'65 Standard

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Dual Port
Posts: 1028
Joined: Fri Apr 30, 2010 10:06 am

Re: '65 Standard

Post by Dual Port » Tue Nov 07, 2017 10:35 am

Assembling the dash wiring is pretty boring and pretty fun at the same time. The WW harness comes with great color instructions that even a moron could follow.
PA260108.JPG
Whattayathink? Should I bead blast the fusebox or stick it in like it is?
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Yea, I blasted it.
PA230043.JPG
Took a bunch of parts and put together two headlights. I'm not sure if the second bucket is Beetle or early bus, but I don't think it's right for this bus. Walking around car shows I do see some early ones with the running light bulb near the glass lens, though.
PA260100.JPG
Turn signal switch wiring didn't match the schematic, which pissed me off and took extra time to figure out.
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Clamped a bubble mirror to the garage door so I could see the taillights while I was sorting out the electrical.
PA270121.JPG
Used a regular 2 terminal 552 flasher and connected the indicator wire to the output pin. Screw that giant factory turn signal relay.
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Here's why you need a 40a fuse in the back feeding the dash harness- the aftermarket ignition switch had the hot lead (blue connector) scary close to the lip on the dash. A little wiggle, a good bump, and your red wire turns bright red. :cry:
PA270144.JPG
Quick work with a die grinder fixes that.
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Just because it's bead blasted doesn't mean it makes good connection. Note the two pieces with the arrows are riveted together but do not have continuity!
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A dab of solder fixes that, just like 6v's HL fusebox.
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And we have LED interior lights!
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Each of the four bulbs draws only 30ma (.030a) so one bulb could be left on for several months before running the battery low. I love these things and am currently converting my home bulbs all over to LED, and am thinking about changing all of the shop fluorescents to LED too. ;)
Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus

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Dual Port
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Joined: Fri Apr 30, 2010 10:06 am

Re: '65 Standard

Post by Dual Port » Tue Nov 07, 2017 10:46 am

Here's the back of the ignition switch showing the updated wiring and shrink tube, It's kind of important to shield hot leads from accidental grounding, (right, Volkswagen?).
PA240086.JPG
Yes, I did the hillbilly glue-the-foil-to-the-reflector on the front lights. They're really bright, though, I put 1156 bulbs in which might be higher wattage than they should be.
PA240090.JPG
I put a new tank in but it didn't fit as well as the WW tank in Bus 1. Some modification had to be made, cutting a reinforcement off and doing some hammer damage to the drain tube.
PA250094.JPG
PA250098.JPG
Last edited by Dual Port on Tue Nov 07, 2017 10:02 pm, edited 2 times in total.
Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus

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Dual Port
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Re: '65 Standard

Post by Dual Port » Tue Nov 07, 2017 7:20 pm

Lurch in action, putting in three panes. Thanks, Lurch!
PB060010.JPG
PB060011.JPG
Electrical is done, here's what the dash looks like. Typical of me is putting in an extra fusebox so loads are spread out, this is easier on the wiring as well as making diagnostics easier if it blows a fuse.
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It's actually starting to look like a bus again. :D
PB070028.JPG
Next are brakes and driveline. I wonder if this mystery trans is any good? :)
PB070053.JPG
Last edited by Dual Port on Wed Nov 08, 2017 10:10 pm, edited 1 time in total.
Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus

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ohiowesty
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Re: '65 Standard

Post by ohiowesty » Tue Nov 07, 2017 8:43 pm

I truly enjoy reading your posts! It's documentation for generations to come.

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Marla
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Re: '65 Standard

Post by Marla » Wed Nov 08, 2017 6:25 am

Nice work Bruce and Dan.

I love LED's too. I really think it's the only way to go. With the prices going down, it's an easy upgrade.
It's Marla with an " L"
(My list of assets is just too long...)

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Karl Kombi
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Re: '65 Standard

Post by Karl Kombi » Wed Nov 08, 2017 9:53 am

Thank you for detailing all the progress -- very nice!

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lurch
Posts: 274
Joined: Fri May 01, 2009 4:48 pm

Re: '65 Standard

Post by lurch » Wed Nov 08, 2017 10:35 am

I had the opportunity while there to check the bus out and wow!!! Bruce has truly turned this bus from tags to riches.It will deffinatley surprise you if you look at all the details.

Now put a sleeper set up in and start camping!!!!

Hahahah
the best ideas are often the worst choices.
vanagons
mopeds

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Dual Port
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Re: '65 Standard

Post by Dual Port » Tue Nov 28, 2017 8:56 pm

On to the Mystery Trans. First, run the selector through all 5 gears and see if they are present, check, but the hockey stick bushings are worn pretty well.

Second, hook up my homemade drill driver tool and see if all five gears are present, check. Note reverse gearshift pattern written on cardboard to help me figure out where I am.
PB090006.JPG
OK, the trans might be OK, proceed with putting new shift bushings in the nosecone. Most people would buy a new $40-60 nose, but not me. :roll: Polish the hockey stick with 1000 grit.
PB090013.JPG
Pull the nose, blast it, drive out the old bushings, push in new bushings.
PB090019.JPG
Use a bolt to draw in the inner bushing.
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Looks good.
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I didn't even need to ream them!
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Thin coat of RTV and it works great.
PB090044.JPG
The clutch lever return spring was broken and the shaft was frozen, this gave me a reason to change the lever. Glow the old lever and remove it, and switch to the later '66 up lever that uses a wingnut and doesn't block the bellhousing bolt. That stupid early lever is ridiculous.
PB070044.JPG
Note the lever on the left blocks the bellbolt making access very difficult. And if you've ever adjusted an early clutch with this double-nut setup it's enough reason to sell the car and buy a newer one. :evil:
PB070047.JPG
On to teardown of the axle assemblies.
PB100046.JPG
Last edited by Dual Port on Tue Nov 28, 2017 9:48 pm, edited 2 times in total.
Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus

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Dual Port
Posts: 1028
Joined: Fri Apr 30, 2010 10:06 am

Re: '65 Standard

Post by Dual Port » Tue Nov 28, 2017 9:08 pm

Forensics during disassembly of the RGBs reveals someone was JUST in here- but maybe decades ago. These haven't even seen gear oil yet, they still have lithium grease on the gears.
PB100048.JPG
But what's the crime? Putting in this stub axle, and some trashed bearings. Who the F would do this?
PB220016.JPG

Weld the nut, pull the plug.
PB100053.JPG
The inner stub nut can either be a hex or some kind of devilish slotted nut that even VW does not make a tool for.
PB220001.JPG
I made my own. :(
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It takes a LOT of time to turn the lower axle into the upper set of parts. A LOT of time.
PB100054.JPG

Before assembly check the fulcrum plate clearance, I think the spec is <.011"
PB240079.JPG
Attachments
PB100058.JPG
Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus

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Dual Port
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Joined: Fri Apr 30, 2010 10:06 am

Re: '65 Standard

Post by Dual Port » Tue Nov 28, 2017 9:18 pm

Here's all of the parts soaked, cleaned, wire wheeled, blasted, scrubbed, inspected, threads chased, brake cleaned and ready for assembly. I have two full afternoons breaking down the axles and cleaning these parts, upwards of 12 hours. :(
PB220024.JPG
Check the fulcrums, install the side gear and axle shaft together as an assembly. Lube it well.
PB240029.JPG
PB240033.JPG
Assemble the inner axle bearing and stub shaft. Don't f$%#! up and put the stub shaft in before the inner axle bearing, 'cause you can't put the bearing in with the stub there. :oops: (BTDT a couple of years ago)
PB240038.JPG
Torque to 108 and pinch the locknut with a dull chisel.
PB240042.JPG
Put the tube on and draw in the bearing with a homemade spacer.
PB240061.JPG
Attachments
PB240036.JPG
Last edited by Dual Port on Wed Nov 29, 2017 9:46 pm, edited 1 time in total.
Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus

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