1957 Oval

User avatar
Ken
Posts: 1919
Joined: Mon Dec 15, 2008 8:18 am

Re: 1957 Oval

Post by Ken »

Six Volt wrote:
CraigOnTheBoat wrote:Please Mr Judge "If the gloves don't fit you must acquit"
I know if I didn't take a picture it didn't happen, but how did you know there was a white Bronco parked outside the house today? Seriously, there was!

Anyway, I'm thrilled this oval is finaly moving along. The immediate hangup now is the need to source a '62-'66 pitman arm for the replacement TRW steering box. The replacement boxes were all designed (understandably) for the later (read more plentiful) '60's bugs. They changed the arm after '61, so now I'm treading water. Even WW, at $99 for a little pitman arm, are out of stock. http://www.wolfsburgwest.com/cart/Detai ... =113415371 The big box outlets at $20 to $29 are also out. http://www2.cip1.com/ProductDetails.asp ... D413%2D041 Nothing listed on the samba. Maybe something will show up at Jim's Custom?
I have a couple old beetle steering boxes with pitman arms at the shop. You are welcome to them if they will work.
1963 Single Cab
1964 Bowman & Sons Camper (Vegas Bus)
1966 Westy S0-42 Hardtop
1967 Westy SO-42 Pop Top
1968 Single Cab
User avatar
Dual Port
Posts: 1305
Joined: Fri Apr 30, 2010 10:06 am

Re: 1957 Oval

Post by Dual Port »

Super sloppy link pins:

Image
Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus
User avatar
Mike Kever Kombi
Posts: 911
Joined: Mon May 27, 2013 12:19 pm

Re: 1957 Oval

Post by Mike Kever Kombi »

Holy technologically advanced batman, we have video in seans build thread.
Mike

1961 Microbus
Image


1971 Super Beetle (1302s)


1975 Westfalia
Image

Sarcasm is just one of the many services I offer.

I like my water filtered through a bed of grains, cleansed by yeast, and preserved with hops.
TRL
Posts: 612
Joined: Tue Jul 03, 2012 1:59 pm

Re: 1957 Oval

Post by TRL »

Wow, those look a little worn...
The Rick Lang
Six Volt
Posts: 3724
Joined: Mon Dec 15, 2008 7:25 am

Re: 1957 Oval

Post by Six Volt »

Ken wrote:
Six Volt wrote:
CraigOnTheBoat wrote:Please Mr Judge "If the gloves don't fit you must acquit"
I know if I didn't take a picture it didn't happen, but how did you know there was a white Bronco parked outside the house today? Seriously, there was!

Anyway, I'm thrilled this oval is finaly moving along. The immediate hangup now is the need to source a '62-'66 pitman arm for the replacement TRW steering box. The replacement boxes were all designed (understandably) for the later (read more plentiful) '60's bugs. They changed the arm after '61, so now I'm treading water. Even WW, at $99 for a little pitman arm, are out of stock. http://www.wolfsburgwest.com/cart/Detai ... =113415371 The big box outlets at $20 to $29 are also out. http://www2.cip1.com/ProductDetails.asp ... D413%2D041 Nothing listed on the samba. Maybe something will show up at Jim's Custom?
I have a couple old beetle steering boxes with pitman arms at the shop. You are welcome to them if they will work.
Thanks Ken, but Bruce gave the original a good cleaning and he thinks it's going to be good to go with some new seals.
User avatar
Dual Port
Posts: 1305
Joined: Fri Apr 30, 2010 10:06 am

Re: 1957 Oval

Post by Dual Port »

Things went smoothly the last couple of days, time for a short update. I cleaned and blasted bolts and hardware and organized it so assembly will go smoother. I drilled out the stupid cotter pins that broke off in the steering coupler bolts. I dug up two spare T1 St Boxes in my junk but they were later, and different enough I took a second look at Sean's box. I cleaned it up and it looks better than I first thought, some 600 grit brought the Pitman shaft back to usable and cleaning the housing showed the worm gear to have no wear and no pitting. Napa and the usual suspects did not have the Pitman shaft seal available anywhere, but Carquest's regional warehouse is in Brunswick and had it, for $5!

Image

The Pitman rides directly in the iron housing (no brass bushing!) and has only a few thou side clearance, very tight. The worm bearings felt fine once clean and I feel this box has many thousands of miles left in it.

Image


Clean things up and push the seal in with a coating of High Tack.

Image

Yes, that nut looks like shit, I'll change it out.

Image

Lube the seal and install the Pitman, assemble the shaft and cover, torque to 18, fill with 90wt, and adjust the sector.
Image
Image
It feels as smooth as silk!

Image
Parts and box all cleaned up, organized and painted. Stub wire is for the ground that goes around the coupler disc so the horn will work. Still waiting on a rear backing plate, whl cylinders, and axle bearings. :(
Image
Welded a couple of nuts on the recalcitrant axle bearing and pulled the SOB off.

Image

6 more hours, total 11.
Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus
Six Volt
Posts: 3724
Joined: Mon Dec 15, 2008 7:25 am

Re: 1957 Oval

Post by Six Volt »

Great stuff Bruce. Rear wheel bearings/spacers came in from WW today. Got the rear drums turned at NAPA in Berea near Bruce's shop. I was impressed by the two old guys, (well they were my age! :lol: ). When I walked in they said "Old VW drums" before I could utter a word. How do these guys now this stuff??

I'll leave the pics to Bruce on these items. (Wonder why? :roll: )

I'm really impressed with Bruce's attention to detail. Because the whole axle, brakes and steering aspect of this involves SAFETY, this is not something that I can just trust myself with. I would have just bolted stuff on and announced "We're good to go!" :o
User avatar
Dual Port
Posts: 1305
Joined: Fri Apr 30, 2010 10:06 am

Re: 1957 Oval

Post by Dual Port »

Another update for 6V to look at: :lol:

I blasted and painted the second backing plate, and installed the axle bearings. Clean everything up good with a wire wheel first.

Image

I used a couple of pieces of 1" electrical conduit and the axle nut to draw the bearing onto the shaft which is a very tight fit.

Image

As it gets to the axle housing I used a brass hammer to walk it into the housing, which is not nearly as tight. Don't forget the spacer which goes on first!

Image

Don't forget the big washer, which goes on before the seals or backing plates.

Image

Now the seals- a bit of High Tack and push them into the seal housings which were already blasted and painted.
Image

Push it in with the vise and a driver.

Image

Seal must be flush and square.
Image

Put a drum on and burp the nut to make sure everything spins free and fits right before putting the seals and stuff in.

Image

Clean all of the paint off the gaskets surfaces with a gasket whizzer and put FIPG on the gaskets and seal housing.

Image

Assemble and torque to 43.

Image

Install the park cables. I keep a bunch of different wire brushes around for cleaning nasty holes out.

Image

All set, waiting for wheel cyls.

Image

OK, now back up front. Let's get the shocks off and out of the way. I heated these MFers red several times and the upper bolts still broke on both of them, they might have been original. I'll drill the bastards out.


Image
Bye, bye, bitch!

Image

Bye, bye, bitch!

Image


Clean shit up with a wire wheel to get rid of grunge.

Image

We're going to put a dual MC with remote reservoir on like '67 up have.

First, make a template from a piece of Mountain Dew box.

Image

Image

Then transfer to .045 galvanized steel (18 ga?).

Image


The hoses are just trial fit, not on for good.

Image



Views from above, box in and torqued (22? Really? WTF?), ground wire installed, etc.

Image

Image

View from front, need some Polar Silver touch up paint. ;)

Image




The last moron had the MC bolts put in without the spacers. :roll: One had fallen between the panels and I fished it out with a magnet, the other was gone. I happened to have a piece of the exact right tube on hand so I made one.

Image



And, he had the MC pushrod hanging by ONE THREAD, and no cotter pin in the clevis pin. Oh, yea, the rod is bent badly, too. :roll: I'll make a new one when the MC shows up.

Image

The new MC will get 8x1.25 Gr 10.9 diesel bolts with built in washer heads and the new spacer.

Image


7.25 hours between yesterday and today, up to 18.25.
Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus
TRL
Posts: 612
Joined: Tue Jul 03, 2012 1:59 pm

Re: 1957 Oval

Post by TRL »

im really looking forward to seeing the cool car on the road!
The Rick Lang
Six Volt
Posts: 3724
Joined: Mon Dec 15, 2008 7:25 am

Re: 1957 Oval

Post by Six Volt »

So Bruce got back on it today. I'm really amazed at his professionalism and attention to detail. Yes, I was in the way most of the time, but I'm not missing the chance at an education and I got a great one today.

I've been gathering the necessary parts (which is an education in itself) and Bruce is great at explaining what to buy and when to buy it. He likes to use the original German stuff when possible and as an earlier post shows, he saved the OG steering box.

One of my biggest fears in getting this bug road worthy was the entire braking system. I also had major concerns about the whole front end. I love the stock look, but I didn't want to be unsafe.

Bruce suggested we do a full upgrade and I'm glad I listened to his advice. The '57 beetle brake system is just not up to snuff for today's world, even if you're driving in the right lane.

Bruce said "let's get it done right" and he is certainly doing it right.

I bought the WW teflon brake line kit for a complete replacement. Proabably overkill, but if I park this down at Morton Salt for a few weekends, the brake system should survive.

Here's a pic I took of Bruces's install on the original steering box. Really profesional high end work.
Image

And one of the steering coupler that replaced the "rag"
Image

When I talked about attention to detail, Bruce really does it. The backing plates I was bolting on looked like s&%$. Bruce bead blaset and painted them and did the rear seals and bearings so the bug will have a real new lease on life.
Image
So Bruce installed all new brake lines. Really nice attention to detail.
Image
Even got the tab right on the line leading to the right rear wheel.
Image
Line into the replacement wheel cylinder that Bruce said was decent qulaity. The box said Denmark. Maybe the box was made in Denmark! :lol:
Image
I learned a lot about the clips. That's mundane and routine to veterans, but I saw how there was a right and wrong way to do things.
Image
I bought one of these, but for the life of me, we couldn't find it. Bruce had a couple old ones and bead blasted this one and it cleaned up nice. Image
Bruce taught me how to properly bend lines and make sure stuff is installed right.
Image
You can see his overall attention to detail.
Image
Since we're running the wheel cylinders on top, he had to cut the lines, but it was no problem as he had the right tools.
Image

Really productive day. I learned a lot.
Post Reply