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VW Beetle Official Build Diary - Pack 4 - Issue 24-31 Options
Levelord
#1 Posted : 18 July 2019 16:41:50

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Issue 24 - The right rear wheel


Gently warm the tyre by immersing in hot water to soften the rubber. When soft, insert the wheel into one side of the tyre and work the tyre over the rims. Check that the tyre beads are perfectly seated on the rims all the way round.
Once done, I then painted the weight on the rim grey. Stage complete.



















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Levelord
#2 Posted : 18 July 2019 16:46:10

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Issue 25 - The right rear suspension.


Fit the stub axle into the hole at the end of the right rear suspension arm. Note, the two small tabs beside the hole engage with notches in the flange on the stub axle, this prevents it from turning. As with the left rear suspension, align the other end of the suspension arm with the notch in the subframe, press the end of the arm into the notch until it snaps into place.

The suspension arm mounting plate (25-4) is angled to match the slope of the rear subframe. Fit it over the end of the suspension arm so that the top of the plate sits flush with the subframe. Fix the mounting plate to the subframe with two SD06 screws, then check that the suspension arm pivots freely up and down.


Take the assembled wheel from stage 24 and fit the brake drum into the wheel, making sure that the tab slots into the corresponding notch in the brake drum. Holding the brake drum in place, fit the assembly over the right stub axle then fix the wheel to the stub axle with an SD02 screw.

Note: Fitting the wheel temporarily allows you to check that all the parts fit together perfectly, however, due to the weight of the wheel being unsupported it is advisable to remove the VW badge, screw, stub axle, wheel and brake drum and store them until you are ready to do the final assembly in Stage 30.

Stage Complete.



























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Levelord
#3 Posted : 18 July 2019 16:49:01

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Issue 26 - The right shock absorber



Take the rear subframe and fit the right rear shock absorber support (26-1) onto the torsion bar housing, the support has a square hole that only fits shoulder of the housing at a set angle. Now fit the torsion bar spring plate (26-2) over the round end of the torsion bar. Fit the end of the torsion bar spring plate behind the D-shaped support on the end of the suspension arm, the two small pins fit into the holes in the support. Press the two parts together and fix with an SD04 screw.

The lower end of the suspension arm has a circular opening with two holes facing each other. Insert the smooth end of the pin (26-8) into one of the holes, but do not push it all the way in. Fit the damper tube (26-3) down through the circular opening so that the eye at the end of the tube lines up with the pin. Push the pin through the suspension arm until its grooved portion locks it into place.

Slide the shock absorber rod into the damper tube and fit the thinner end of the rear suspension spring (26-5) over the damper tube. Fit the internal damper spring (26-6) inside the rear suspension spring and over the damper tube. Finally, fit the shock absorber body over the internal damper spring and inside the rear suspension spring. Now compress the shock absorber a little so that you can secure it to the top of the shock absorber support with an SP12 screw.

Stage Complete.























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Levelord
#4 Posted : 18 July 2019 16:51:22

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Issue 27 - The door panel


Note which way up the hinges go. The door panel has a locating pin and a hole that correspond to the two holes in the hinge Fit the first hinge to the top of the door with the locating pin in the top hole and secure in place with an SD07 screw in the lower holes. Make sure that the hinge is securely fixed and does not move up and down. Fit the second hinge in the same way and secure it with another SD07 screw.

Now fit the inner door panel, ensuring that the three mounting holes line up. Press the panel into place so it fits flush, then fix to the door with three SD04 screws. Check that the window still slides up and down freely, slacken the screws slightly if it feels stiff.

Stage Complete.




















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Levelord
#5 Posted : 18 July 2019 16:54:05

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Issue 28 - The door panel



Begin by mounting the window winder handle (28-2) onto the door card. The handle has a small lug that fits into a notch in the upper right corner of the mounting hole ensuring it fits at the correct angle. Press the handle into place, then turn the door card over and secure the handle with an SP09 screw.

The door handle support (28-4) fits into a matching recess in the door card. The handle support has round and rectangular lugs on the back that fit into the matching holes in the door card. Press the handle support into place so it fits flush then fit the door handle (28-3) into the matching hole in the support. Press the handle into place then turn the assembly over and fix with an SP08 screw.

Finish fitting the accessories by positioning the door pull (28-5) into the two remaining holes in the door card. Note that the hole on the right has a notch which matched the lug on the back of the door pull ensuring the door pull will only fit the correct way round. Holding the pull in place, fix from behind using two SP09 screws.

Now take the door card and match up the three tabs on the back with the slots on the inner panel of the door. First, fit the two tabs on the left into the matching slots, making sure that the tab on the right is still in line with its slot. Finally, press the remaining tab into the remaining slot in the panel, checking that the card is properly aligned with the door.

Stage Complete.























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Levelord
#6 Posted : 18 July 2019 16:55:46

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Issue 29 - The Central Floorpan


Align the central floorpan with the front subframe, ensuring the floorpan is the correct way round. Fit the parts together making sure the posts and holes all match up. Press the outer edges of the parts together to make sure that the locating pins lock into the corresponding holes. Start by fixing the parts together with an SD10 screw in the central hole, then drive two SD05 screws into the outer holes.

Turn the assembly over to check that there are no gaps between the parts.

Stage Complete















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Levelord
#7 Posted : 18 July 2019 16:57:54

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Issue 30 - Passenger Compartment Floor


Take the rear subframe from stage 18, the two rear wheels and the parts held over from Stage 19 and 25. Fit the stub axle (19-2) through the hole in the left rear suspension arm making sure the tabs in the suspension arm lock into the notches in the flange on the stub axle. Fit the brake drum onto one of the wheel hubs, then fit the assembly onto the stub axle, making sure the axle stays in place in the suspension arm. Fix the wheel to the stub axle with and SD02 screw, the press a VW into the hole. Fit the other rear wheel in the same way.

Now take the floorpan and suspension assembly and fit the rear subframe over the mounting points at the back of the subframe. Press the parts together with all the holes matching up, ensure they fit together flush. Check that the four mounting posts have fitted all the way into their holes and screw the parts together with four SD04 screws from issue 29. Finish off by securing the central support with the SD10 screw from Issue 29. Turn the assembly over and check there are no gaps between the parts.

Stage Complete
























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Levelord
#8 Posted : 18 July 2019 17:00:51

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Issue 31 - Passenger Compartment Fittings



Take the passenger compartment floor from the previous issue and fit the footwell bulkead by lining up its mounting points with the four holes, press the parts together and secure them with four SP12 screws.

Fit the gear lever into its corresponding hole in the central tunnel, the lever is thin and fragile so handle it with care. There are four holes in the central tunnel behind the gear lever, used for fitting the handbrake lever and its mounting and the heater levers. Fit either of the heater levers into one of the small holes beside the long slot in the middle. The pin will only go into the hole when the lever is facing forwards. Fit the second heater lever into the other hole in the same way.

Fit the tab on the handbrake lever into the long slot, making sure it goes all the way in. Now fit the handbrake lever mounting into the hole immediately behind the handbrake, making sure it fits all the way in.

The two seatbelt buckles are identical, make sure you fit them with the red release buttons facing the centre of the car. Before fitting the first buckle, fit an SP11 screw through the mounting hole from the side opposite the red release button. Fit the screw into the hole on the left hand side of the central tunnel, with the seatbelt buckle facing slightly forward. Fit the second seatbelt buckle on the right of the centre tunnel and secure it with an SP11 screw. Make sure that both buckles are at the same angle towards the front of the car.

All the fittings are thin and fragile so be careful not to catch them on anything as the build progresses.

This completes Pack 4.






























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