Engine Rebuild: 3

With most of the major components now re-installed on the engine, it was time to start putting in and on all the ancillary pieces, like the engine tin, the manifold and heat risers, the alternator and stand, the carburetor and fuel pump.

Clutch alignment tool

Before I could put all those pieces on, however, I had to take care of some alignment/adjustment issues with some of the key components like the clutch.  Although I had managed to install the clutch plate correctly in round two, it turns out that I needed a clutch alignment tool to make sure it was perfect.  Fortunately this is a cheap plastic tool and I found one for a couple of dollars at Austin VeeDub.  It only took a minute to remove the pressure plate and install it correctly.

Oil Pump gasket seal

Another problem that had to be fixed was the oil pump cover plate.  This was leaking, and long before any serious pressure had been applied to the engine, so I knew it was a problem.  The specs call for a paper gasket between the pump cover plate and the pump housing, but for some reason this wasn't actually sealing the oil in.  I did some reading on the Samba and it seems this is a common problem.  Many old timers swear it just takes a gasket and the proper torque on the bolts; many others say it's a common problem best solved with a gasket compound like the stuff I used to seal up the case.  After a couple of wasted gaskets, I decided to go with the latter procedure. After all I had plenty of the gasket compound left over, and I figured that if this doesn't work I can always go with the 'belt and suspenders' approach and install both the gasket and the compound.

Engine tins

With the oil pump cover solved (for now) I moved on to installing the engine tin.  I have been cleaning, buffing, blasting, priming and painting all these bits for weeks.  Whenever I don't want to pull the cover off the car but I have some time to work, this has been my task.

...and painting.

Lots of buffing...

Lots of the tin is pretty banged up, but when I started looking at the cost of replacing it, I decided to keep to my original plan and re-use as many pieces as I can, especially when they are still functional.  Another factor--quality--also has influenced me.

I like seeing it...

The VW mark...

Most of the aftermarket products, including the engine tins, are just not as well made as what was already on the engine.  In fact, most of it is cheap crap that wouldn't even last.  In addition, the sight of the VW mark is enough to make me want to keep a piece if at all possible, keeping as much of the car a 'real' VW.  This has happened a number of times now.  I get some new pieces that look good, but when I compare them to what came off the car, I always choose the original piece, even if it's a bit beat up looking.

All set to install the tin

Pieces go on slowly

So I came to the conclusion that even though brand new tin would look a little nicer, it wouldn't be that substantial a difference because the tin is functional, not decorative.  Most of it won't even be visible.  Of course, I also want even the invisible parts of the car to be right, so this seems fair, and in keeping with the plan to 'refurbish' rather than 'restore' this car.  This meant a lot of time spent getting all the pieces straight and painted, but eventually I had them all done.

Most of the tin is on

Time to install the rest

Getting all the tin painted was just the first step.  Next I had to get it all to go back together and fit.  Just general wear and tear has taken its toll on the shape of these flimsy pieces, and getting them out distorted them even a bit more.

New screws 

Painted fan shroud

It was not until finally I tried to line them up and bolt them together with all the shiny new sheet metal screws I bought that I realized that they were getting a bit scratched up, and that a second coat of paint would be necessary after I had gotten them all in.  This was a small price to pay, though, for getting it all lined up well in advance of installing the engine in the car.

Buffed up alternator

Oil cooler is in

With most of the tin on but before I took it all off for a re-paint, I went ahead and mounted several other key components, like the alternator (now buffed and painted), the intake manifold and heat riser, the oil cooler and the fan shroud that covers it.  After those pieces were back on, I installed the muffler and one of the heater boxes.

Muffler goes on

Although I have purchased some shiny new chrome valve covers, I decided to put the old painted steel covers back on.  They don't have the bling of the chrome, but they do have that VW mark on them.  I found the same mark on the oil cover cap and the hose clamps that hold the fresh air hoses to the fan shroud.

With everything on, the engine is finally starting to look like it will work!

Almost done!