The Cal-look Lounge

this week i started to dismantle my 67 bug to restore it into my dreamcar...
probably will take a few years but i want to do do it right and all the way this time
and for daily use i still have the notch
so this is what i am starting with, a swedish 67 with less then 100.000 km from the first owner
looks bad on the outside but the metal work looks to be good.

goal is to get a 67 ragtop ( i had a 67 standard with ragtop a few years ago and loved it) with
a 2276 cc engine and the cal-look spirit, witch i mainly want to use for the strip and little road use

i will take some picture's every now and then, and will ask fore some tips to get the right
parts fore strip use because this one is my first with a big engine..

Looks like an awsome car dude - Hope to see some more pic's soon dude  :)

cool you're finally starting your dream project.


michael

i have been doing some work yesterday, taking the car aprt, found a lot of good stuff and very little rust here are some pic's

and a few more

as you have shown me before, pretty good quality stuff hans!
and i see you're running BRMs these days?  8)

Looks like you have a nice base for a project there. Keep posting pics of your progress.

--louis

that's a sweet 67 Hanzel  ;)

how is your engine for the bug... are you start building or first the body?

"off topic" i drived my notch saterday  ;D 7000 rpm "off topic"

Seeya at DDD5
Mycha

Never seen White wall tires on a Cal Look ?

 It's a project... not the end result...

you are right shubee, it's even worse it used to be redline's but they are going off the rims in front i have the 135 firestone's and for
the back i want m&h dot aproved racingtire's and wider BRM's the 6,5 flat 4's instead of the 5's

Cool  I bought a Pair Of the 6 1/2 Flat 4 BRM's for my 8 inch M&H Slicks  the 5 inch are to narrow for the 8 inch slick plus the fit perfect with short axles  I will only be using the flat 4 's with slicks for the Track I will Run the Originals on the street

okay i will be using short axels to so nice to knowe, i want to buy the 6 inch cheater slicks so space enough then, or will i gain much by going to 7" or 8"
slicks otherwise i keep the 5 inches with street tire's to get there and the slicks for the strip, engine will be 2276 from around 200HP at the moment build at steve's vw shop in belgium

I think the 6inch are wide enough the wider you go the easier you break your gearbox and 6ses won't spin

michael

time to start this up again.....done a lot off work at the job...made a huge amount of extra hours so the parts did come in...so now it's time to do some things, started on the pan to do the little welding what was needed pic's follow soon...

the two little rustspots on the floor are repaired and the line lock is placed..
also a hole in the floor is been made for acess for the hydraulic clutch.

now find a way to get two fuell line's in the tunnel in a neat way

maybe i try it the way Louis is doing it...

i hope to get the pan blasted and painted somewhere in march...but first i need my gearbox to see where the supports must be welded...

it's on it's way....and i am really happy with it...i first had a type 1 berg build at Kevin shull racecars, but he took 2500 dollar from me and i have never got a trans...and it's impossible to get contact with him...this one is coming from Rancho

Really sorry to hear about that :( Wish there was something I could do to help.

But the Bus 5 speed looks bitching!!

yeah i am really happy with the bus box....hope to see it in real in jan..or feb  it's at my family's garage in texas now and they take care off shipping it over to the netherlands..

Hey Hanz,

Good to see you'r working on the bug again. Better hurry it's summer before you know it, or are you racing that hunch-back ;D

Paul.

hi Paul

the 2009 mseason will not be with this bug....at 2010 maybe... ::)
the notch will be fine for next season

Nice work! I especially like the access plate for changing the clutch cable. I did that to my '67 a few years ago and I love it.

Always nice to see a nice becoming '67 !!!

Cheers

wasn't happy with the welds on the narrowed cb beam so this is also completely welded now

what a nice unmessed car! those inner arches  :o 8)
whats happened to the albert mirrors?

yeah the car was a real survivor all original and i was really happy with it , it needed a lot of cleaning before all the black stuff was removed, just a few welding areas..
and the alberts where the first item's sold to some resto lover... he was happy and the first cash for parts was there  ;D
 

at this moment we are doing some welding on the body, the hole's from the eberspacher heater are closed and some rust is removed, so hopefully in a few weeks it can go to the mediablaster

and also we removed the rear valance and now i am fitting the new one , what will be removable for easy work on the engine..
the exhaust holes will be closed also because i will use a A1 sidewinder

and for a question... ???  should i make acces holes in the side for easy acces to the carb's and nitro system and does someone has some pic's from a nice solution

rear valance is finisched now and closed
almost al the welding is done heater channels are closed so there will be more space under the seat for battery and other electrical stuff, most of the grinding is done, now do some more cleaning and make my mind up about grafting a ragtop in...
also made some more room for the 091 gearbox

looking good, how come you didn't reuse the original 67 valence?

nos 67 valences are pretty common!  :D 8)

i had all the spotweld drilled out, so it's still a perfect one for replacemend , only for a removable you need to fill all the hole's again, and while i had a new one.... ;D  use it....

the ragtop is grafted in now, finished the box for the extra space for the gearbox, and did some more cleaning, this upcoming week the roof will be finished and all the welding so in the next few weeks it will go to the blaster...

Nice job Hans. :o

Cool Project !

body is completed yesterday, i took some hours off, the ragtop is totally welded now and everything is ready for the blaster, where it will go to next week, then i can go on with the pan again...

It looks like you are on a deadline ;)
Michael

Dig the clearancing for the gearbox. Looks almost factory :)

great work hans, keep it up ;)

thank you guy's for the kind word's aim is to have the car finished next year, so it will take a little time  ;D

today I have got the body back from blasting and primer,  ;D
one door to go and all the body doors and lid's are in primer so they can rest for a while , and i can get started with the chassis...hopefully next weeks i can weld the trans supports in and get the floor blasted and painted to...

great work ;D

As siad before that"s a really solid car.You won't need much bondo on that one. ;)

Do you allready have a coor in mind Hans?

Michael

Man that looks awesome.  Great job.

cant wait to see this one finished  8)

Hey Hans,

Looking good.

Is the gearbox in yet?

Paul.

hey michael

color is not known yet....thoughts are  fontana grey (original color)  yukon Yellow  or a light blue, it will be a last minute decision...one off the things i can't decide..

and hello Paul

the gearbox has been at home at the momnet it is at Steve's vw shop to make the support's he is making a beautifull alu support, what will be done in a few weeks...and pic's will follow when it is on the chassis , yours will be in sooner i think

and for the rocket man....can't waith also at the moment the finish date is set at the end of next year  :(  it's a balance between time money and work , i want to do it all the way....

Nice Hans. The car looks very straight.

Fontana Grey is a nice color btw  ;)

Especially time and money are the key elements when you want to go all the way. ;)( how do I know :-\)

You'll get there.....

Michael

You'll get there.....

Michael
[/quote]

and hopefully very fast.... ;D   aiming at over 200 horses and that without that blue bottle that's also in at the moment

time for a little update...this weekend i got my gearbox back from Steve's VW shop
he made me a beautiful alu bracket for getting the 091 in the bug and on the other site a berg support will be used, so now i can start on the floor again finisch the fitting and welding and start painting and building...

The picture of that bracket is on my cool board now, sub zero. 8)

Paul.

http://www.hookyspanelshop.com/


try these carb windows, I'm putting some in over the winter.

You will need them, unless you've got the hands of a 10 year old boy you wont be able to get number 3 plug in and out without taking off the carbs

Regards Ron   

i think i will take that advise from you ron...i have big hands  ;D
when the gearbox is on the floor i will lift the body over it to correct the panels in the engine room, the engine will be 1 cm out off the middle due to the 091 gearbox, so i have to do some more work...
and this would also be a plus...

gearbox and CSP brace are getting in place...

some more..

oil cooler in place

and some questions for the jaycee retainers....do they need spacers between the plate's and the chassis ??
i can't bolt them together without blocking every thing ???

they are the retainers wich fit the sway way plate's ..any idea's or pic's ??
 
one off the pic's show there is about 5mm between the plate and the chasis

That tranny is a slick setup. Really looking nice.

--louis

thanks louis i hope it works the way it looks... ;)

how bizarre! say hello to one of europe's fastest 67s  ;D
nice craftsmanship!

so time for some small update's...

closed the torsion tube up (made a big hole to get the gearbox closer to the chasis )
made the shiftertube and tested the shifter....and they wher there all five of the gears  ;D ;D

in the fuell department , i made some brackets for the fuelpoms and the fuel filter, wich can be cleaned from the underside..
and routed the fuelline's thru the tunnel...

now only some small stuff and the chasis can go to the blaster wher it can be treated on some new paint....hopefully this year

and in about three weeks time the engine should be ready also.....for a christmas present

Thank god, he is still alive :D

There are not much updates, but when they come 8)

Adjustable shiftrod length, fuel filter through the sheet metal, fuel line through the tunnel, working 5-speed :o :o :o

I am loving it 8) (why does that sentence make me hungry ???)

Paul.

So it's coming together very nice Hans :)

Are you using 2 fuelpumps?

Michael

hi michael

one for the ida's  and one for the nitro system  ;)

Aaah power in da bottle ;D ;D
How is the body coming together.Is it getting painted before the end of the year?

Michael

hopefully the floor will be painted this year and the body in the first half off next year...

Some nice ideas!

any updates ??

only a lot off small stuff....all the alu is going to get black anodising and a lot off small things are getting their galvanising done..
i got carried away on the summit site.....thats on it's way...including the painless wiring fuse box (thanks to zach's info)
body parts are in the paintshop...
chassis will leave next friday...and will be returned at the end of februari...
Qaiffe dif is ordered


lots of things going on but not picture worthy...this will really start when the engine is there and the chassis....and then i will show off  ;D

also started another job in the company and that's also taking a lot of time and energie...but i will go on.... ;)


 

cant wait to see the up dates, sounds great, one of my favorite threads

this weekend was a good one...the last off the old paint is gone now...the chassis is blasted galvanised and primed...so now do the last corrections and get some nice shiny black paint on it....

and next week there will be a movie ...my engine on the bench at Steve's.... ;D i am looking forward to that

Looking good Hans, always love the looks of a fresh painted chassis 8)

Can't wait to see the movie.

Paul.

yesterday i picked up the engine at steve's vw shop....over 200hp with fanbelt en around 220 without with a compression 10.5 :1 so these are good figure's, what will happen with the nitrous installed  ;D

foto's will follow and hopefully a movie

in the back off fast scrap for the testrun's...
and again steve thanks for the work on the engine

al my tinwork is coated black and it will have a sidewinder exhaust so it will look different but it's the same underneat  ;D ;D

the testrun on the tube....

http://www.youtube.com/watch?v=EPG0H2MpnaA

Hey Hans with those numbers "wannabe"doesn't apply anymore ;)

Good to see the motor is ready and running very nice.

Michael

Sounds GOOOOD!  8)

Looks like Steve is synching the carbs by ear!  8)

i wasn't there when he syncronished but the sound good part is agreed , and that's an understatement, i still have the happy face...one off the major and most important parts of the build.

now lets get that chassis painted black and put some parts together

two fenders and a door came in today with a fresh coat of Fontana grey paint ( original to the car )
and i cleand some of the black parts and made them ready for fitment on the car

had a good day today, the chassis is shiny black now  8)

Looking good Hans. :o

thnx JP

Nice work dude  :)

Wow, very nice work ! Hope to see it soon side by side with mine...

I hope to have it ready for EBI-4,so mine will take at least another year then we can let them meet  ;D

finally did some assembly and parts are coming together now.
i have put the hydraulic clutch in place, after replacing the clutch lever for a longer one from another year, this because the original don't seem to work as well as the longer one, this i have been reading on a samba forum.

also put the pedals in, i had them chroomed because I like shiny stuff, and also changed over to a cruiser pedal, for that i changed a roller pedal to a smaler size

put the 2" narrowed cb beam in with lowered spindles, had the caster shim black anodized, and got those mounted, and put the CSP disks in place and also the 10/90 QA! shocks.

line lock installed with CSP bracke cilinder for front and rear disks, spacer and so on, still waiting for the reservoir (this is on it's way with other parts from the US)[attachment=1]

and this was followed by a koni steering damper one of the fuel pumps and the fuel filter, the other pump is waiting for a tune up kit, and also started on the aeroquip hose stuff, now thats a bit hard, is a difficult procedure, i have to look around what i am doing wrong, or get some more excersize  :-[

DFL cruise would have been nice but i really wanted to do some work on the bug now, all in all a nice day and go on tomorrow, hopefully next year i will be in Hanover only this time with this car..[attachment=1]

 :o :o drool....

put some paint on yours then we double drool  ;)

awesome work as usual

cant wait to see what's next.

Will the car be out this year, DDD later this year or next year 

Hi Ron

i don't think it will be this year, but i am aiming at next year, hopefully EBI.
i want to do this one right so when there is no time or money to finish it the way i want it will take longer.
today i have put in the 30mm torsion bars

 

i also made new bushings for the crappy one's i got with the retainer plate's, on the pic they are on the left and i made the new one's on the right
fitted the bus rubbers and the adjustable springplate's.

i alsoo test fitted the wheels the BRM's fit without any problems, and the centerline's just fitted, but just is enough  ;)
and now wait for the Qaiffe dif what will go in first before the gearbox goes in...as far as i know now the boat will be there in two weeks...then the axles and it will be put on the earth again :D

today the other door came from the painter's and also the conv decklid....
the doors are even straight at the inside..... ;D

and at the moment doing the small invisible things and waiting on the mailman from the US

awesome work, keep it up ;)

it took a while but the qaiffe dif is in the gearbox and the axles are there ....steve's vw shop did exelent work

today i put the box in it's place and hydraulic's
put the axle's on also
now get the axletube's painted and get the rear end ready

I was just thinking; what happend to Hans. ;D

good update Hans, this car Will ask a lot of cleaning after driving it 8)

Paul.

i am still there paul  ;D....

i also saw a rancho add....i think i know that gearbox..

Tissue please ;D ;D ;D ;D

Michael

I hear you, I know the guy how paid it (it never arrived)

Paul.

Rancho delivered.....you have the evidence above...and needles to say i am very happy

and the other company paid back...after 1.5 year, because the didn't deliverd, in the end i am happy, now i have a 091 berg 5 instead off a typ 1 berg 5

OK, sorry. good to hear they set thing wright.

this morning i had some time to put on, one axletube and the CSP diskbrake kit, somewhere this week hopefully the other side...

today i wanted to be at DDD8 but the notch decided differently... :-\ yesterday i changed the gearbox from the notch and did a tune up but when i went home it started ticking, so i have to pull the engine again  >:( 

the body is back on the 67 again to see what fit's and what not

to start with the not
the A1 sidewinder due to the engine hanging to the right by 1 / 1,5 cm due to the 091 gearbox...so a merged header and A1 muffler needs to be found (someone up for a change?)
the stacks are to long to close the lid , so these need to be replaced by Berg or CSP stacks.
the fan on the oilcooler needs to drop 1,5 cm
the engine plate on the right needs to loose some metal

The body fits nicely over the box the engine is in far enough so this is also okay, some small issues but they will be fixed..
some pic's...

This car is hot !

thnx  ;D

Hi Hans,

Sorry you didn't make it to DDD8,you missed some action ;);)

Give me a call regarding the velocity stacks,we can make that work with the decklid.
BTW you are doing a very nice job there! Glad the axles worked out great!

Best regards Steve

WWHHEEEEE HHHAAAA....the paint is on... ;D

 :P :P :P :P
What a f..k..g car !
I can't wait to see it at the next EBI.
Well done, Hans !

+1

+2, p.s. great colour ;)

Beautiful !

Looking good Hans, new paint is always a good moment.

This is indeed a nice car in the making.  Hope to see it here at EBI4 in real, with all its nice aftermarket bits, the best that money can buy.

Good luck with the startup.

Philip
Flatline-Lowriders
Belgium

looks great Hans can't wait to this this car finished!  8)

thanks for the compliments guy's  i hope to have it finished before the next EBI,  but the project took already 4 years so it will take some time....EBI 5 it surely will be ready.. ;)

That's a F.cking cool ride Hans, thanks for all those horny piqa's  ;D

Greetings mycha

the body is back on the floor....

few more

 :o 8) 8)

very nice, great project! and happy newyear also!

Very nice 67. I really love it.
I wish mine was as good... (guess it's the same color)
Greetz
Wim

STUNNING CAR!

 :o

today i got the dust off the car , so next weeks i am gonna do some work again , so next week new pic's...... ;)

Wow! Very impressive job so far!

Rick Mortensen

keep them coming  ;D

i have been putting on some stuff...looks like a car , and the fun is back again... ;D

and also been busy with the fuel line's ...time consuming stuff , and put a nice badge on the deklid

Great looking car so far,really like to see it for real when it is finished.(awesome look with those centerlines).
(BTW,nice garage)  ;)

Beautiful bug!

why a blue fire exthinghuisher ;D ;D ;D ;D?

Michael

so it will mach the interior color.... ;D  the coice was red (safety)  or blue (speed)   what wouild you do.... ???  choice's

Amazing work and great detail. That's going to be one pissed off street car. :o Can't wait to see the rest of the build. 

Blue!!

I was hoping this car would look good when it's finished, but....... ;D

Nice job Hans, keep going.

Paul.

some off the shiney stuff is done to the dash, put the steering wheel in and the front window, was inspiring... ;D

Vey nice 67 Hans.
Mine looks shit compared to yours...

it seems that a few belgian cars have empi dasboard  ::) ::) ...................... ;D ;D

nice work , i would like to found one of those speedo 

well...its been awhile...we need some pics of this awesome project

 ;D i know ...

after a long search i finally found the correct NOS grey runningboard covers i had to put them on today....and made a start with the engine tin

Stunning car allready!!!

gr
Wout

This is gonna be a head turner. love the runningboard Hans.

to cold to work on the car so went searching for the fabrics for the roof cloth for the seat's and so came up with this....

roof color is the same as runningboards
carpet is choosen
cloth for the seat inserts
leather is also found...now

found a shop in germany so will take the stuff when i go boarding in austria

this weekend i left the interior at the upholstery shop....will be better then i left it  ;D
in the right corner is a black mercedes seat with the same pattern of fabrique, this will be used on my seats in the grey color (as in the picture above)

and in august the car will be in for the carpet, headliner and ragtop, untill that time lots off small stuff what takes a lot off time

Very nice choice for the upholstery, can't wait to see it finished.
Keep us updated Hans.

Very Sweet, You do good work..... ;)

some progress...a lot of little stuff
fuelline's are ready
oillines are ready
brakelines are ready
only the clutchline's must be finisched and the put some fluids in and hopefully they stay in  ;)
made a board to put all MSD and NOS on....
started some final assembly on the engine
interior can be picked up next week
car must be ready and fully tested for next season don't wanna mis EBI 

and some pic's

Hurry up!!  ;D

Nice work Hans!

It's amazing that you can still get wise out of all these things ;D ;D ;D ;D

Top work Hans

Very nice indeed Hans

Hanz
the car build is really good,lots of nice detail,well done :)

2 things I noticed,the blue vent tube for the nitrous bottle needs to vent outside the car,do you have a hole for it to go out of? and with big torsion bars[not sure what size you have?] you dont really want to use the bus bump stop/snubbers,they are ok for on the street but can cause problems on the track,and when the car is together you may need to shorten them,you need about 25mm clearance from the top of the rubber to the bump reciever on the body

Keep up the good work :)

cheers Richie

hello richie

the hole for the blow off tube is not drilled yet, that's on the to do list   and the bus snubbers are not needed then for me i have the 30mm torsionbars so the i put the original rubber in ??  thanks for the advice...
i also heard (from tiki michael) you had NOS a few years ago so maybe i will send you a pm with some questions about it, when i do progress a little with it.

thnx hanz

The original rubber is even harder,you can get thin bump rubbers or shims that fit around the shock absorber shaft,thats all I would use,I dont run any bump stops on the old cabrio with 30mm bars and QA1 shocks,if you drive on really bumpy roads then you can use the bus bump stop cut down shorter to act as limiting device,nothing more.
When you are ready ask away on the nitrous stuff,still got some good info stored in my brain ;)

cheers richie

thanks richie it''s apriciated

today i picked up the two seats and half of the backseat....next week the rest off the parts...

and i am very  ;D  it even smells as good as it looks

doorpanels are also in....i am happy...again  :D

Whooo, very cool color. looks really nice

Regards Edgar

It's really AWESOME !!!

We want to se more!  ;)

 :) this weekend i Will take Some pictures all the little stuff  taking ages   :P :P

 ;D ;D ;D

Looking good!

I noticed that you`re using the CSP tower style breather box and inlets are:

1) The alternator tower, approx 19mm
2) The fuel pump block off, AN 10

Not sure if the AN10 fitting in the 3/8" on the right hand side of the box is there to let breath out? If not out your current outlet is a fitting in the 1/2" NPT. You should reconsider this or at least make it as big as absolutely possible. I have the same box and modified my outlet to 34mm. I have more volume out than in.

[attachment=1]

-BB-

Nice work cant wait to ebi ;D

Mhhhh thinking you are right .....   Will keep it in mind

and some picture's, the front off the car is getting there, at the moment the BRM's are on and the bumpers, for the normal cruize mode, and for the DDD weekend and so one i have centerline's and Tbars so every now and then i will change over

picture off the front and from under the hood..

Also got my manifolds shortend by Steve from Steve's vw shop so hoppefully the lid closes now, it got shorter and it also flows more air also as a bonus, so i can get on with the NOS instal on the engine, some pic's from the carb's and manifolds.

and said before, i probably gonna make a bigger breatherfilter and i also have to modify one off the airoquip fittings because as is now it doesn't clear the fuellhose and carb, so a little bid of welding drilling and new coat and it will also fit..

and a shot off the berg shifter and the instruments...

still waiting on the upholstry shop, hopefully in two weeks it will go there and a month later it will be back, can waith to see the result, it will finish the car a lot futher for sight.. ;D

very nice  ;D

thank you all for the friendly word's  ;D

today at the upholstery shop 2 67 ragtop's  thei beige one is a original 67 standard and mine and the daily , three 67's in a picture 67 heaven  ::)

Nearly there, almost time to drive the MF. Looking good.

Hey that's rene from kevermagazijn he is the best...

Your right Cédric thats why the car is there hè is the master with à ragtop  ;)

so sweeeeeeeeeeeet  8)

with Rene his in good hands to make it perfect  ;)

in the previous picture's there was a wooden empi steering wheel, that's in the daily now...

last week the other wheel was ready newly rapt in black leather and new repop hornbutton, i am happy with it will look good with the black dash

Nice 1 its original .... ::)

slowly.... 8)

 ;)

You got a 5 berg in it!

very nice and clean work! i know how hard it is to get the headliner looking that good.

Yes à busbox with berg 5 so i really want to drive and experiance it next season  ;)

Great work Hans as usuall!

ragtop is in..... 8)

pick up this saturday and take him home again for the next step..

i think i have the same colour ragtop. is yours from TMI?

mine is from a german company www.cabrio.de  and not tmi, but i think the color is not far off, this ragtop is the same color as the runningboards...

this car will be way better as it ever was. :o love it.

test fitted the rearseat....and it's gonna look like a car again...
and also the newly rapped steering wheel is in now

Great job...

so...brakes and clutch have oil now original wiring is in and a lot off small jobs are been done now....it;s good to have a few day's off

front off the car is the way it should be now
and couldn't resist this license plate frame....

Looking so goooooooood,love this car already,even it isn't finished.Great job Hanz   ;)
Maybe a stupid question,(never saw this before) but I see there is a clock in the speakergrille instead of a fuelgauge.Was this an option or what?

the clock is an old option, you don't see them often but mostly there is one for sale on the samba, it's 6v but also working on 12v  (so far  ;D)

Zo,weeral iets bijgeleerd.   :D
Thx for the info.

Looks like you are almost done and ready for a little test drive ;)

Michael

getting closer.... ;D i think i'll take another week off

Such a nice car. Love the interior!

Very nice there hanz !!

Hans, you know I really love this car and what your doing to it. But I do not like the thing in the dash, it does not fit nicely in the corners. als een echte muggesifter moest ik dit ff kwijt ;)

really cant wait to see it running!  :)

Thank you guys for the kind words  ;D. Keeps me going.

And Paul...the dash was not mounted in the right way yet, but when it is, its still a little rough in the edge  :-\

Al the thing you do to this car are perfect, this clovebox just isn't perfect. I am sure you will solve it ;)

got some off the line's done, just waiting on one connector to close the system...

then test it , is it leak free or not  ??? ::)

and a lot off wiring to do, in 5 weeks the car goes to steve do bring it alive again...

i also have a problem with the hydraulick clutch, it doesn't work, so it's probably me...
i made a picture in what order i think it should be in...please advice

and also the pressure and filling line should be the other way around i think.

I experienced the same with my clutch (same Saco kit as you) Let me guess; take a good look at the front seal and take especially note of the surface rubbing against the wall in the master cylinder. Is there a small bite missing? If so you have to change seals. Then take a good look inside your master cylinder and note how sharp the small holes for the in/outlets are. If they have sharp edges you have to polish the inside of the master carefully. It is also very important that you use the correct hydraulic fluid and nothing is mentioned about this in the manual. I made 4 test cups and filled them with DOT3, DOT4, DOT5 and a special hydraulic fluid that was supposed to be very gentle toward any rubber compund and you would not believe how quickly the rubber seals swelled with DOT3, DOT5 and the hydraulic fluid. DOT4 seems OK. Also, when changing rubber seals make sure you lube them and the cylinder with a well suited grease that will not clog the system. The rubber seals will be destroyed immediately (on the first pump) if not.

I got master cylinder replaced by Saco and they also sent me 2 rebuild kits. After 1 season I have replaced rubber seals 5 times.  Enclosed are some pictures and note, all the seals in the pictures are exactly the same! I have cut 1 into 2 pieces:

(http://www.raceinfo.no/temp/clutch_3.JPG)

(http://www.raceinfo.no/temp/seals_1.JPG)

There is also a problem with getting enough travel on the clutch arm to release and of course nothing is mentioned in the manual about this.

Mmmhhhh. So for a street car... ???  Sounds like it sucks ...don't want to change those every few months.
When it works , how does  it feel then ? 

When it works it is smooth and nice. Mind you I`m using a Stage 4 now (and clutch management) The seals are a pain to change... and messy. Also note that after I polished the master and lubed the seals I have not had 1 gone wrong.

Best rgs
BB

Okay thanks i am gonna gave it another try. And use dot 4. And do the polisch and deburring..

Let you know later, thanks for the info

Hi,

I also have the Saco clutch kit, I've not installed it yet.

I'm going to modify it to fit my 67 1200 RHD, has anybody used it on a RHD car?

Have you tried Automec silicone brake fluid?

Cheers, Nick

Hi nick mine is lhd can't help you on that sorry...

I've just started fitting my saco clutch today.
Stripped down the master cylinder to check it over, all looks OK.
Its the billet ali one.
Cheers, Nick

Wednesday i am gonna try again  ;), let you know what happend..
Yours is working ?

Did you finger it really well  ;) and noticed the sharp edges around the inlet and outlet holes?

Sorry for hijacking the thread here, but just wanted to thank BB for some great information here.

I've also just fitted one of these kits but needless to say I shall now be taking it out and checking that the seal is not damaged and that the bore is clean and smooth.

I have a few other more urgent jobs to do, but once I get it out of the car and apart I'll report back.

Thanks again BB, I'll buy you a beer if I ever manage to get my act together and get the car to SCC!

Peter

Thanks man!

What would this hobby be if we didnt share our knowlegde?.... I know, just like the Porsche forums  :D

Now get your act together and book that ferry ticket!  ;)

Best rgs
-BB-

In mine there where no sharp edges...so let's see what happens wednesday

I sure did  :P the holes are very small but I found no rough edges.
Should I lube the seals with brake fluid?
Cheers, Nick.

yes, brake fluid or brake assembly 'grease'

oops double post

Very nice build Hanz!

 :). Thanks

Fingerd the mastercylinder put dot 4 in it , and put everything in again.....and... ;D ;D
It seem to work fine now so another thing out of the way. 

Thanks BB

Nice to hear the clutch is working Hans, good luck with the rest!

I checked mine last week too, its not all up and running yet, but the bore has been checked and its all back in the car now.

The holes in the bore did have sharp edges but no damage to the seals fortunately. Polished the bore as suggested so fingers crossed it will all be OK in a couple of weeks when the gearbox is back in and I bleed it.

DOT 4 is on the shelf ready to go!

Thanks again BB!

Peter

The car is at Steve's vw shop where hè is doing his magic
Car is running , modified the carb's , manifolds and Valvecovers, still Some small things to solve but it's getting there

Love this car  :)

Thanks... ;D. Hopefully on the road in a few months now

Any update?

 ;D ;D

Is that enough ?  Last week i picked up the car at steve's vw shop , it was driving it feels strong, and next week a few day's off
So next week new picture's and hopefully new APK. ( dutch mot ) so next spring , it Will be there after 6 years...

rear is almost complete...lost one rearlight somewhere , so have to search the garage....

more next week

That looks great Hanz,  :)

the outside is done now, i have the roadlook with BRM and Bumper  , and the dragweekend look with the Centerline's
some small issues to make it roadlegal and some electrik stuff to solve and then ready for next year...

[attachment=1][attachment=2]

centerlines + Tbars!  ;)

That's what I prefer also....but for the sleeper look the BRM bumper look Will be used also .... ;D

i like it!

Looks great, in both guises.  :)

x2   ;)

Thanks ...
As soon as the interior is back in , there Will be picture's again, now go on with a lot off small detail work....

today i put the interior in and enjoyed the weather, been playing al little , still some things to do but the car is road legal

Looking good Hanz, liking the interior

Also this Will be updated with last year adventure's and the next year's update....

lookonig forward to!

last year was a year of up's and downs drove 7000 km to different meetings
first one was DFL cruise in hanover together with JP, but before that, my fan blew up at 8000rpm, so first repair....

after the repair all went well and had a good time car was driving great

then there was the Hangarz callook edition in belgium, i went there with some friends , an took a very nice half 48 IDA trophy home (best of show callook) , good meeting nice atmosfere

the on to wanroij at he Netherlands, first show with al little sprinttrack so my first little practice, al went well and took second place at the sprint and a top 20 award in the show, so another weekend off good fun with friends and good weather

then on to the bugshow at Spa Belgium, with the honour to display the car at the coolflo box, al went well, bit playing around with the other cars on the way up there had good fun, put up my tent and then shit hapend...some noise in the engine, could make it to the coolflow box , had a look underneat the valve cover , and it showed a dropped valve seat.....

still can't thank marco enough that i could borrow his van and trailer, so i could bring the car home overnight and still have some fun at the bugshow...

after the bugshow, next on the list VW action at Santa pod, this should be the first real 1/4 mile experience.....at it was  :)
but first i had to arrive at Santa pod on the way thre my clutch pedal broke...lots off waiting on the AA but in the end they brought me from somewhere Londen to the Pod, and there the search was on for a funtional clutch pedal witch was found on the swapmeet...

so the race was on then.....first gear fun, second gear fun, and then.....no fuel enough so as a result 14.1 second run, but much more in it, so have to find the problem...

and again a top 20 show award, very fun trip, will be there again, want at least a 12 second run on the Pod

Home trip went well

and at home it went wrong again.... >:(  again a valve seat dropped the seond inlet valve seat on the same head, the first one got repaired by steve's vw shop under garantuee , but this couldn't be bad luck again, so steve contacted CB and they admitted that there is a bad serie CB wegdeports...

so what to do next, had a good talk with Steve and now working on some modifications for next year, i now put my thrust in new JPM heads..combined with a new wasp header and muffler
also the clutch leaver is replaced with a longer one so this is more friendly for the clutch pedal and my leg

so for next year get it ready for EBI and hopefully a year without engine problems, after that i want my NOS system functional , but first a trouble free year with all little issues resolved

and at the end off the year my car is in two magazine's a beautifull artikel in the Ultra VW magazine , and even on the cover off the indonesian magazine Aircooled Way, but for now lots off this to do in the winter to get the car in good condition for next year, get the engine updated , get the fuel issues resolved and have fun.

(and get my daily done from my other thread on here, because i both want them at EBI this year)

Very nice indeed!   Love the interior particularly..,

very very VERY nice car!!! every time  see it i fall in love again with fontana grey...

Thank you for your update. Very nice car indeed!

When did you buy your heads from CB? Or do you have any more info related to the bad batch of CB heads?

Best rgs
BB

Engine was build at Steve's vw shop with cb wedgeport heads heads from a badge produced about 4 years ago.
if you want any specific info please ask and i will ask Steve

Looking great Hanz, very jealous of all the shows you managed to get to.

I think you upgrade the car with JPM heads....good luck..next year..hope to meet you then!
Fontana gray is the way to go!
Greets cedric

Wow loving the car! Work looks really high quality and is a credit to you😊
Actually have a few pics of this saved on my phone from when I was searching Fontana grey!

I spent a lot of time looking at this car this weekend. Lovely parts, very well put together, and the end result is a car that just gets better the more you look. Beautiful, and deserved trophy winner.

Had Great fun this weekend , the trophy wil be a good memory keeper

Right year right time.  I have been following and have to ask.  Where did the seat insert material originate?  Is it Volkswagen material or could you indulge me with details.
Regards,
Art

The carpet and inserts are from the Mercedes rage the cloth is from the karo serie , more Nice colors available  ;)
The leather came out off Some samples and almost match the original blue doorpanel color