still waiting on the Imported parts, and then the motor has to be done.

This will need more time (read money)

So we will get stuck into the drive gear now, as I see I have a reduction box seal that needs replacing.

Hope to get the side shaft off, then hopefully the seal can be extracted without stripping the reduction box, that would be a job.

Anybody done this before, I know there are not many Brazilia out there, but who knows....

Herman