1970 Karmann Ghia AS project

Bookwus · 13 January 2010, 19:54

Hiya Sid,

Quote from: Sidco7 on 13 January 2010, 06:08 ........ I've lined up a shop to do the parts cleaning for me.....

While I do my own parts cleaning, I can certainly appreciate your choice. Cleaning the parts has to be the worst part of doing any sort of rebuild.

Sidco7 · 13 January 2010, 21:30

Ya, I've got a small (5gal) parts cleaner for the little stuff. Too small to fit an engine half or a transmission into. I've just got too many things on the go right now and its a logical choice. I'm going to load it all up and take the whole works over to them. Big worry now is making sure they don't lose anything. lol.

Have you ever taken off one of those crimped bands off of the servo before? I'm a little apprehensive on cutting that thing off. I know I can get a replacement, but how careful do I have to be? I would hate to ruin the pod itself.

Cheers, Sid

Bookwus · 13 January 2010, 22:40

Hiya Sid,

In rebuilding servos for a local repair shop I have done a few of those OEM attachment bands.

If you look round the circumference you'll find a gap (a couple of millimeters usually) in the band. At this point you can force a suitable sized flat bladed screwdriver under one strap end. Before I do this I work out the edge of the band (where it's pressed under the servo-half lips) with a small 90 degree punch tool. With those edges forced away from the servo lip you can start forcing the screwdriver under the band as above. From that point it's just a matter of continuing to pry up the band. Dont worry about the servo body - it's much thicker than the band. Just make sure that your screwdriver blade is about as wide as the band.

Sidco7 · 13 January 2010, 23:49

Thanks Mike.

I had thought the band was welded, it was full of rust and crap, but your post made me have a closer look at it. I took a wire brush to it and sure enough, there is a gap where I can get something in to work it up. I'm going to start the edges up first and then work the band straight off the rim.

Cheers, Sid

volkenstein · 14 January 2010, 00:23

Sid,
Levering it up at the join, small hacksaw cut (from a small hacksaw) and ripping it off with a pair of pliers is good too

. And you certainly can't re-use the crimped on band!

Regards
Sean

Sidco7 · 14 January 2010, 01:37

Quote....And you certainly can't re-use the crimped on band!...

Yes, I can get a new band and diaphram out of CIP1.ca for $26.39
VWC-113-142-055-RK - AUTOSTICK CLUTCH SERVO REPAIR KIT - BEETLE/GHIA 68-74

I was more afraid of cutting into the band and damaging the servo body.

Sidco7 · 02 February 2010, 20:28

Well, Got the parts back from the washer and I am really pleased with the results. The engine block and the transmission are squeeky clean. All the tin, doghouse and other parts need a quick brushover with a wire brush and they are ready for paint. I gotta say that I would do it this way again no question. The guy had a big "Snap-On" heated parts washer which sprayed hi-temp water-based solvent at the parts which turned on a turn table. Everything was cleaned perfectly. The guy did do some pre-scraping and got a coffee can of crap off before he put the parts in the washer (my bad). He only charged me $220 for the entire lot. Well worth my time.

I am going to take apart the transmission and rinse out the guts with an oil based solvent just to be sure there is no residue that might have leaked inside during the wash. Other than that, the transmission just needs a coat of paint and she's done.

The engine will start going together soon too. New parts coming from CIP soon.

Cheers, Sid

Sidco7 · 08 February 2010, 04:47

Servo Rebuild.

Well I opened up the servo tonight and thanks for the tips. It opened like a can of sardines. Just started it with a screw driver and then started rolling it back with a pair of vice grips and the band rolled off really easy.

Once open, I inspected all the parts and just as I had thought, the rubber diaphram was old and cracked. Definately needs replacement.

I'll wire brush things up good and paint them up. Will look brand new.

Cheers, Sid

Sidco7 · 08 February 2010, 04:50

Couple more shots of the servo.

Forum doesn't allow very many pictures per post.

Cheers, Sid

volkenstein · 08 February 2010, 13:20

Sid,
Damn dusty wherever that's been! The two I've ripped apart have been nowhere near caked like that is!

Enjoy
Sean

Sidco7 · 12 March 2010, 19:50

Well,

Finally got all the new parts for the engine rebuild and will be starting on that shortly. Painting old tin and what not too.

Question:

Does anybody know what this puppy is for??

It's the pump that was located 'piggy-back' on the top of the transmission and I believe it is the vacuum pump, but I can't find it in the Bentley manual anywhere. I've taken it apart and cleaned it up. It's a sliding vane type pump but I can't seem to remember where the lines go. Pretty sure it provides the vacuum for the system, but can someone confirm that for me?

Thanks, Sid

Bookwus · 13 March 2010, 01:52

Hiya Sid,

For some strange and unfathomable reason I am not picking up any of your pictures in this thread. Not even any indication that there is supposed to be a picture there (other than the references in your text). Dunno what's going on but I'm out in the dark.

Sidco7 · 13 March 2010, 06:18

That is weird. The pictures show that they have been viewed. Wonder if anybody else cant see them either. I know that I can only post three small pictures. The forum won't let me post anything more or of any substantial size.

I've seen other people's posts with huge pictures, but mine are limited to mere postage stamp size.

Sid

hercdriver · 13 March 2010, 15:08

Sid,

I see your pictures fine. Everything looks great, but I've never seen that pump before. I doubt that it's original but can't rule that out. Are you in the US or elsewhere?

Dave

Bookwus · 13 March 2010, 16:19

Hiya Sid,

I'm going to forward this little picture problem I seem to have on to Bjorn and see if he can make any sense of it