1602cc full flow routing & 2 x weird exhaust clamps...

More engine nightmares but progress nevertheless.

The heater boxes (original to the car) were missing these weirdo clamps for the duration I have owned the car so I got hold of a pair of them NOS and sat them where they belong. Quite what they do is beyond me as the muffler is clamped by the conventional clamps onto the heater box. Anyhow.... they are installed and the muffler can go back on once the fan housing's are bolted on.

I thought I would share the images of the full flow set up on the 1602cc.

It's just regular brass fittings out of the Gene Berg relief valve pump cover (3/8 NPT) and the case with adapters to -8 speedflow alloy angled fittings and speedflow hose all in black which is orientated correctly to clear the fan housing without clearancing the magnesium and once they get below the lower tinware the hoses are clamped together and ran as a pair up to the o'Berg oil filter which will be mounted near the air mixer on the passenger side (left side for us RHD people).

Yes it looks weird but this ain't no bug so you have to do things a bit different to suit the VW-1500.

Next up is to get hold of a non-thermostat inner fan housing and that will get a lot of other parts bolted onto the engine. As you can see, this 1602cc is based around a brand new AS-41 magnesium VW crankcase because the original crankcase was heavily cracked and is now of little use except perhaps as a foot stool.

Engine Reference Images including OKRASA Type 3

Thought I would share some of the images I have found on various public forums' that I have been referencing for my engine build.

Since my engine is a unique build (74mm SPG x 83mm = 1602cc) I have had to combine a few parts from various Type 3 1500 models plus the aftermarket parts to make sure it resembles something 'stock' visually, which has been a challenge.

Rear ash tray seals sealed & seat belt plugs

I sealed the rear ash tray seals in the body tonight using the original liners and some fancy product from Sikaflex. Previously the seals were not sealed in the car well from the factory and did leak water everywhere thus leading to some heavy rust and corrosion which was one of the triggers to the restoration.

Once this has set somewhat, I may apply more sealant or evaluate if I need to do anything else to remove the water from being able to enter which is the death of these Type 3's.

You may wonder why the hell I painted the inner fender areas so well in this area and this is also because of the water sealing situation - if I have polished up smooth paint (instead of the VW applied primer back in 1964), I believe I have a better chance this time around of avoiding the rust in the future. Makes sense huh?

Also note I have used Wurth rubber seals for the interior trim (and will be used on the external side trim too) as I believe these are the best seals on the market.

I also found a bag of NOS seat belt plugs in white a long time ago and have started to install these in the car including under the back seat area. The bolt in the center is also the original KNIPPING brand bolt that holds the rear seat in place and I am now almost ready for the interior to be dealt with. 

Next update might be the seat back release cables. I have almost finished the installation of them after remembering how they all connect. Not the most enjoyable job but had to be done.

Air vent's and stage #1 of wiring

Assembly time day #1