Episode 40 (April 1 - 15)
 
 

Spring has arrived and the car is getting closer. Each of the systems in the car is starting to come to life. The engine is now in and starting with the ignition key, the clutch is working, the wiring is all hooked up and the car will actually move under it's own power now. This is actually kind of scary since the brakes haven't been bled yet, so stopping is a bit of a problem. Details, details.....

Tail Light Housings

These are the original tail light housings with a new rubber seal to keep the water out. Originally the light would have grounded to the housing, but I decided to run a separate wire through to the main body for a more secure ground connection.
 

 

Making it look Nice.

This is where the tail light wires come into the engine compartment. I have them strapped down nice and tight so they won't find their way into the engine works and cause trouble. The aluminum insulation was put into the engine compartment mostly for sound deadening.

Under the Bonnet

All the under-bonnet wiring is complete with the exception of a few relays that I have to order soon. Also, the brake fluid reservoir and wiper fluid bottle have been installed at the very front of the car. Both were re-used and seem to be in great shape.
 

 

Test Fitting the Bumper

The next step in the operation is to install the engine. Before doing this, I test fitted the bumper brackets and bumper to make sure they would fit later. It would be very difficult to re-align the bumper brackets once the engine was installed.

Getting Ready

I had to prepare the transmission before the engine could go on. I installed a new seal, new throw bearing and fresh gear oil.
 

 

Up in the air.

The engine is sitting on a rolling cart at the moment. I had to jack the rear end of the car up 30 inches to allow the engine to roll underneath it. Notice I have both concrete blocks and the jack stands in place for added safety.

Rolled into Place

The engine rolled under easily and the car was then lowered down over it. I then put the jack under the engine and raised it up into place and pushed it onto the transmission. I should say that the whole process took about three hours, which I thought was pretty reasonable.
 

 

All Hooked Up

There are only two wires to connect to the generator and one to the starter that needed to be connected. The gas line, accelerator cable and clutch cable hooked up easily and the car started with the ignition key almost immediately.

For Comfort

With the clutch and gas pedals in place I can now drive the car in and out out of the garage. I have a few concrete blocks strategically located to stop the car since the brakes haven't been hooked up. I also put the drivers seat in place to make moving it a bit easier.
 

Click Here To Go Ahead an Episode

Click Here To Go Back an Episode

Click Here To Go Back to Main Beetle Page