Bub: the Buggered Up Beetle

Nearly a year after Bub went up flames, nearly taking me with it, I'm back on the Beetle trail and very similar reasons .... I will be starting a new Blog as much for my own entertainment as for everyone to read while locked away but that can't start quite yet so here's a taster {insert name} The Jeans Edition Baja Beetle I have had almost a year of not thinking about it but some itches have to be scratched and my deep love for the funky wee 'Classic' Beetle has again resurfaced. So here we go again, but better, and slightly more sensible I hope. I built Bub for the sheer entertainment value but that engine was doomed from the start and doomed the whole car in the end. Lots of reasons, with 20/20 hindsight, it was a really poorly thought out supercharger kit, the base engine was probably flawed, the set up was too much ad I had neither the technical understanding nor bottomless pockets to do it properly but the rest of the car was spot on. So it was back to ...

I really don;t know how to process this news, so I'll do it by sharing my pain and upset .... Bub went on fire during his first road test with the fully rebuilt engine. I got the engine back on Monday and fitted it straight away. Today, I got busy getting work out the way and got the engine plumbed and wired in. All sorted and ship shape - nice.  Ignition on, pumped the loud pedal 5 times and turned the key ... fired up beautifully and after a minute or 2 ticked over really smoothly. Brilliant. Left it to warm up then out for a wee drive - exactly what I expected ... really quick off the mark, really smooth through the gears, instant pickup, almost no throttle hesitation (a problem before). For sure the handling was evil but with some weight in the front to hold the nose on the road and the gear loaded in the back it would be epic. So ... off for a longer run and after 25 miles it was just getting better (as I got used to it) and on the A77 heading home with the wind behind m...

It's been a while, a long while since I Budated or even looked at the damn thing in earnest. Actually that's not quite true, Bub has been sat in my carport looking forlorn and unloved while my Veteran Car (1912 Alldays & Onions) sat on the ramp being sorted after a breakdown. Now, however, the engine is back from the builder and is only lacking a few parts before it can be fired up and test driven and run in. Here's the video (words below for the literate) So, what went wrong? Short answer - the engine blew up, long answer ... read on When developing an engine and making it run as best it can you need 20/20 hindsight as well as all the knowledge that all the 'experts' have. Clearly I have neither! What I had was a pile of parts, a bolt on Supercharger Kit that was nothing of the sort and about one third of an idea of how to put them all together. I'm going to cover the bits that led to the broken engine ... Parts 1300cc engine in very good co...

Here is a sorry tale of the perils of buying from overseas .... headlines .... "Bolt on kit" fucking well is not "good quality carburettor" is a crappy chinese piece of shit copy "lifetime technical support" lasts about 3 days until the retailer gets bored All kits come missing parts,poorly set up with incomplete or misleading instructions Now read the details .... I bought a supercharger kit and ignition system from Joe Blow, I am not putting his website ro FB page here because I have no wish to advertise him, and I have been both very impressed, adn massively disappointed in both his attitude and his products. My dispute with him is over his misdescription of the ignition system. He didn't make it clear that I would have to adapt parts already received, his website totally failed to mention some parts that were needed and the kit arrived with parts missing that were listed as being included. His reaction to his errors was barely even a shr...

I hate missing deadlines but sometimes it's better to sort things properly especially when you're talking about little things like engines. So it's been a month since the last Bubdate and I've not been sitting on my hands .... things wot have been done accessory wiring loom 8 blade fuse box) fitted using 16mm cross section cable to bring a permanent live to the dashboard a couple of accessory sockets wired in Intercom has been fitted and works very well, I can connect my phone, an iPod/iPad/tablet and CB CB antenna fitted Brakes adjusted Tyre pressure experimentation started - 10psi front, 20psi rear. Low pressures in a ttempt to gain front grip and some rear suspension New horn fitted: the original one is earth switched and all the wiring was cacked so I rewired it and converted the steering wheel button to positive switch seat pads made from mechanics crawler mats Roll cage padding to protect heads and legs new battery, terminals and tie downs fitted new...

Opinion are like arseholes, everyone has one and they often stink. It's been a frustrating week with self proclaimed experts offering 'advice' which basically comes down to sucking their teeth and saying 'you've got that all wrong mate'. Oddly they all contradict each other but there are plenty of nuggets of gold in there - these guys have had lots of business and racing success so they know their stuff but they forget that they don't know it all .. anyway, back to Bub. Took a drive to a local specialist about 25 miles away. Ear plugs in and still, damn that is LOUD!!! Bu's running but not very well, stalling but going quite well on an open throttle. Smelling horribly rich but impossible to lean out. As I get to John's place the charging warning light start playing up - very odd. A good hour spent with John as he tells me what I should've done while admiring the oil cooler, showing me the right oil thermostat and giving me a few pointers ...

Well, Bub is a road test ready, but not a complete car. For sure, the suspension is all new, the brakes are in fine fettle (although not been used in a few years some polishing up will happen through use), all lights work so it's time to test. Old cars and MOT's it's the responsibility of every owner/driver to make sure their car is safe no matter the age MOTs are valid for the period of the test itself - drive round the block and you're on your own again Cars over 40 years old no longer require to be MOT'd but it is advised to get them checked by a 'professional' most old cars are owned by enthusiasts who maintain them professionally or to a very high standard themselves there are proportionately very few of them and they do a low mileage many modern mechanics don't know what they're looking at and the tests are not appropriate for old cars Bub doesn't need an MOT but once the engine has been tuned (emissions) he will be checked out ...

oil pipes connected - check fuel pipes connected - check fresh petrol poured all over me - check rest of petrol poured into the fuel tank - check Fuel pump primed and fuel filter showing 'full' - check following starting instructions Set timing as best you can prime the charger by going full throttle 15 times turn on ignition turn over a few times wait then turn over again until it fires runs and stops runs and stops runs, stops and backfires - not good Check HT leads are in the right order ... D'Oh, dizzy turns clockwise .... swap cylinders 2 and 4 on the dizzy. prime 5 times turn on ignition (battery is now low so assisting with my starter/charger) turn over  IT FIRES AND RUNS ...... Oh my very word, it is LOUD. Not loud as in "turn that music down" loud, not even ACDC at Hampden Park loud .... oh no, this is wearing ear defenders and earplugs and don't stand too close especially if you're in an enclosed space loud. It's ...

I'm starting to get excited ... just to refit the engine, check some plumbing and wiring before firing up the rebuilt engine. Here's a wee walk through video Jobs to do before roadtesting fettle the maximum distributor advance check for leaks and obvious problems double check everything is tightened up refit rear wings Jobs to do before running in fit horns properly adjust headlights fit battery retaining bracket fit power outlets for phone charging and running my motorbike heated fleece (remember - no heating Things to do before first Mad Plan (details to follow) Drive around 500 miles without going over 2500rpm or sticking at one speed for too long Full oil and filter change and set the tappets change oil in gearbox change brake fluid and pads/shoes as required Fit CB Fit some kind of sound system make seat cushions

All the best laid plans ..... First job on Saturday morning was to use my new spring compressors to get the mac struts apart and the new springs and inserts fitted. All went well and it came apart really easily and then back together in under an hour per side. Nice! Wheels back on, car off the axle stands and back on its boots and ... BANG!!! The strut top mount bushes collapsed - holy shit, you don't want that going on 2" above your head. The driver's side was sort of okay but the passenger side was nasty. Even though, I saw an increase in ride height of about 3/4". That is NOT right! Can't order anything at the weekend (Bub is a crossover year so always best to check you're ordering the correct parts) so I started on the clutch. With help the engine pops out, down on the ground, new 200mm Kennedy Stage 1 pressure plate and funky clutch parts taken out the box, admired and offered up to the ..... BUGGER .... 180mm flywheel. Buggerty-fuck, Arse. Ok...

Stage 1 Kennedy Clutch pressure plate (good for >150bhp) - check Kush lock HD clutch friction plate (good for street/strip use) - check HD clutch release cross shaft and bushing kit - check new clutch release bearing - check new clutch cable - check steering wheel spacer 20mm - check engine cage single tube - check megaspark ignition - check Front suspension/steering Driver's side front suspension before Passenger side front suspension before the driver's side spring was significantly weaker than the passenger side (although the gap was about the same) new springs, new inserts, new bump stops strut brace ready to fit front brakes are almost new (the discs will need some bedding back in) new steering damper - old one had leaked all over the suspension leg and made the bolts come undone easily; a partial win old v new all steering joints checked and found to be in great condition Ready for the new springs and inserts So it's been...

Aaargh ... waiting for parts ..... waiting for parts ..... waiting for parts .... still fecking waiting! Since the last Bubdate, I've waited for the ignition system from Joe Blow which he didn't send with the kit because he didn't spot my order the specialist ATF for the supercharger the parts for the support rod (not really, arrived the next day and took 15 minutes to fit) the ignition system which Aussie Post  says has been sent despite the lack of tracking number because 'It's too hot mate, the scanner's bust" oil cooler hose fuel pump the ignition system which, after 10 days, STILL isn't in the UK the kennedy stage 1 clutch pressure plate and HD friction plate (and I need a stronger clutch release system - another £250 I hadn't budgeted for) The bloody ignition system which Oz Post now says (after Mick at Joe Blow spent an entire day on the phone to them) got double scanned and therefore lost. It is now (4th Feb) en route, allegedly ...

With the engine finished barring a few wee bits of fettling it is looking braw and it's a rather neat kit but some aspects are a little disappointing. The welding on the bracketry and inlet manifold could be a bit neater and the inside of the manifold tube seems to have surface rust when the rest looks like its been passivated. The instructions are clearly written but could be 1,000 times better with a few photos or even a wee video on the website. One thing that is a serious pain in the arse is the clerance between the carb and the alternator. For sure an old style VW generator is smaller but if it could be rotated by 45deg then there would be no issue about shorting out the electrics. I'm going to cut down the +ve terminal by 5mm and fit a strong rubber boot to avoid the immediate isses and to aid easy engine removal, an anderson connector will split the main +ve leads at the side of the engine so I'm not having to access the 2 terminals. The supercharger mounts on ...

Cap'n slog: Wednesday 9th Jan 2019 Arrived at work to find, a full top end engine rebuild kit and a supercharger kit, nice! Problem; no ignition kit. Contacted Joe Blow who basically said 'oops, I didn't spot your message adding it to the order' so now I'm waiting a few weeks for that to arrive. Ah well, I can get on with everything else Thursday10th Today I started the engine rebuild. With the engine on the bench I stripped off the tinware (the thin metal covers that direct the air around the cylinders), removed the fan and alternator and gave the engine a quick clean. Next, the rocker covers unclip, the rocker rail comes off with 2 nuts and then 8 nuts later, the cylinder head was off. The cylinders came off with some persuasion with a rubber mallet and the pistons come off with a removed circlip and a tap with a long screwdriver to push the gudgeon (wrist) pin out. As the great philosopher Haynes says "replacement is the reverse of removal". T...

Firstly to everyone who's been following my stream of consciousness recently, thank you, Merry Xmas, a Happy and prosperous New Year and here's to a 2109 filled with car parts, nice surprises and lots of road trips...... Bublist as at 24/12/18 (in no particular order) headlights wire side and dipped beam together fit with correct screws fit chrome bezels when they arrive Horn test horn wiring buy fit a new standard type horn  screen washer make a 'Blue Peter' style air pressure reservoir for standard washer bottle test rubber pipes & replace as required Seats repair driver's side outer rail (seat comes loose) fit plastic runner covers when they arrive (stops rattling) make new longer seat belt extensions  repair passenger seat belt mounting point fit passenger seat belt Engine Parts have been ordered to enhance performance Not chasing power but torque should be noticeably better  cars that weigh 900kg fully loaded don't need m...

Here's a thing about Beetle engines, and when I say 'Beetle', I mean real Beetles not those Golfs in party frocks, you can get seriously meaningful power and torque gains with very little effort and at reasonable cost. Of course 'meaningful' and 'reasonable' are entirely relative! First we need to define our terms; Power, Torque and how they relate to Bub and then discuss the options Power Power is what everyone discusses when comparing engines. It's the definition of engine performance, measured in Horsepower (HP/PS/DIN), brake horsepower (BHP), or kilowatts (kW), and is the measure of the maximum output of the engine . Everyone understands BHP but HP is 1.4% higher and kW (which no one really understands) is 34.1% lower. I'll talk in HP because that's what VW quoted and what information is available, not forgetting that I'm being general as 45 years cars may have had 50 horse power when new but not only are the horses geriatric but m...

Apologies for the length of this Bubdate but I've been a busy bee.. The last proper Bubdate saw the rollcage fitted and painted with Zinga galvanising coating, the tub had been painted, and the engine had been run with the twin carbs (for a short time) but there were issues with the engine, the wiring was all to cack and the whloe project is clearly fractal in nature like all projects are, i.e. the more detail yoou look at the more you find ..... Note: Videos are at the bottom - I was too busy doing the jobs to take many photos or videos While Bub sat out for a few days to help the zinga coating cure properly, I cleaned up the workshop and finished off the seat bases. The didn't need much, a wee bit of welding to finish off the frmes then painted in black paint so they look fresh. Then Bubit was dragged back onto the ramp and the reassembly started. Roll cage: The zinga coating is excellent and will take a lot of abuse but it feels horrible and rough so I got some sil...

Not an update as such but as Bub is out the garage to let the galvanising paint cure (needs moisture apparently) there's a chance for some quick pics and a wee video to see how Bub looks from a distance

Progress has been slow this last couple of weeks but the roll cage finally arrived and it's the last big piece of the puzzle. Ewart and I wasted little time in getting the cage unwrapped and set in place and ... it didn't fit! Removed, turned round, put back in and ... it fitted, after a fashion.  The cross bar that holds the tub together had to be cut out and then it fitted nicely. The front cage was loosely bolted in and it became clear that something was wrong with Bub ... he appeared to be a little twisted! Much measuring and he seems to be about 8mm shorter on the right than the left ... wheel base (adjustable), inside the tub, door gaps ... everywhere. Solution, rebate the dashboard so the front hoop fitted nicely! First rule of construction; cut it large and kick to fit! A moderate amount of swearing and welding (messy but effective) and the rear cage bottom mounts had been bolted up with extra spreader plates, front hoop built up and bolted down and it looks great...

I've been busy fettling and fitting the last few days and with the roll cage due for delivery on Thursday or Friday and a new exhaust on order I have lots to do but none particularly interesting ... except for one ... get Bub running again With an alternator conversion, twin Weber 34 carbs and a 009 distributor, new plugs, leads and lots of pissing around ... will it start and run? Jobs done twin carbs and linkage fitted (lots of fettling, they were well battered) manifolds needed  fettling to get them to fit linkage mounting bolt threads were stripped, drilled, tapped (one helicoiled) and sorted linkage adjusted and balanced alternator fitted (need more shims to adjust the belt correctly) remote charging regulator removed main charging wire connected to Loom and battery charging lamp re-routed LED indicator ballasts fitted (no more disco flash) Jobs still to do fit the new halogen headlight conversion fit fan belt and cover fit the exhaust fit the roll...