Back in beige

[jamie]

Thanks Lewis. I didn't realise he did one. Got a link?

[inaglasshouse]

Thanks Lewis. I didn't realise he did one. Got a link?

Here you go Jamie:
http://www.classicretrofit.com/products.html
Cheers, Richard.

[jury]

Look at his happy face https://vine.co/v/iZqeg2glvUI

It does revs: https://vine.co/v/iW2r1zQzhgh

Dear.....God.....! Go on son !!!!!

[jury]

Nice work Jaime and Miss Jaime

On a side note, I fitted blade fuses to the Modrod...very secure, easy to see which has blown etc etc Though Darren has got a thing about period correct looking details

[jamie]

Yeah - Repa harnesses, Heure stopwatches, Haldex Tripmaster - you'll see more 'mongrel' on the podium at Crufts.

[jamie]

Thanks Lewis. I didn't realise he did one. Got a link?

Here you go Jamie:
http://www.classicretrofit.com/products.html
Cheers, Richard.

Thanks Richard. No good for me - this is for later cars than mine. My one has a much smaller fuse board.

As such, I could probably just as easily make one from a generic eBay blade fuse holder.

[jamie]

The stainless J-tubes arrived from AMS Auto in Germany. Lovely things.





Like everything on this car, fitting was not as straightforward as it could have been - the pipe diameter was marginally different (by perhaps 0.1 or 0.2mm) to the internal diameter of the pipes on the silencer I got from NickT. So I filed it down slightly and polished it up again with a paint stripper disc on my angle grinder.

Then I discovered that the heater box holes didn't fit over the out-hole on the big, weird flapper box assembly that hangs down below the engine. This was nothing to do with the exhaust, and everything to do with the fact that this car has been exited the road backwards over rocks etc at some point in its life. The Dude did a stellar job of straightening-out the flapper boxes, but the out-hole was still oval. He didn't know, I didn't know. Anyway, I fiddled the exhaust heat exchanger holes with a hammer and some pliers, and now everything fits nicely.



After this, I fitted and wired-in the regulator. So as it stands, I have to

1. reattach the right-hand carb
2. install the remote filter
3. buy and fit oil lines to the remote filter
4. fit a few more wires down below - gearbox stuff, plus earth strap etc
5. check the valve clearances
6. add fuel

and then... it's ready to run.

The engine is currently filled with 'Millers Running In Mineral Oil 30'. There's also a break-in procedure I have to follow to work-harden the cam lobes or something - details here: http://www.aircooled.net/vw-engine-break-in-procedure

[Jonny Hart]

Hi Jamie. I'd like to see the fuse board as I'm thinking of doing ones for early cars. Is it the same as an early 911?

Post up a picture if you have a minute.

[sladey]

and then... it's ready to run.

Getting exciting now Jamie - how close is the interior?

[jamie]

Nearly there, but I can't do the driver-side door as the car is on axle stands, up against the wall!

To Do list for the interior:

Cut out the passenger-side floorboard from the template that Gary made for me.
Fit brake switch
Fit throttle cable
Sort out door locks
Fit door handles
Fit driver-side door card
Make replacement winder handle knobs and fit handles
Fit heater vents
Fit the last few bits of carpet
Fit gear stick
Fit earth cable to instrument pack
Fit front carpet set
Fit the rear screen

Other stuff I need to remember:

Fit front suspension crossmember supports
Fit crossmember / steering rack cover
Fit front strut top bolts
Make and fit exhaust-to-tinware supports
Fit rear lights
Fit the -old git- headlamps

[jamie]

Today I decided I would fit my re-chromed door handles. On investigation of the lock cylinders, I discovered that they matched the ignition key! Hurrah! Although I had driven the car in the US, I couldn't remember why the car came with two keys and assumed it due to mismatched ignition and door locks. Turns out the other key is for the glovebox (is this normal?).

The cylinders were encrusted in old grease, so I cleaned them up in some thinners, re-greased and installed them in the handles. It took me a bit of time to remember how the mechanism all went together, but with a little help from a thread on Pelican, I worked it out.

In case anyone arrives here looking for info on this task, here's how the assembly should look (tighten up the screw, though). I think the handles are '68-only, but I expect the mechanism is the same as the earlier-style push-button handles too.





They're on the car now and look great.

[jury]

Looking good Jaime...the J-tubes are a nice looking item, may need to get abit more info off you.

I am going to re-read the engine build process/specs


Start up before Christmas ? This Christmas!

[jamie]

When I woke up this morning, I didn't have any plans to get it running by Christmas. After reading this, I realised I could have it running by Christmas. Or even on Christmas. So instead of catching up with work as planned, I spent all day in the garage.

Everything except the starter cable is now wired up. The earth strap is on. My girlfriend helped me with the rear screen again - it went in after many failed attempts, although I'm not sure even the new seal, which I bought direct from Porsche, fits that well either. But it is in, so I'm going to just leave it alone in case I crack it like the front.

The wiper arms are on and working.

The right-hand carb is on and connected to the other with my linkage. I've ordered a Bowden cable for the throttle.

I tried to connect the heat exchangers to the flapper boxes, but the silicone duct that I bought is too small. I also don't have any of the bolts that clamp the cables in place, so I need to make some of those...

The list as it stands:

Cut out the passenger-side floorboard from the template that Gary made for me.
Fit brake switch
Fit throttle cable
Fit driver-side door card
Make replacement winder handle knobs and fit handles
Fit heater vents
Fit the last few bits of carpet
Fit gear stick
Fit earth cable to instrument pack
Fit front trunk carpet set
Fit front suspension crossmember supports
Fit crossmember / steering rack cover
Fit front strut top bolts
Make and fit silencer-to-tinware supports
Fit rear lights
Fit the bloody headlamps
Fit & plumb oil catch tank

[sladey]

Nice drive out on New Year's Day - got to be done!

[jtparr]

Go for it Jamie.....!....gaffer tape around the headlamps if all else fails with them.....