1967 VW Variant.

I ran the rebuilt engine in the car today, and its a better starter than my own white fastback. I noticed that the generator light was on constantly, so I checked it out. I thought it might be that the dynamo needed to be polarised to suit electrics. It was a common thing when dynamos gave trouble, and was a quick process to do on the generator terminals.

I did that, but the light remained on and no charge at the battery. So out with the multimeter, and a quick check showed that the dynamo was putting out .5 volts. So it needed a specialist to check it out. Dropped it into Tullamore, and will get the verdict tomorrow. I could have gone for a replacement, but at the moment I would like to stick to original.

Thats exactly what I am thinking. I would hope that its repairable. But the original starter motor blew segments out of the commutator when it got the amps on it from start up. Repair guy said that the old resin adhesives on the motor and the insulation failed after all the years lying up.Hopefully its not the same with the generator. Fingers crossed.

Yep. The brushes are good, and the commutator is clean and in good fettle. I checked across it with the multimeter and got .5 volt output where there should be 20+ volts at high revs. I never opened the dynamo, but I suspect a short in the windings, thats why I put it into a good spot for repairs. I will know this morning.

Just heard back from the dynamo specialist. The armature has a major fault and cannot be repaired. Only option is to find a replacement armature, or a replacement dynamo, or a new unit.

Not a problem as I have an earlier replacement dynamo, with the threaded pole connections. I will check its out put later today.

I checked my earlier dynamo, probably early 60's. But brushes are well shot and armature a bit shabby looking.

So I took the good brushes from the damaged dynamo. Pulled out the bad brushes from the early dynamo and gave the armature a good clean and paid particular attention to where the brushes seat.

Re assembled the early dynamo, and checked it on the bench. And its working well. I will re fit it tomorrow.

So back to work on my Variant since the engine rebuild. As I needed to be able to move it in and out of the shed for work, I had no choice but to fix the brakes first. I stripped and rebuilt the front calipers and fitted new hoses. I also replaced all the lines with new brakelines that I made and flared myself. And then to the rear drums. Both wheel cylinders were seized, so had to be stripped, cleaned along with all the adjustors that were welded together with rust.

And lastly the drivers side hub was seized and would not release from the hub no matter what amount of hammering took place. To buy a new larger hub puller was over 700 euro. So I made one.

I used a VW Beetle rim that I knew would bolt on, and a scaffold adjustable foot lift, that could take the brute force needed.The parts I needed.

Welded up and ready to fit on the hub.

And fitted and ready for the big pull.

A bit of effort and hey presto,

And now I can crack on with the brakes.

I moved onto the back wing as it was too wet to bring the car outside to work on the roof.

Its a common place for rust issues on a type 3 , hopefully its confined to the wing.

Bottom half of the wing is well shot with rust and bad corrosion.

Plenty of sand lodged behind the wing.

But thankfully no serious rust damage.

And a quick measure and mock up of a replacement repair piece.

Just need to mark the arch contour, and prepare that, and the jobs a good un.

Then onto the wing on the opposite side to make a similar panel.

More of the rust issues in the spare wheel well. The two side panels are no longer available so I will have to make them and just made a start on them.

Ah fek off.......a heart attack sort of feks up yer timeline.. Thanks for your enthusiasm😀

But never fear, its back on track now. The fuel tank supports are available now, so they will be bought for it, and the side panels will be made now.

I am back full blast at the car repairs now.thanks for all your kind sentiments. Now enough about me, more on the car.

The fuel tank support on the right hand side took a whack when the bumper did, it probably got crumpled a bit, rust set in, and now needs replacing. I'll post a pic of that later this morning.

The other side appears fine, but I notice some rust issue there as well, so its best to come out too. As the rear panel of the spare wheel well is also being replaced and is attached to the lower prongs of the fuel tank supports, its best to replace both sides, once the tank is out.

Pics to follow.

Here is a better pic of the side panels that need to be made. The panels from 69 onwards are still available with a different bumper mount, but the earlier one's which I need are no longer made. This pic has the 2 front wings removed, but the front clip, and inner clip still intact.