Episode 38 (Feb 16-28)
 
 

Spring is getting closer and so is the car. All the panels are on the car now and most of the original hardware has been cleaned up and installed. I've started to work on some of the electrical system and the car now has an ignition switch. I have placed a couple of big orders from a few suppliers which should be in soon. When they arrive, I will have everything needed to finish the mechanical / electrical systems.

Steering Wheel & Horn Button

The car gets pushed in and out of the garage about 5 times a week at this point. Right now I can steer the car by twisting the front tires as I push it. Once the front fenders go on, I'll have to use the steering wheel to navigate. The entire steering column comes apart fairly easily, so I can clean it up nicely before putting it in the car.
 

 

Signal Switch

Unlike modern vehicles, the signal switch on the beetle serves only to indicate which way you are turning. No high beam controls, cruise control or intermittant wiper settings. This simplicity results in a grand total of three wires coming from the unit, one bringing in the power, and two to take the signal either left or right. I used my meter to check continuity in the switch and it passed with flying colours.

In the Car

After a good cleaning and a fresh coat of paint the steering wheel went back into the car without much trouble. Installing the grommet that seals the wheel as it passes through the firewall was the hardest part of the process.
 

 

The Dash

I love the look of the painted dashes in these early cars. The way everything fits together and looks when completed reminds me of a Tonka toy. In fact, there are lots of comparisons that can be drawn between the bug and a Tonka toy.

Rough Alignment

Now that the steering wheel is in, I could give the front wheels a rough alignment. The tie rod ends were replaced a year ago, but couldn't be properly positioned until now. They will still need a bit of fine tuning that will most likely have to be done by a mechanic.
 

 

A Final Tightening

Before I start to bolt on body panels and doors, I snugged up all the bolts holding the body to the floor pans and chassis. My earlier efforts to align the mounts really paid off here. All the bolts and rubber cushions fit on perfectly.

Remember this?

In week 24, I pointed out the alignment problem in the rear body mount. It turns out that the piece I welded in was for the later model cars. The fit is close enough to be made up with this custom made body cushion. I bought a 12" hard rubber roller and cut it to the proper size with a chop saw. Try making parts like this for a Ford Focus!
 

 

Passenger's Side

The passenger's door and fenders fit on as expected. It took some patience to align the door properly especially with the new rubber seals. I cleaned all the latching hardware up and re-lubed all the pivots hinges and catches. These doors likely haven't worked this well since the early 70's!

From the Front

It's almost a car again. It takes a lot of time to put the fenders on properly. They have to be wet-sanded and buffed before being bolted on and you always have to be careful to not slip and scratch the fresh paint
 

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