VW Beetle Official Build Diary - Pack 5 - Issue 32 -40 - VW Beetle Official Build Diary

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VW Beetle Official Build Diary - Pack 5 - Issue 32 -40

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Levelord

#1 Posted : 03 August 2019 17:48:29

Rank: Pro

Groups: Administrators, Global Forum Support Team, Administrator, Moderator, Official Builds, Forum Support Team Germany, Registered, Forum Support Team

Joined: 20/01/2013
Posts: 137
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Location: Celle, Germany

Issue 32 – Driver’s seat mounting.

Take the driver’s seat assembly, alight it with the seat frame and press the seat frame firmly into place, securing it with four SP12 screws. Now fit the seat runner slider into the grooves in the seat support, pressing the locating pins into the holes. Fit the assembly onto the seat frame so that the holes in the seat support fit over the two mounting posts at the front and the rear of the slider engages with the crossbar of the seat frame. Press the assembly into place making sure that the slider is hooked onto the crossbar, then fix the seat support to the frame with two SP12 screws.

Fit the seat onto the floor of the passenger compartment so that the two posts at the back fit into the holes and the seat support fits over the rectangular recess with the four slots near the corners. Make sure the two tabs at the front of the seat support snap into the slots at the front and the two tabs at the back snap into the other pair of slots. This should allow the two posts at the back to fit down over the holes. Turn the assembly over and secure the back of the seat with two SP12 screws.

Stage Complete.

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Levelord

#2 Posted : 03 August 2019 17:49:24

Rank: Pro

Issue 33 – Gearbox

Fit the gearbox mounting into the keyhole shaped recess in the gearbox end casing. The shape of the fitting ensures they will only go together one way. Press the parts together firmly then secure with an SD11 screw on the inside of the gearbox end casing.

Fit the large hole in the tab projecting from the gearbox end casing over the post in the right-hand half of the gearbox casing, the end casing should fit flush. Now fit the other side of the gearbox casing pressing the two parts firmly together, then secure with two SD11 screws.

Fit the locating peg on the starter motor into the hole in the bell housing. The hole is D-shaped so the starter will only fit one way up. Ensure the starter motor is pressed firmly into place. You may wish to apply a spot of super glue to secure the starter motor but take care not to mark the surface of the parts.

Stage Complete.

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Levelord

#3 Posted : 03 August 2019 17:50:28

Rank: Pro

Issue 34 – Crankcase

The two halves of the crankcase both have cut-outs. The right half has two cut-outs and the left half has only one. These match up with the tabs on the gearbox and crankcase cover.

Fit the large tab on the gearbox assembly from stage 33, into the cut-out in the back of the right half of the crankcase, checking that the parts fit together flush. The tab on the crankcase end cover is shaped like a ‘T’ in the cross-section to lock it into place. Holding the parts the correct way up fit the tab on the crankcase end cover into the other cut-out in the right half of the crankcase, checking that the tab is fully seated. Now fit the left half of the crankcase over the assembly so that the cut-out slots onto the other side of the T-shaped tab. Check that the crankcase fits together flush. Note: There should be a small gap between the block and gearbox to allow for fitting it to the motor support in stage 36. Secure the crankcase together with two SD11 screws.

Stage Complete.

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Levelord

#4 Posted : 03 August 2019 17:51:24

Rank: Pro

Issue 35 – Cylinder Barrels and Heads

The cylinders are very similar in appearance but each of them only fits in one position. The mounting lugs are different shapes, matching a specific location on the crankcase. The cylinders also have a flat on one side which allows them to be pressed together.

Fit cylinder 1 into the hole shown in Step 35-B of the instructions, pressing the cylinder all the way home. Now fit cylinder 2 into the adjacent hole, noting the two flat sides go together. Fit cylinder 4 onto the other side of the engine followed by cylinder 3, again ensuring they are pressed all the way home and the two flat sides are together.

Take the engine mount and exhaust assembly from Stage 4. Take the left-hand cylinder head section and identify the hole that fits over the locating pin in the exhaust. Press the hole onto the pin to fit the cylinder head and secure together with an SP13 screw. Now fit the right-hand cylinder head so it mirrors the one on the left and secure with another SP13 screw

Stage Complete.

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Levelord

#5 Posted : 03 August 2019 17:52:35

Rank: Pro

Issue 36 – Cylinder heads and Pushrod tubes

Take the two sub-assemblies from stage 35 and fit the engine/gearbox to the motor support, tipping it so that the end of the crankcase fits into the support. Check that the end of the crankcase is fitted all the way onto the support and that the horse-shoe shaped cut-out in the support bracket fits over the slot between the engine and gearbox. Press the support bracket all the way into the slot. Check that the engine and transmission is properly aligned on its mountings and check that the ends of all four cylinders are properly lined up with the cylinder heads.

Fit the end of one of the pushrod tubes into the end hole of one outer section of the cylinder head, making sure it goes all the way in. Repeat the process to fit three more pushrod tubes to the first cylinder head section, then mirror the assembly with the second cylinder head section. Take one of the cylinder head sections and line up the other ends of the four tubes with the four ports in one side of the crankcase. You also need to fit the two pins into the recesses in the outer section of the cylinder head. Press the assembly firmly into place. Carry out the same process on the other side of the engine. Check that both sets of pushrod tubes and cylinder heads fit flush.

Stage Complete.

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Levelord

#6 Posted : 03 August 2019 17:53:53

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Issue 37 – Rocker covers & cylinder protection plate

Moulded letters inside the rocker covers indicate which side the fit. Take the left rocker cover and fit its projecting pins into the holes in the left cylinder head, pressing it all the way on and checking it fits flush. Now fit the right rocker cover in the same way.

Take the air pipe and fit the pin on one end into the hole in the motor support, align it as shown in step 37-E of the instructions. Turn the assembly over and press the retaining collar onto the end of the pin to fit it in position. Now take one of the rocker cover clips, (these are fragile so handle with care). Fit one end into the hole in the end of the cylinder head and lay the clip in the groove on top of the rocker cover. Carefully spring the other end of the clip into the hole in the other end of the cylinder head. Fit the second clip in the same way.

Take the under-cylinder protection plate and position it under the engine so that the transverse part of the plate fits into the slot between the engine and gearbox. Press the part into place so it fits flush. To retain the plate in position, press the small pins into the holes on the four corners of the crankcase.

Stage Complete.

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Levelord

#7 Posted : 03 August 2019 17:54:58

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Issue 38 – Rear drive shafts

The two CV joints fitted to the gearbox side of the drive shafts have moulded letters to indicate which side they go, be careful not to mix them up. Fit the left CV joint to the left side of the gearbox. It has two barbed tabs that lock into the hole in the gearbox, which is shaped like an upside-down T. The narrower tab goes at the top, the wider one at the bottom. Press the CV joint all the way in to lock it in position then fit the right CV joint to the opposite side of the gearbox in the same way.

You can now mount the engine and transmission on the rear of the chassis. The assembly is supported by the gearbox mounting at the front and the cross-member at the rear. Fit the groove under the bell housing between the engine and gearbox over the cross-member and fit the hole in the gearbox mounting over the hole in the chassis. Fix the gearbox mounting to the chassis with an SD04 screw.

The two drive shafts are different lengths and it is important not to mix them up. The left drive shaft is one millimetre longer than the right. Take the left drive shaft and fit the mushroom shaped end into one of the CV joint boots, then fit the CV joint boot into one of the CV joints. Repeat the process to fit the remaining CV joint and its boot onto the right drive shaft.

Stage Complete.

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Levelord

#8 Posted : 03 August 2019 17:56:11

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Issue 39 – Cooling fan and shroud.

Take the two drive shaft assemblies from stage 38. Remember that the left-hand shaft assembly is one millimetre longer than the right. Look at the drive shafts carefully, the tip of the free end has a square section that fits into the CV joint mounted on the gearbox. This is at a slight angle to the drive shat and must be fitting into the CV joint, as shown in step 39-B of the instructions. With the chassis upside-down, take the longer left-hand drive shaft assembly and match up the CV joint with the stub axle on the left rear wheel. Push the CV joint onto the stub axle, keeping the drive shaft out of the way. Turn the drive shaft so that the square end is angled as shown in 39-B. Then spring the wheel outwards slightly so you can fit the tip of the drive shaft into the gearbox CV joint. Now fit the right-hand drive shaft to the other side of the gearbox in the same way.

Now start to assemble the engine’s air-cooling system. The fan fitted to the shroud spins in the same way as on a real car. Fit the front panel of the shroud by matching up the locating pins and mounting posts. Press the parts firmly together and secure with two SP15 screws.

Stage Complete.

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Levelord

#9 Posted : 03 August 2019 17:57:17

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Issue 40 – Carburettor and induction System

Take the fan assembly from the previous stage and fit it into the rear housing, pressing the parts together firmly. Fix the fan assembly together with four SP07 screws.

Start assembling the inlet manifold. Fit the hole in the left inlet manifold onto the pin on the end of the centre section ensuring the parts are aligned as shown in step 40-D of the instructions. Now fit the right inlet manifold in a similar way.

Fit the carburettor into the central hole in the inlet manifold, ensuring it is aligned correctly. Align the assembly with the engine, matching up the ends of the inlet manifolds with the holes shown in step 40-G of the instructions, press the inlet manifold into the matching holes then do the same with the right inlet manifold.

Fit the fan assembly in front of the carburettor so that the air intake passes through the rectangular hole and the tabs on the bottom fit into the slots in the crankcase. Press down on the fan assembly to lock the tabs into the slots in the crankcase.

Stage Complete.

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