Episode 41 (April 16- 30)
 
 

It's all coming together. I like to work on one system at a time, but the point when all the systems meet has arrived. I had to bleed the brakes to test the lights and then install the windshield so I could test the wiper switch. Of course the weather is getting nicer, so it's nice to work on the car outside, so I had to install the gas tank to drive the car in and out of the garage. In the end, I'm that much closer to the road!

Brake Fluid

The smaller container is the brake fluid reservoir which connects to the master cylinder. Dave and I spend a couple of hours bleeding all the air out of the lines and the car now stops properly. At the same time we adjusted the emergency brake cables so that the car won't roll around when I'm working on it.
 

 

Gas Tank

My old gas tank was pretty rusty so I decided to put in a new one. This was one of those parts that would be a real pain to replace later, so it only made sense to just start fresh. The complete tank is under the front bonnet and you have to actually open the bonnet to fill it up at the gas station.

9 Prong Flasher

This is one of those weird parts that VW only used for two years and my car was one of them. I got lucky at a swap meet and found a guy that had a bunch of them. I bought two for 5 bucks AS IS and was relieved to find that both still worked. It's nice to have a spare.
 

 

Front Signals

I also found some needed parts to complete all the lighting circuits. The one thing I didn't find was a decent chrome housing for the front signals. I wire brushed all the rust off of this one and painted it with aluminum rust paint. I'll either rechrome it or find a better one a future swap meets.

Headlights

I cleaned and repainted the headlight buckets before putting them on the fenders. Another oddball feature of my car is use of older style glass-covered headlights. I had to modify the wiring harness to accomodate the European parking light which is located inside headlight bucket.
 

 

Switches and Knobs

The holes in the dash are slowly starting to fill up as the electric work needs completion. I picked up a used switch at the same swap meet which works better than the one I had. Swap meets are wonderful things, I also picked up an original '67 style rim which will eventually be used for my spare.

Windshield

Installing windshields in VW's is a surprisingly easy task. It takes two people, some dish soap and a wire to complete the task. Once again Dave came my rescue one evening to put mine in.
 

 

Wiper Fluid

The squirter mechanism works off pressure that you put into the reservoir. You use a bicycle pump to fill it up and then the pressure blows the fluid onto your window. The fluid actually runs through the switch on the dashboad before making it to the window.

Electrical System

With the exception of the dome light and the high beam headlights, the entire electrical system is working perfectly. Both items will be taken care of when the next (final?) parts order comes in next week.
 

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