Aircooled VW South Africa

Thanks

The replacement pushrod arrived in the mail today! (Despite the delay, it was actually pretty painless)

Already cut and waiting with the others!

Whilst waiting for my exhaust and some powder coating done, the oil cooler has been cleaned and prepped. Also decided to tackle the gearbox this weekend, so started with draining the oil and then cleaning.

Oil cooler good to go:


Working around the suspension and gearbox will now be a much more pleasant task.




Two questions though... The Bentley manual says there are two magnetic plugs to pull for drain, but I only see one? Is the other the filler?

And when replacing the boots, the manuals indicate orienting the split horizontally, but most people seem to incline it a little. Any reason for the deviation?

Think some box's have an for and an aft plugs, the filler is on the side halfway up / or halfway down depending how you look at it.

The reason you place it at 45 Deg angle from the top facing back, is that if not properly sealed, the oil can not run out and the water splashing from the road will not be forced in.

Herman

retrovan wrote: ↑Sun Oct 06, 2019 9:20 pm Think some box's have an for and an aft plugs, the filler is on the side halfway up / or halfway down depending how you look at it.

The reason you place it at 45 Deg angle from the top facing back, is that if not properly sealed, the oil can not run out and the water splashing from the road will not be forced in.

Herman

THanks for the info. I am assuming that the boots can fill to above the mid-point with oil, hence people incline them at 45deg instead? Just seems to me that horizontal places the least amount of stress on the boot, which should allow them to last longer?

put them horizontal and make sure they dont leak... thats what I do
use sealant on the halves

And don't overtighten the clamps. If you tighten them too much it will leak.

Thanks for all the tips and tricks! I will tackle this during the week.

Got a bit distracted last week, but got my powder coated parts back. They bent a lot of it in the process, but I have largely rectified it. Will post pics this evening.

Got the boots off and clean it up a little more, but the kit I have is missing a set of the small clamps. Will need to get a set of stainless ones during the week.

Otherwise, all the fuel lines are now finished, and the alternator is prepped. Any feelings on the amount that just be threaded in? In order to get the 2mm clearance behind the impeller, I have shimmed it rather high. And the. With the spring washer there is only about 6mm of thread engaged with blue loctite.

mount it on the fanhousing and adjust accordingly. You want the fan as far forward (towards the driver) as possible, without it rubbing.

Tony Z wrote: ↑Mon Oct 14, 2019 12:12 pm mount it on the fanhousing and adjust accordingly. You want the fan as far forward (towards the driver) as possible, without it rubbing.

Thanks Tony. I decided to ditch the spring washer which will give me some room to maneuver. Red loctite will serve as it's replacement

Some pics as promised...

... of the coated valve covers. Matt black for heat transfer, as opposed to polished silver before.



Mock up of the front tin with fuel fittings. I feel a little more clearance around the louvred trim is necessary, but at least it all fits in.



And the front tin with the cut out for the oil filter return. Unfortunately it creates a bit of a gap in the tin, but it will have to do.



New Jtubes will hopefully come late this week and then I can finalise the mock-up process and move on to cleaning and final assembly.

Simmy wrote: ↑Mon Oct 14, 2019 9:44 pm Some pics as promised...

Looks damn good Simmy!

Simmy wrote: And the front tin with the cut out for the oil filter return. Unfortunately it creates a bit of a gap in the tin, but it will have to do.

Maybe you put some of that u-shaped rubber on the tin?

Riaan.N wrote: ↑Tue Oct 15, 2019 10:29 am Maybe you put some of that u-shaped rubber on the tin?

That's the plan, but will only fill some of it. I know it's pedantic, but hey... Unfortunately I am not much of a welder, so closing it up with sheet metal was never going to happen.