First E.Mail. From Anthony,
Just wanted to give you another update on the bus. I received those sunroof cables, but they ended up being no good as well. Pretty frustrating, so I'm resorting to plan C, and fixing the old ones. I ordered some aluminum brazing rods last week so I can repair the broken cast aluminum pieces on the sliding mechanisms. The rods came in yesterday, and so I got to work on those right away. It was a challenge in itself to braze that stuff as I had no idea. However, I think it'll work. They seem stronger than ever so far. I have one tiny piece to make from scratch to hold the mechanism to the sunroof itself that allows it to pull back and forth and then I will have grind down the pieces to make all the necessary contours so they work properly, and don't bind up. Lots of metal filing! I'm really hoping this works. Otherwise, the only option is to order the cheap 300 dollar cables again, and reinforce those, which I totally want to avoid. But if worst comes to worst, we may have to. I'll do my best! I also talked to Ron at Wolfsburg West in California about it. They just announced that they are remaking all the beetle sunroof parts now, and inquired to see if they were planning on making bus sunroof parts. No go there he said. However, I talked to him about the cables, and he mentioned that he's heard similar stories of the after market ones breaking too. I told him they should be made from one solid piece of billet aluminum, and CNC'd as one piece to reduce the risk of breaking. He thought that was a great idea, and is going to look into it. That will take a few months of R&D, which we don't have, but cool to hear none the less.
Besides that fiasco, i've been concentrating on the other things to get the bus finished up. Firstly, re-keyed the front door handles, so they take one key. I think I already mentioned that all the windows are now in. I had installed new clutch, and throttle cables. The old clutch cable looked as if was going to break so that was good to do for sure. I also finished the wiring harness that had been cut and partly missing. I ended up getting the whole rear harness from a parts bus, so all the factory colored wiring, and connectors are present again. I replaced the power brake hose underneath the rear of the bus due to it looking pretty beat. The transmission was then installed along with a new cross shaft, clutch cable spring, and also put the starter in. The C.V. axles were then repacked with grease, and installed as well. Yesterday, the engine went in. Looks great by the way. I may have to send you some pics from my phone, due the digital camera I had being on the fritz. Time for a new one I think. But so on, now i'm moving onto the brakes. The rear brake lines are on. One of the main front to rear hard lines had been cut for some reason, so i'll be repairing that today also. All in all, we are yet again, getting closer and closer. I refrain from giving a pick up date this time :) but it'll be soon. Actually, i'm glad that we decided to take the extra time needed, as it will better guarantee a nicer product in the end.
Well, i'll quite blabbing for now, so I can get back into the garage. Hopefully I can start this puppy up today. I'm charging up a battery, and painting the exhaust before that happens, so it'll probably be later today. I'll shoot you a call or email once I do, so you know she's alive! Hope you been good, and talk to you soon!
Best regards,
Anthony
THEN
Feb 11
Hey Kellee,
The bus is now running. There were a ton of little gremlins, I like to call them, that needed to worked out
here and there. I'm going to work late tonight to get the brakes going, so it can be taken for a test drive. Pretty excited. It's been a long time coming as I know you can imagine, but a milestone has been met with making sure the electrical all works, and engine running.
Putting the sunroof cables back in again is being saved for last, as I had to regroup by moving on to the runability (I don't think that's a real word), and figured at this point that should be priority. I've also been buttoning up the loose ends here and there as well.
That's all for now, I know it may not be much to report, but a huge part of the completion. Sunroof cables, brakes, horn, and detail is all we have left! Maybe now we can see the light at the end of the tunnel? :)
Have a great weekend, and talk to you soon,
Anthony
