Wednesday, April 24, 2019

VW-1500 M265 on the streets again!


Ahhhhh so good to have the car registered and on the road for some local cruise's.

So far nothing has proven a problem with it such as brakes etc.

I suppose with only 300-400 miles on the car since it was built in about 2000/2001, it's not exactly knackered and has less mileage than my new MK7 Golf I bought in February which has 4000 km on it now!

Tuesday, April 23, 2019

Wiring 99% completed on the 1500 'S'

Amazing how quickly the car is now being assembled with the headliner now complete. it almost looks complete in this photo except for the carpets and perhaps the radio once that has been gone through (again) and installed.


As can be seen there are now ZERO loose wires hanging down below the dash which is fantastic.


Next step is to install fuses and test the circuits one by one. I still might replace the globes in the car with LED's me thinks (6v) just as I have already done with the dash bulbs. I think modifications like that are a bit of a no brainer in order to maximise the light output with the 6v.

Another update shortly to show the headlining which was completed before these images but not sure where they are right now.

Friday, March 1, 2019

6v Starter Solenoid Relay for the 1500 'S'

I was pondering the 'issues' the notchback had when I used to drive it and one of the annoying things (and common to a lot of 6v VW's) was that if the battery wasn't quite up to charge or it was cold etc, the car was a nightmare to start or sometimes I had to resort to push starting it. Not a good look.

As I have installed an engine with 8.5:1 compression as well as the highest output 6v VW starter into the car (extra 0.1hp), I figured I might as well install a relay to provide as much possibility to the car that it would actually start!

I removed the relay shown below from the notchback when I dismantled it and had it put aside for this very situation. I think it was used for the horn or something last time (can't remember) and this being a West German 6v 30A relay, well, it seems like the right thing to use on the car being somewhat of the right era and of the right power carrying capability.


Made in W. Germany. This is good.


Here it is with the wiring pigtails I made up just now. One wire for earth, one wire for power (with in line fuse - currently 25A), one wire for the solenoid and the empty terminal is where the original red wire to the solenoid from the ignition switch gets connected, thus no modifications are made to the car or the original wiring. Neat and simple.


Same view but different.


I crimped all connections as indeed I do for all my wiring projects and then installed heat shrink just because I could.
The relay is now tied to the solenoid with a single cable tie very tightly which is OK for now but I will replace that single tie with two once it's up in the air on a hoist. My back was killing me and I crawled out from under the car looking for a beer...

Easily removed, secure and should provide some assistance with starting the car.
Fingers crossed on this modification.

Next up is to better align the drivers side rear fender as I am not happy with the way it is sitting. This is not something I am looking forward to. All other panels are now very good and this one panel is giving me grief.

Saturday, January 12, 2019

Special visit from Ron Fleming to Adelaide 2018

Late 2018, I was advised that Ron Fleming would be in Adelaide to see the sights and sounds of this wonderful city. I had met Ron a couple of times previously in the USA and Germany, and as Ron was staying with a mate of mine here who is assembling a VW drag car, it seemed the right thing to do to offer my hand out to show Ron dinner (on my birthday with my wife no less) and my pair of air cooled VW's currently in the garage while he was in town. And perhaps sign an original magnesium BRM as well.


Here we are behind the black 1500 in front of the signed FAT shirt I bought back a few years back while in California. I think Ron was a bit surprised to see it. He also liked the Berg shirt signed by Gene and Gary Berg under glass too.


Wearing my finest worn out DKP shirt with grease on it and welding holes no less! Who gives a toss.

We had a good chat about an engine currently under construction here in Adelaide based around a brand new 2-piece ARPM case bought back in the day by our friend Andrew. Roller lifter cam modifications have me excited. More than that I cannot elaborate yet...


Here we are in Adelaide after eating way too much decent French food and requiring a lay down! Sam the plumber pulled out the keys to his bug and took Ron home after dinner and didn't manage to hurt him so Sam is in the good books although seat belts were mentioned (!).


Thanks for heading over Ron and sharing your input and wisdom on a number of issues. It was rewarding to hear some of the insights into the early days of the scene I am so keen to be involved with and I hope you enjoyed seeing both my black and green VW's while here. See you in Germany 2019 at Bad Camberg.

Monday, January 7, 2019

2019 & another SPG crankshaft

Welcome to 2019.

Just before the new year began I found another SPG roller crank, this time it's an 82mm pinned unit with minor wear to the main journals and unused for many years.


As you may be aware (and contrary to a lot of folk who think SPG crank's are crap) I think they are fine if you use your brain and look after them. Yes, my 1602cc engine in the notchback right now has an NOS 74mm SPG roller I swapped 60 x semaphores for about 20 years ago! To be honest I did put 1000 km on the crankshaft as soon as I got it to see what it was all about and it is very impressive.


So why does the SPG come in for such a flogging? I think it's a little harsh to say these crankshafts are crap when the EMPI Inch Pincher (among other race VW's) was setting records with them back in the day. Very quickly, people worked out that due to the construction of the cranks (non splined joints), they did require pinning (look at the top photo to see evidence of this) to reduce the likelihood of the crankshaft from twisting when dropping the clutch at ridiculous RPM's and coupled to sticky rubber. Of course that was going to screw them up! It's a no brainer.


The other thing which does not bode well for them I am told (and I do agree) is that they do like to sit at reasonably high RPM's and not to idle them for prolonged periods of time which can kill the rod bearings. Why? It's all to do with the big end bearings and their oiling. Unlike a regular drilled crankshaft with passage ways from the mains to the big end journals providing pressurised oil, the SPG has no passages due to the pressed construction and relies on altered main bearings which have essentially slots cut (filed / milled) into them to enable oil to squirt out the side of the main journals into holes drilled on the cheeks (see the image above) of the crankshaft thus oiling the big end bearings (roller bearings) by a 'mist'. Yeah I think it's a bit crap and not ideal but it does work OK. I will keep the RPM's up and not race the notchback so it's no big deal.


So this 82mm SPG crankshaft - I saw it advertised locally and made inquiries. I am lead to believe this was originally bought back in the 1970's by a chap that taught me how to screw around with VW engines back in the late 1980's when I was young and stupid (I am now older and stupid).
Anyway, he bought it new, didn't do much with it and then it got sold to a well known chap here in Adelaide whom I believe did use it in a limited manner and then it went through another chap to the chap I bought it from just now. I am awaiting clarity around that story from the original purchaser but it seems I am correct and can trace it's history (my old boss from back then agreed it was correct). If so, it is cool to own another piece of Adelaide VW performance from back then and know it hasn't been overly abused.


What are my plans for it? Well nothing 100% at this stage except I have measured up the main journals and they are on the outer end of wear for standard journal dimensions which is a little sad so with that I took it to my crankshaft grinder man - Jim - who agreed to grind the main journals to suit a set of new main bearings (0.25mm) which I have now just received from Vintage Vee-Dub Supplies (http://www.vintageveedub.com.au/)
I have a brand new AS-41 case tucked away for just such an engine I had in mind for something like this as well as a set of NOS 90mm (no, not 90.5mm) NPR 'B' pistons and cylinders from the 1970's that were originally bought with a new Okrasa crankshaft back then. I have a number of other engine parts (as you may imagine) to go with all this and will begin the hunt for additional period correct items so the engine is 100% 1970's themed and visually correct.
The engine will not be installed in anything at this stage or even assembled but all measured up, machined, checked and boxed as a complete pile of boxes until I work out where it will go.


And in case your wondering about grinding a crankshaft like this - Jim the crankshaft man has ground one other SPG many years ago (also 0.25mm) the same way. You tie the rods together via piston pins (as per the images above) and then run a cable tie through the pins to hold them solid and not flap around. Simple as can be. And while on the subject of the rods, nobody can feel any 'wear' in the rod bearings so while this is not the way I like to do things (no measurement what so ever), I have always been of the belief that if you can feel wear in a bearing, the bearing is screwed and in this case I think I am in the clear with the rod bearings. A gamble of sorts but not the end of the world if it turns out that a bearing is naff as I can always slip a conventional 82mm crankshaft in there fairly quickly should that prove to be the case. I have swapped crankshafts out in air cooled engines previously over night in my youth so I couldn't care less to be honest! 

Fortune favors the brave as they say.

Some Notchback updates very shortly as the car nears the headlining stage and final assembly.

Wednesday, December 5, 2018

LIGHT MOTORS foil sticker update


Huge credit to Chris Anderson (http://wrapman.com.au/) for recreating the LIGHT MOTORS PTY LTD foil dealer dash sticker reproduction for my car.


The correct colour for your car as delivered by LIGHT MOTORS PTY LTD here in Adelaide is dependent on the sticker it came with - there was no hard and fast rule by the looks of it. All of them look fine (light blue, medium blue or black) and all are OK.


As you can see below, the reproduction and the original are almost 100% identical.
If anything, the new one is more accurately laid out as you might expect and the corners are nicely cut.


The rear window water slide decal for LIGHT MOTORS will be the next candidate to finish my car off and may prove to be a bit more difficult than I initially thought.

* UPDATE January 2019 * these foil stickers are all now SOLD. Contact Chris Anderson on the above URL if you require any of these for your Adelaide delivered VW please.

Small updates on the 'S' assembly