Rescued a fat chick today

[vwkombi1966]

[Woreign]

I made the exact same mistake with those small tins when I assembled my engine. But I refused to undo all my work and simply bent the tins a little to make them fit. When the next engine rebuild happens, I'll install them properly.

[vwkombi1966]

[vwkombi1966]

so i'm covering days 4,5, & 6. i can't remember exactally what was done on what day, but I\we got quite a bit done! there were a few things that raised some ?'s, and a few other things that were just a pain in the @$$, but this square is getting close to being fired off for the first time!

- FUEL INJECTION WIRING HARNESS:
inspected the old (supposedly original) fuel injection harness. found various cracks, broken connectors, and some "Jerry rigging" as inspection\cleaning progressed. Here’s a few pics of the OLD harness:

Nate GRACIOUSLY broke into his "private reserve" and kicked down a known good (we think it's a 71?) fuel injection harness. plaese see my " ECU year\type Identification..." thread if you can help me ID this ECU P\N. I cleaned all connectors on the new harness using phosphoric acid. cleaned every contactor up like new! no corrosion here! i carefully ran the new harness taking great care to not over stress or bend the new harness in ways that may cause breaks. Here’s a few pics of the new harness installed:

- I also went through the wiring under the back seat and cleaned all contacts there too!

While I was rooting through the wiring, I cleaned up the solenoid contacts too. But whilst I was back there, I came across a piece of equipment that I have never even heard of, let alone seen. Anybody ever seen one of these? What is the purpose?

- Next, Nate helped me out with cleaning up my deck lid. I had decided that the original sound dampener was pretty toast, so I took it out with the intent of “I’ll just fix it later”. Nate said “here, why don’t you try using some of THIS” and tosses me down a couple pieces of sound deadening mat! Here’s a few pics of him showing me HOW to apply this stuff..

- so then we focused on getting the engine put back together! After we looked at the heads of the original engine, we discovered that there was no hole for the head temperature sensor in the new (donor) engine. So Nate busted out with a tap & die set, and we made our own hole, using an existing engine tin screw hole. We are going to use it to not only hold the head temperature sensor, but it will double to hold down the engine tin in that part (just like type 4’s do) Here’s a pic of the results:

I\we reassembled the D port fuel injectors, fuel rails, intake manifold, plenum, distributor, exhaust manifold, and a few various fuel\vacuum lines here and there. Here’s the grand tour:

Of course, it also helps if you know a buddy with an original MATCO 47mm exhaust wrench!

Well, that about covers the last 3 days. I think that after we get some more fuel line, hook up the dizzy, and get this baby stuffed into the square, it’s going to be time to fire off this baby! More pics to come, as I progress!
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Aircooled VW: more expensive than CRACK!

- 1968 Squareback (Scarlett)
- 1969 Westy

[Tram]

Install the harness to the engine and then install the engine. That's how we were trained and it's easier that way. When pulling a FI engine, disconnect the ECU and 3 or 4 other wires (depending on year) and keep the harness on the engine.
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Немає виправдання для війни! Я з Україною.

[vwkombi1966]

[Tram]

[Bobnotch]

[vwkombi1966]

[vwkombi1966]

UPATE: DAY 6.1 forseeing that i can't spend EVERYDAY at PROVOLKS, i descided to take a few small items home for cleaning. Rainy day stuff, ya know? so here's a pic or two of the VW nose emblem and interrior dome light i was tinkering with today...

my magnetic VW nose emblem works so well that i can even use it as a fridge magnet! once i refine my technique & find a nicer replacement emblem, i plan to make a MUCH nicer one. might just keep this one as a fridge magnent once i do! the interrior light was it surprisingly good shape. Only one small crack, and slightly dirty. i claened all the corrosion from the contacts, and in doing so, discovered that the light lens position actually determines if the light comes on when the door opens, always on, or always off. never new that they did that! those krafty krauts! i think that the next items i bring home for rainy day work will be all the external lights...
_________________
Aircooled VW: more expensive than CRACK!

- 1968 Squareback (Scarlett)
- 1969 Westy

[Tram]

[vwkombi1966]

[Tram]

[vwkombi1966]

actually, let me "re-phrase" all of this:

1. the PO told me they pulled the motor because it smoked something aweful. but that could be any number of reasons (bad rings, short in the wiring harness, injectors, ect.). SO, i have taken off all the top end stuff, and exhaust and placed it on the DONOR 1600.

2. the DONOR 1600cc, was pulled out of a 68 square and rand like a champ (with carbs), so we are fairly certain that the donor is good to go, as long as the F\I stuff from my OLD engine is also good.

3. the ECU that came with my square was attached to a 70(?) F\I harness, and that harness is pretty toast (lost of breaks, and brittle wire). so i have pulled the 70 ECU\71-72 wiring, and replaced it with...

4. the REPLACEMENT (71-72) ECU that has a 70(?) wiring harness attached to it. THIS wiring harness is pretty sweet (no breaks, and wires are semi-supple). THIS ECU and wiring harness combo came from a running 71.

5. SO, given these circumstances, what is the BEST combination to yeild the best results?...

p.s. TRAM, thanks, but i am working on a fairly tight budget, and i am trying to work with "what i got" if ya know what i mean! but i may hit you up later if i can just make work what i got!
_________________
Aircooled VW: more expensive than CRACK!

- 1968 Squareback (Scarlett)
- 1969 Westy

[Tram]

[vwkombi1966]

oh! gotcha! to be more clear, i am interested in making my 71 as "stock" as i can, but she needs to be my daily driver before i can truly worry about stock. so, functionality sadly, musty come first. that's why i am trying to make do with what i have first. but later down the road (so to speak) i might very well hit you up for that proper harness, when i can scrape up some more $. ya know? either way, i want you to know that i appreciate all your help with sorting this out. lastly, so is it possible to work with the "D" ECU, the 70 harness, and my donor engine? or should i try some other combination?....
_________________
Aircooled VW: more expensive than CRACK!

- 1968 Squareback (Scarlett)
- 1969 Westy

[Bobnotch]

[vwkombi1966]

DAY 7
So day 7 was spent, mostly sorting through the F\I wiring loom, adding new fuel line and various hoses. Nate and I decided that it would be in our best interests to stick with the 71-72 brain\70 harness After double checking our work, Nate and I got my fat baby on the lift, and stuffed an engine in her butt. We took some time to re-inspect all the wires, lines hoses and what-not while we’re back there. We ran out of the proper F\I fuel line, so we are at a stopping point because of that, and we’ll need to get so gas in the tank, and a battery too. Oh, and we found that the throttle cable was held on by a thread, so that’s gonna get replaced too. I wish that I could say that I did a lot of work to the old girl, but today was mostly Nate, since HE is the one who has to show me where everything goes! However, I was able to pull off the headlight buckets, and turn signal assemblies for clean up while at home. Figure I can shine up some stuff, bust some rust. Not to mention remove the “cat eye” inserts some PO has installed. Never was a big fan of those! I’ve also finished up the deck-lid. Nate had some left over foil covered foam, so we decided it would be a good idea to add a layer of that to the underside as well. We are currently holding the foam with the original clips that held the original aluminum covered fiber glass, but we are thinking of spraying some 3M adhesive and calling it a day. It won't be much longer before we lite-off this engine fir the first time! Here’s some pics of the days’ work. ENJOY!

_________________
Aircooled VW: more expensive than CRACK!

- 1968 Squareback (Scarlett)
- 1969 Westy

[vwkombi1966]

DAYS 8 & 9..
to start with, i decided to use some spray adhesive to tack the foam onto the underside of my decklid. no more drooping! then we decided to go through the FUEL SYSTEM. that was a WHOLE LOTTA FUN! simply put: every fuel line in the car has been replaced. we verified that the origional fuel pump works, inspected the fuel tank,and the sending unit. also replaced the broken accelerator cable, and put some replacement rubber on the kidney tubes (thanx to home depot!). everything worked except the fuel sending unit, which happens to be someting that i have repaired before. SO, after drilling out the brass rivet at the top, cleaning all corrosion from the delicate copper contacts there with phosphoric acid, i replaced the brass rivet with a small machine screw and nut. WORKS AWESOME NOW! here's some pics of the front hose work (before we changed the fuel hose with all NEW german fuel injector hose):

so next on the list i decided to do a little interrior work. i started with looking at a way to fix or replace the "puffy" and drooping sunvisors. after a little thought, i used nate's heat gun and had a little success with getting the vinyl to shrink back to something of it's origional form. not perfect, but workable! next, i looked to replace the broken plastic handle that attaches to the backrest of the back seat. I took some seatbelt material from the donor 68 square, adn fassioned a handle for myself that would not get in the way, look like it belonged, and wouldn't pose too much hassel when the seat back was in CAMPER configuration (remember those cool camping hinges i got?). seat belts seemed to be the PERFECT answer!

so then it was time to break out Nate's pressure washer and hit up the carpet kit. while the carpet kit dried in the sun, i took the shop vac and hit up the pans. especially under the back seat. I also removed and cleaned the heater bags (not shown here). they look almost brand new. i am pleased that the rust i found is all surfacue, and will be easily dealt with! so here's a few pics of the interrior, post vacuume...

and lastly, i took off the headlights, and turn signals. I took them home, and cleaned everything up. UNFORTUNATELY, i discovered that the turn signal bases are broken. it would seem that each is missing a "post" the the plastic lens screws actually screw into. so the plastic lenses are only going to be held by one screw each. guess i'll just break down and silicone a set until i can purchase a new set. anyway, I also got rid of the rusty cat-eyes while i was at it. here's the latest and greatest of the square after I cleaned the lights\turn signals.

[
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Aircooled VW: more expensive than CRACK!

- 1968 Squareback (Scarlett)
- 1969 Westy

[vwkombi1966]

I'm stuck at FT. Lewis training\yelling at ROTC Cadets... damn i wish i was workin on my square right now......
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Aircooled VW: more expensive than CRACK!

- 1968 Squareback (Scarlett)
- 1969 Westy