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VW Beetle Official Build Diary - Pack 6 - Issue 41 -49 Options
Levelord
#1 Posted : 16 September 2019 17:58:57

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Issue 41 – Alternator, coil, fuel pump and pulley.



This stage involves fitting several ancillary components to the engine, including parts of the charging, ignition and fuel systems.

The alternator support has a curved tab corresponding to a notch in the front part of the alternator. Slide the support all the way into the alternator. Now align the back part of the alternator with the two locating pins and the notch in the front part, press the two halves of the alternator firmly together, trapping the support in place.

Now take the oil filler cap, it has a D-shaped hole corresponding to the pin on the end of the pipe angling up from the support. Match up the hole and press the filler cap into place. The breather pipe also fits into a D-shaped hole next to the filler cap, ensure it fits the right way round. Fit the small mounting plate onto the alternator support, the hole is D-shaped to ensure correct alignment.

Holding the alternator the correct way round, align it with the D-shaped hole in the right rear corner of the crankcase. Press the alternator support firmly into the hole. Now fit the fuel pump base into the hole next to the alternator support, pressing it firmly into place.

Fit the pulley into the hole at the bottom of the crankcase, pressing it firmly into place. Finally, fit the ignition coil into the hole in the fan shroud, as shown in step 41-L of the instructions. Make sure that the pointed terminal is at the bottom of the coil.

Stage complete. Carefully store the assembly.






































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Levelord
#2 Posted : 16 September 2019 18:00:50

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Issue 42 – Left front wing.




This stage provides a distinctive part of the bodywork, on which you will be fitting the first of the headlights.

Take the headlight from Pack 1, fit the shell into the recess of the wing and press the mounting post into the matching hole. Fix the headlight from the inside of the wing using an SP05 screw.

Stage complete. Carefully store the assembly in a stage labelled bag.














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Levelord
#3 Posted : 16 September 2019 18:03:36

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Issue 43 – Spark plug leads.



There is a hole at both ends of the rear suspension torsion bar. Fit an SD04 screw into each of the holes and screw them all the way in. The purpose of the screws is to prevent the suspension arms from moving and coming into contact with the other parts.

The spark plug leads are all different lengths. To ensure you fit them in the right position, lay them out as shown in step 43-E of the instructions. The lead for plug 1 (43-1) goes into the rearmost hole in the left cylinder head cover. One end of each plug lead has a pointed barb that will hold the lead in the hole. Press this all the way in. Now fit lead 2 (43-2) into the hole in front of the left inlet manifold.

Fit the coil lead (43-5) onto the pin on the end of the coil. The ends of the lead have one short cap and one long one. You need to fit the short cap to the coil. Now fit lead 3 (43-3) into the hole behind the right inlet manifold. Finish off by fitting lead 4 (43-4) into the remaining hole in front of the right inlet manifold.

You now need to route the leads correctly. Refer to step 43-L of the instructions and run leads 3 and 4 behind the alternator and the carburettor. Bring cables 1 and 2 round next to the pulley. You will attach the leads to the distributor in the next stage.

Stage complete. Carefully store the assembly.






























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Levelord
#4 Posted : 16 September 2019 18:07:03

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Issue 44 – Air filter, fan belt and distributor




This stage involves the installation of the air filter, the belt that drives the fan and the alternator, and the distributor to which the leads fitting in the previous stage are connected.

When fitting the distributor, a drop of super glue is recommended to ensure the part does not come loose. The pin on the bottom of the distributor goes into the D-shaped hole behind the pulley. Press the distributor all the way in. Take the plug leads coming round behind the alternator and fit them onto the back pins on top of the distributor. Then fit the coil lead onto the central pin on top of the distributor. Now take the plug leads coming from the left of the engine and fit them onto the front pins on the top of the distributor.

Fit the fan belt onto the pulley at the base of the engine, then stretch it over the pulley on the end of the alternator. Now fit the base of the air filter box. This has a hole shaped to match the top of the carburettor to ensure that it is fitted the right way round. Secure it to the carburettor with an SP05 screw.

One end of the air filter box has a tab that fits into a slot in the inlet pipe. Fit the parts together the correct way round, as shown in step 44-J of the instructions. Fit the pin on the end of the connecting tube into the hole under the inlet pipe, matching up the shape that ensures it fits the correct way round. Fit the assembly onto the two pins in the air filter box base and press it firmly into place.

Stage complete. Carefully store the assembly.































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Levelord
#5 Posted : 16 September 2019 18:09:50

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Issue 45 – Fuel system accessories




The components fitted in this stage include the pipe work that connects the carburettor to the air filter and fuel pump, plus the vacuum advance unit that controls the ignition timing.

The black support for the air preheating regulator valve has two locating pins that fit into holes in the side of the air filter, make sure you fit it the right way up. Fit the end of the white tube onto the pin projecting from the back of the carburettor. Now fit the end of the black tube into the hole in the side of the carburettor.

Now take the round black valve on the end of the red tube and fit its two pins into the holes in the air inlet pipe. Fit the vacuum advance unit onto the pin near the base of the distributor. Then take the silver tube from the vacuum advance unit under the plug leads connected to the distributor and plug the end into the hole in the carburettor.

Take the top of the fuel pump and fit it onto the fuel pump. The fitting is D-shaped to ensure it goes on the correct way round. Take the silver tube leading from the top of the fuel pump and pass it under the plugs leads and the air outlet of the fan housing. Now take the end of the silver tube round the end of the fan housing and plug it into the hole indicated in step 45-I of the instructions.

Finally, plug the end of the black pipe leading from the top of the fuel pump into the hole in the back of the fan housing.

Stage complete. Carefully store the assembly.








































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Levelord
#6 Posted : 16 September 2019 18:11:24

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Issue 46 – Right front wing



This stage provides the second front wing, which is assembled in the same way as in Stage 42.

Take the remaining headlight from pack 1 and fit it into the recess in the wing, pressing the mounting post into the matching hole. Fix the headlight using an SP05 screw from the inside of the wing.

Stage complete. Store the assembly in a stage labelled bag.









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Levelord
#7 Posted : 16 September 2019 18:13:25

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Issue 47 – Hoses



The hoses that link the fan to the shrouds around the hot cylinders are a distinctive feature of the Beetle’s simple, but effective, air-cooling system.

Take the first of the warm air hoses. One end has a flange onto which the hole clip fits. Squeeze the end of the hose to make it easier to fit the clip over it, making sure the two tabs projecting from the clip face outwards. Make sure you can turn the clip, which you will need to do to fit it at the correct angle. Repeat these steps to join the second hose and clip.

Position one of the hoses on the left side of the engine so that the two tabs on the clip line up with the slots on the left heat exchanger. Press the tabs into the slots to lock the clip and the hose attached to it, into place. Rotate the hose so it lines up with the pipe coming from the fan housing, then press the hose onto the end of the pipe. Carry out the same process to fit the second clip into the right heat exchanger and attach the hose to the fan housing.

Now install the carburettor warm air hose, the top end of the hose has a pin that fits into the connecting tube under the inlet of the air filter box, while the lower end fits into the heat exchanger. Fit the lower end of the carburettor warm air hose to the heat exchanger first, then carefully fit the pin on the other end into the connecting tube under the inlet of the air filter box.

Stage complete. Carefully store the assembly.



















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Levelord
#8 Posted : 16 September 2019 18:15:05

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Issue 48 - Wheel arches



The part provided with this stage incorporates the rear wheel arches, part of the rear floor of the cabin and the support for the rear seat. With the chassis almost completed, you will be starting to install the interior fitting in the next stage.

Stage complete. Store the assembly in a stage labelled bag.





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Levelord
#9 Posted : 16 September 2019 18:16:58

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Issue 49 - Heater hoses



The passenger compartment heater hoses are mounted on the rear interior floor .

The heater hoses are marked with letters to identify which side the go on, R – right and L – left. Align the right hose with the underside of the wheel arch, matching up the locating pins and holes, press the parts together. The hose should stand a small distance off the surface. Turn the assembly over and fix the hose with and SD07 screw. Now fit the left hose under the wheel arch in the same way, securing in place with a second SD07 screw.

Take one of the connecting hoses. One end has a D-shaped hole that matches a semi-circular tab on the end of the right heater hose. Press the parts together. The shaped hole ensures that the hose curves in the right direction. Repeat the process to install the second connecting hose.

Stage complete. Carefully store the assembly in a stage labelled bag.

This completes Pack 6




















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