Amongst all the little improvements that I wanted to make on Kitty, was the replacement of my clutch cable, which used to make a squeaky noise for a while now.
In order to replace that cable, one need to take the pedal assembly out of the car ; but when I saw how ugly it looked, I decided it definitely needed a bit of TLC before I could put it back in (and no, that's not what she said).
So here I go again, disassembling / cleaning / sandblasting / painting, beadblasting of the hardware, and reassembling with new parts...
That's the kind of setback that screws up my planning... Well, that and the delevry time of VW Classic.
The pedals feels much smoother now, I can't wait to actually try it on the road!
However, I uncovered a tiny crack at the base of the clutch pedal, so I may have to take it apart again in order to weld it... Well, I guess we'll see if it holds like that once the gearbox and engine are back in.
In order to install the Fuchs, I need to switch from the original 4x100 wheels bolt pattern to the Porsche 5x130 ; which means, at least, replacing brake discs and drums.
So, here I to again, renovating the whole thing!
Front end :
I replace brake discs and bearing with new ones (thanks Laurent!), and I fully rebuild the brake calipers : renovation kit from VW Classic, new brake pads and flew lines, beadblasted nuts and bolts, and Foliatec-painted calipers. I wanted to paint them red at first, but then I thought that would look a bit to "bling", so I went for a more classy lossy black finish.
Why paint them, one may ask? Well, just for the sake of avoinding to see an ugly rusted bit of metal behind my shiny polished Fuchs' spokes!
Rear end :
Complete renovation here too : degreasing/sandblasting/painting of the brake plates, beadblasting of misc hardware, and reassembling with new brake cylinder/pads/springs!
Yet another thing done... To be continued tomorrow!
I'm sorry, ShamWerks may have looked like on hold for quite a while now...
Actually, I'm currently in the process of making many improvements on Kitty (that's my Ghia's nickname - don't ask), and it's taking me more time than I had planned for... And I was waiting till I had reached some major steps before posting anything about it here!
So brace yourselves for quite a series of "Kitty Upgrade" posts ; speaking of which, I'd like to thank Bazoom who made the drawing I use in this post's title ; this is kind of a preview of what my Ghia should look like when I finish it. I know, I know, I got quite a lot of work to do before I get there!
One of the long awaited modifications was installing the Fuchs wheels presented here almost... Phew, 6 years ago!
These are genuine, original, pre-Feb '71 Porsche Deep Fuchs, not repops, 5.5" in the front, 6" in the rear... Überlike! :
It took me a while, I finally got them polished. Yup, I went the easy way, bringing them to a professional to do it, I didn't have the courage/patience to spend 15 hours per wheel sanding! (Olive-from-the-Hills, if you read this : yes, I'm kinda ashamed )
So, I first took the rims to paint stripper to get rid of the many paint layers. Fun fact, he didn't manage to remove the original black layer from Porsche, even after putting the wheels four times in his paint stripping bath! That paint was pretty tough!
Then, I took the rims to Moriano to get them fully polished. He ain't cheap, but the result is just perfect, they look like they're chromed!
And to those who tell me "that's too shiny, too bling, go on and detail them", well... No. I do like'em this way, they'll remain fully polished! (well, at least until I get tired of cleaning/rubbing/polishing!)
Then I had to decide what the size of the tires would be... Not an easy task, since there's not that much room under the fenders of a Ghia.
So I first spent quite some time browsing several Aicooled VW forum (F4E, FKG, TheSamba...) to see what tires other people used on their Ghias. I compiled all these data in an Excel file, which might prove useful to anyone out there who wants to put Fuchs on his Ghia : download this file here, you'll thank me later...
I finally set my mind on Yokohama tires, 165/65 R15 in the front, and 185/65 R15 in the rear, ordered on the french website 123pneus (and delivered within 48 hours as usual, that's a good address!). Tires were installed with tire tubes inside ; that's not perfect, but you don't really have a choice with Deep Fuchs, since there's no ridge around the rim to keep a tubeless tire in place...
After a quick test, the Fuchs seem to pass just fine inside the front fenders with the 165/65 R15 tires. That's mainly thanks to the 42mm inside offset of the Deep 5.5"... The tire just slightly rubs the fender when I'm turning full left, but it should be ok. To be confirmed with dynamic driving on the road, though, but I might very well not have to change my front beam for a narrowed one!
On he other hand, the rear tires do not fit the rear fenders, but I knew that would happen.
While I was at it, I installed four red Koni adjustable shockers, trying to make the best I could to improve the road holding. Concerning the shockers, they were out of stock at all the aircooled VW dealers I contacted, but I found them available, and cheaper, directly on the Koni-Shop website, delivered within 24 hours!
Well, I've made the mistake of taking a part off to clean it... Then a second... And a third.... And well, finally, it wasn't a priority for me, but I've restored the whole thing!
I must admit, spending time of the online (french) forum usinages.com (there's a thread about my lathe there), and seeing all these beautifully restored machines, temptation was to high!
I've started by painting the stand. Degreasing using solvent F (naphtha) and Scotch-Brite scrubbing sponge to remove most of the thick coat of grease that was all over it (with some additional WD40 on sticky grease patches). Then complete washing/cleaning using "St. Marc" (french equivalent of your "Cillit Bang", I guess), rince, and a good rub with 90° alcohol to remove any remaining greasy film (the cloth has to remain white when doing this).
Finally, a coat of green, hammered finish Hammerite paint (not that easy to brush, but final visual result is really nice).
Painting the bed and the headstock : same process as for the stand, solvent F/Saint Marc/90° alcohol/Hammerite... While cleaning'em, a lot of metal chips came out of the little space between the bed and the headstock : aluminum, steel, brass, bronze, nylon, you name it ; my little lathe has been using on many different materials!
On some of the following pictures, you can see the bed standing up in quite an unstable position : that was the only way I could access the under and inside parts of it. Unfortunately it almost fell off on me, my cervical vertebras hurt for 3 days... Don't do this at home, kids.
Then I start on the feed gearbox.
There again, I originally just wanted to give it a good external clean, but... I got carried away.
I must say I had a moment of doubt when everything was disassembled on my workbench, with gears averywhere... But finally, with a bit of patience, methodology and organisation, it's not that complex.
Some of you may think I went too far with the mirror finish on the bronze bearings, but I couldn't help.
Then, dismantling the carriage assembly, down to the smallest screw... Now this is where you gotta be cautious : dozens and dozens of small parts just waiting to be lost... You must be organised : containers, reclaimed jam jars, Ziploc bags, hand-drawn schemas, pictures, anything's good to make sure you don't lose anything, and preparing for the re-assembling step later.
I won't go through the detail of cleaning each and every part here, the process was always the same : degreasing in a tay with solvent F (naphtha) and a brush, then brushing/polishing with a rotary brush mounted on my hand drill (soft blue plastic brush) to remove oxydization marks. Eventually, some scrapping when there was paint stains, and/or 600 grit sandpaper with abit of WD40 to remove deeper oxydization.
Aaaaand finally, reassembling everything with clean oil/grease, while adjusting all the necessary plays : this is the funny part.
Tailstock and spindle
There's stillthe tailstock and spindle to restore. Regarding the latest, you must be extra cautious to reassemble it just the way it was originally, since the different parts broke in together.
Originally, my lathe had a little drawer, which is quite handy to keep tools protected and within a hand's reach. Unfortunately, the drawer was lost at some point in the history of the lathe. So, here I go, building a new one out of 10mm. plywood.
A quick tip about plywood : to have a smooth finish once painted, you have to sand it before painting ; a good thing is then to humidify the wood a few minutes before sanding (use a spray or a sponge to slightly humidify the wood, don't soak it!). This will raise the grain of the wood, so you can sand it smooth. If you don't, the grain will raise with the humidity of your paint coat, and you and up with an ugly rough surface.
Since I don't have three-phase current available in my workshop, I use a variable speed drive to drive the motor (I use a Schneider Altivar 31, great product.).
The original motor (1,5 kW/2hp, dual speed) will finally be in too bad a shape to be used. I don't know what its previous owners did with it, but boy does it have suffered : the output shaft was beaten, it was impossible to mount the pulley on it without heavy vibrations. I may have been able to grind it back straight, but since the motor made a naughty noise when running, I preferred to replace the motor + pulley assembly. For 160€ for both (same power as the original motor : 1,5kW, 1500 rpm, pulley 160mm in diameter), I preferred to have my mind at peace on this point.
As per the commands panel, I had on my mind for quite a long time a nice engine-turned aluminum panel. But I wanted the engine turning pattern to be very regular, so I built myself a jig for that.
The abrasive grindstone I use is from PolirMalin, a bit expensive, but does a great job. The circles are 30mm in diameter, I've decided to shift each line by half a radius, the final aspect is much nicer. A bit more complex to do, but the result is worth it, see schema below. This is when the jig comes really handy!
403 holes precisely drilled (that took a while...) in a bit of melamine chipboard (not ideal, but does the trick).
The holes on each line are spaced by a radius distance (15mm). On each line, the holes are shifted by half a radius compared to the previous one.
Then I just need to put the buttons in : I use paint adhesive tape (two layers) to protect the aluminum while driling the holes. Additionally, you can write on it, which is hande to note down where the holes should be!
As per the electrical box, I called for some help. I didn't have all the necessary skills/knowledge to make one up to standards, plus the equipment get pricey when bought one after the other...
Fortunately, a member of the forum usinages.com proposes refurbished high-end second-hand products (thank you so much Emmanuel aka "Turbo Gros Michel S.A" for your help!), and he prepare a complete electrical box for me : relays for the motor drive, pump and light (even I don't use these last two for now), 27V transformer for the commands, 12V transformer for an electronic speed indicator that I'm gonna install later, emergency stop button with an adjustable 2.5s temporizer for the speed drive (which wouldn't appreciate being disconnected while in charge, so it waits for the motor to brake before shutting the current input)... A real electrical bow, up to standards, full options!
And finally, the result... It's such a pleasure to use this machine!
Here are a couple of "before-after" pictures!
Motor pulley :
Speed drive :
Electrical box :
Miscellaneous (paint, hardware...) :
The final total cost is way below the current price this kind lathe resales nowadays, so I guess I did good... Well, obviously, as long as I don't take into account the dozens of hours of labour I've put in it!
My only regret : the size of this lathe. A bit too small, I can't work on my VW drum brakes for example. But well, a bigger lathe wouldn't fit in my workshot anyway, would it??
That's it for today fols, I'm going back to the workshop, I got metal ships to make!