AoT's White Wonder

[realbluefoot]

Looking real good! When you replace the tarboards make sure you put all of the spikes through it so it holds tightly against the firewall, otherwise the fan will suck it in.

[Tom]

Looking real good! When you replace the tarboards make sure you put all of the spikes through it so it holds tightly against the firewall, otherwise the fan will suck it in.

X2 Throw some self tapping screws with big washers just to be on the safe side.

[AoT]

Looking real good! When you replace the tarboards make sure you put all of the spikes through it so it holds tightly against the firewall, otherwise the fan will suck it in.

As my hands will atest ll those spikes are all al there. Want to get the area painted and the seals replaced.

[AoT]

Took advantage of the good weather and extra time to getting the wonder closer to be being back on the road.

Got the accelator cable run thru the tunnel, just waiting for the clutch cable and rear seal to be delivered to get them installed.

Got the rear compartment cleaned up and new rear boards installed.
Before..


After..




the front DS floor was showing some rust damage so I POR 15 the floor and topcoated it.



After the luck getting the exhaust studs off was able to get the newer ones on. Thanks to Jim Lynch for the step up stud that was needed on one of the connections.



Planned to get the engine pulley off to get the correct tins on the wonder but had a prob with the puller.

The tins are primed and painted but the puller would not align over the pulley. The fixed side of the puller did not clear the depth of the pulley and I did not want to force it and do some damage. Any one ever use one of these?

Going to try some heat to se if I can get the fixed side to go at a right angle rather than lean into the puller.

Going to work on getting the pedal cluster cleaned up and the new accelerator pedal put on. Get the new engine seals on and the should be ready to reinstall the engine soon.

Lots to be thankful for!

[Glenn]

A little heat around the hub on the pulley and with two large screwdrivers you can wiggle it off. That's how we did it when you first got the engine.

[AoT]

That's how we did it when you first got the engine.

Wow, makes me a little misty eyed, like a parent of a newborn!!

[AoT]

Got the clutch cable run thru the tunnel last night so time to get the pedal cluster done.
The unit was covered in sand and grit so I got it wired brushed and marine cleaned.







final cleanup before paint


Painted and just need to put the gas pedal unit on and slap it back on.


Want to work on the pulley tonight so will see how that goes.

[gotboost79]

nice! looking good... its amazing how the little stuff makes the difference

Hope the pesky pulley comes right off with some heat...

[Glenn A]

Pedals look sweet. You could drive the pin out of the bottom of the clutch pedal and pull the shaft out clean it up even more and grease it.
Knowing you you probably did that already though

[Glenn]

Pedals look sweet. You could drive the pin out of the bottom of the clutch pedal and pull the shaft out clean it up even more and grease it.
Knowing you you probably did that already though

[AoT]

Pedals look sweet. You could drive the pin out of the bottom of the clutch pedal and pull the shaft out clean it up even more and grease it.
Knowing you you probably did that already though

Looks like a schematic from Wolfsberg West! A good time to get out the wire wheel and take it down to the bones!



Started working on the pedal cluster but got side tracked to the pulley...

After some motivation I went out to see if I could get the puller to work. Put the fixed side on and and gave it some pressure to latch the adjustable side. Got it to catch on the top and a few gentle taps with a hammer and the pulley slid down. Got it bolted to the crankshaft and the pulley started backing off.


It bottomed out before the pulley was free so I took it off and put some extra washers in the front of the crankshaft and repeated the process. A few more gentle turns with the wrench and voila~~



New tins in place..Need to do some touchup painting on the pulley.



Sorry BusBBQ for dissing your puller before I gave it a fair chance. It worked like it was supposed too!

[Raj]

Very nice AOT. I love working like a gentleman. ( I have so very rare chances to do so......)

Is that a german pulley tin or aftermarket?

[Brown]

Very nice AOT. I love working like a Lady. ( I have so very rare chances to do so......)

Fixed it for you!!

[Glenn]

Very nice AOT. I love working like a Lady. ( I have so very rare chances to do so......)

Fixed it for you!!

Easy Ken, no visuals please.

[Glenn A]

Very nice AOT.

[mannys66]

it's nice to have the rigt tools for the job, last time I took a pulley out, I spent over an hour hammering it out.

[Raj]

it's nice to have the rigt tools for the job, last time I took a pulley out, I spent over an hour hammering it out.

i totally hear you. And then the pulley prob ends up as gargabge.

[mannys66]

it's nice to have the rigt tools for the job, last time I took a pulley out, I spent over an hour hammering it out.

i totally hear you. And then the pulley prob ends up as gargabge.

I agree, and in tha tcase it did , lucky for me I already had a pulley ready for the second motor, so I didnt care much about that one coming out, all I wanted was that stupid tin behind it

[AoT]

Pedal cluster done, Had to shave the two metal tabs that fit into the slot for the pedal spring clip otherwise the pedal was grabbing.





Need to get the engine seals on, put the pulley back on and the clutch/plate, reinstall the pedal cluster, connect the clutch cable and then hope to get the engine back in next week.

Lots to cross off the list!!

[Glenn A]

pedals look great! What a gas!

[Tom]

Nice work .

[Brown]

Pedal cluster done, Had to shave the two metal tabs that fit into the slot for the pedal spring clip otherwise the pedal was grabbing.





Need to get the engine seals on, put the pulley back on and the clutch/plate, reinstall the pedal cluster, connect the clutch cable and then hope to get the engine back in next week.

Lots to cross off the list!!

Looks Great!! Expect a call from the B-man!!!

[B MAN]

hey AoT,


have u lost weight? man you're really slimming down!

[AoT]

Countdown to the engine re-install.

Got the pedal cluster back in this morning. Clutch cable stayed connected but the rear bolt was a PITA!! Need some new pedal covers.



Moved on to get the clutch/plate back on the flywheel. Got the alignment done and the bolts torqued to 18 ft lbs.




Last on the list today was getting the crankshaft pulley and fan belt back on.




Only have to put the front engine seal on tomorrow and check to be sure all my connections are tight. Then get the jacks ready.


This punch list included:
replacing the main engine seal
new accelerator cable
new clutch cable
new accelerator pedal
new rear tar boards
new engine rear and front seals
new heater boxes
getting front DS floor POR15 and painted

A glimpse of the day I brought the engine home!!



Two years ago this weekend, the wonder called my garage home!!

[67SAMBA]

IMPRESSIVE!!!!!!