DDK - Die Deutschen Klassiker

Tackled the nosecone today, started by undoing all the bolts and then gently prising the nosecone off, was pretty well sealed even though it had been leaking.

Next I had to clean all the mucky oil out and scrape off the old gaskets, unfortunately the battery on camera ran out so only have a before pic

Next i prised out the hockeystick seal, you will note the difference between the new seal and the old metal seal.

Finally got it all cleaned up and then got nosecone back on although had to do this twice as i had trouble getting hockeystick into correcdt place, only time will tell now as to wether its in properly.

Then got the diff all back in which wasnt as easy as i thought it would be to get first side in, in the end I had to put case on side on the ladder rack and drop it all through from one side.

Arms are all ready to go on now and hopefully all the hub seals will have arrived from karmann Konnection in the morning

good work.....and be carefull...your eyes !
many thank's for the pics....
impressive metal work.....and rust....
rapido

cheers, hoping to get hubs back on tomorrow, all depends on weather though as if its good i will be doing some welding on a 67 bug

Got a little bit more done today

nice work nic
I have to admit with mine I am just doing what I know mechanically- until I know it needs stripping, Im leaving WELL alone !
Ive done my brakes up, and stripped down the cylinders though. I certainly didnt have anything like the trouble you had getting your hub off !
Id be interested to know where you got your new stock of seals etc for the rear hubs etc, I have to do a shopping list for mine, its a bit daunting !
dan

Just got everything from Karmann Konnection as was quicker and easier that way however I have now discovered a few much cheaper places in US especially for panels.

Not had much time on this for a while but when I came back to it I found a problem with the rubber mounts being corroded on the bolts, one was so bad that when I went to put nut on the free thread the internal welds broke off. Priced up new ones and said no way so instead cut off old bolt and then carefully cut a square hole around it and then ground out head of bolt.

I then got a bolt of same diameter and thread and then shaved head down so it was like origional. This was then welded into the square and square welded back in and ground down. Yesterday I used P60 to fine fill it all and painted it as well as cutting the bolt to length and voila a rejeuvanated gearbox mount at the cost of my time and a new bolt

No pics as camera motherboard has committed hari kiri.

Having a nightmare with hub seals and CV boots though and gearbox has dumped its contents all over workshop floor so Im going to have to redo them all with a fair bit of instant gasket as well grrrrr.

Anyway nearly ready to mount it all up now just need a mate or two to pop over and give me a hand as well as get some new bolts for the spring plates as I dont trust the origional ones

Great thread Nic.

Looking forward to seeing it out and running.

Ad.

Getting fed up now having major woes with the gearbox, cant get it to seal no matter what i try and the arms seem very tight despite cleaning everything maticulously and using genuine gaskets etc exactly the same as it came off


Any help or advise would be appreciated.

Tried two lots of Cv boots and different styles of clips as well. All I have to show is gearbox oil all over the workshop floor

Give Paul at PR Services a ring. I know they rebuild gearboxes all the time. 01277 630099

Might well have to bug him again as something somewhere along the line aint right as arms are just too damn tight unless this is how they are supposed to be on a rebuilt but I think not

Plus this sealing problem in so annoying.

Called him a few times already and hes been very helpful.

Thing is its all rather on a budget now as im out of work as of next week and so is owner

As i ahve moved workshop had to get it rolling so here it is in its new homes

How's it all going?

Got that gearbox fixed yet?