Hi Jon,

Thanks very much! I've been messing with Aircooled VW's since I was 14 so I've learnt alot along the way. I work in a Mercedes dealership by day. I just read up as much as I can and get stuck in.

Cheers, Jim

On with the update:

Got down the unit this evening with the heat gun. Installed the crown wheel to the super diff housing. Also popped the bearings on.









Also I need a new syncro body looked up the prices last night wow. So I have a spare box, got that on the stand and stripped. The early signs are good took it all to work and gave it a good clean.





Shafts out tomorrow so I can get a closer look at 1st/2nd syncro. Fingers crossed its all good. I think I will probably use the later casing as well to take advantage of the clutch release guide and beefed up release arm.

Evening,

Had a good day at the unit today! The gearbox rebuild continues. Got the pinion shaft rebuilt, installed the shafts back in the shift housing and set the shift forks.







Blasted and primed the main case and nose cone.









Whilst I had the cabinet fired up blasted a few odds and ends ready for refinishing.

Evening guys,

Good start to the week, if a cold one!

Primer was dry so I got the trans case on the engine stand.



Warmed the case up and dropped the reverse idler shaft in and fitted the input needle roller.



Installed the gear housing.





Gonna be waiting for a pinion nut socket from CSP before I can drop the diff in and check the tooth contact and backlash.

Got the van loaded up with engine parts tonight as I'm passing the engine shop tomorrow so will drop off the bottom end for balancing.

Finally lacquerd the calipers on Saturday so they are now at home in the warm for the week so the paint can cure.



Shiny!

Probably won't fit anymore in this week but will see how it goes. Until next time!

Evening guys,

Had a good day at the unit today, got the box back together this morning. As my pinion socket arrived from CSP yesterday.







Also decided to make my own gearbox stabilizer, ordered the rubber mountings yesterday. Made a start on the bar today.



Template of the box first.













Also had a play with my new heads and throttle bodies



Dubfreeze tomorrow! Very excited!

Bus weekend started early tonight,

Good start the rubber bushes have arrived for my gearbox mount so I can finish that tomorrow.

M10 50x50mm should do the trick!



Also made a start on the caliper re-assembly got 3 finished tonight but it got pretty cold by 9pm, number 4 can wait till tomorrow morning!





Some touch ups required but looking good.

Evening guys the build continues, finished the calipers today. Then moved on to finishing the gearbox support.





Fabricated the brackets for the frame horns and welded them in.





As I had the welder out and the chassis needs notching for the steering arms so that was next on the agenda.













All cleaned up and looking awesome!

Some proper tidy work once again mate! Great update. When will you be there next??

Cheers bud, Hopefully get over there this evening for a little tinkering. Got plenty to be doing!

where did you get the caliber decals and the refurb parts from? all looks good work

Hi bud, thanks very much, decals were ebay, seal kits were from Bigg Red in Worcester.

Cheers, Jim

Morning guys, first of this weekends updates.

Had an odds and ends day yesterday as I only had the morning.

I had left the heater tube cut outs on the cargo floor till last as I was unsure weather or not to re fit them. The decision was made for me when bought the turbo kit as there are no heat exchangers. Time to blank them off then.







While the welder was out I had some more time so started one engine tin. Cut and weld the fan outlets on the shroud.





Also trimming the nose shroud to fit the case and the crank trigger ignition sensor bracket.









Off to the unit shortly for more tinkering!

Got a little more tinkering this afternoon, still on the little jobs.

I had some tidying up to do on the bulkheads front and rear filling screw holes also test fitted the upper bulkhead panel as the tracks and fixings needed sorting.







Very pleased with that, more to come this week hopefully.

Evening guys, gonna try an update a day through march so let's see how that goes!

Tonight's action was filling the redundant check strap mounting in and cleaning the tub edge up.











More tomorrow then!

Evening, as promised more done tonight after work, R/H a pillar this time.













More tomorrow hopefully!

Isn't it a nice feeling towards the end of the metalwork when you actually have to look carefully arou d the bus for bits that still need welding!

Almost at that stage on mine now!