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> Rebuiding Inside-out
bkrantz
post Jun 2 2021, 09:04 PM
Post #2861


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The outsource saga continues. I brought my cylinder heads to Tucson, and in between helping my son move, called around for trouble-shooting shops. That led first to Chirco, VW air-cooled specialists. They sent me to an old school machine shop. The plan now is for Chirco to take the heads apart, then the machine shop will weld up the bad stud holes and crack and redrill the holed (and heat treat the heads), and then Chirco will reassemble the heads.


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bkrantz
post Jun 4 2021, 07:34 PM
Post #2862


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Home again, and time to work on more electrical things.

I have a plan to convert the fog lights to LED, but have not found a bulb that will fit the over-size socket. Instead, I want to insert a standard socket inside the larger one.


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bkrantz
post Jun 4 2021, 07:35 PM
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Here's the old base, with the positive tab removed.


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bkrantz
post Jun 4 2021, 07:37 PM
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And here's my first attempt, with a collar around the new small socket made from copper pipe--double layer.


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bkrantz
post Jun 5 2021, 07:11 PM
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Second attempt, after I could not get the copper pipe filler to fit: good old JB weld. Now I have 2 fittings with the correct socket for an 1156 type bayonet bulb.


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bkrantz
post Jun 5 2021, 07:13 PM
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Sockets complete, with new LED bulbs. If these are not bright enough or have the proper beam pattern, I will look for others.


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bkrantz
post Jun 5 2021, 07:15 PM
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Now to sort through and select the best parts from 2 pairs of lights.


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bkrantz
post Jun 5 2021, 07:15 PM
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Plus new lenses.


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bkrantz
post Jun 5 2021, 07:16 PM
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And new gaskets.


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bkrantz
post Jun 5 2021, 07:17 PM
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Modified bulb holder installed.


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bkrantz
post Jun 5 2021, 07:18 PM
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Rubber grommet in housing.


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bkrantz
post Jun 5 2021, 07:18 PM
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One complete light.


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bkrantz
post Jun 5 2021, 07:19 PM
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And it works!


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bkrantz
post Jun 5 2021, 07:19 PM
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And installed for testing. Ignore the temporary electrical connections.


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bkrantz
post Jun 5 2021, 07:21 PM
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With the fog lights installed, it was almost time for the car electrical test. I tried to temporarily install all the remaining components, like the gas tank lever sender.


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bkrantz
post Jun 5 2021, 07:22 PM
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And some engine components: coil, alternator, starter.


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bkrantz
post Jun 5 2021, 07:23 PM
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Time to connect a battery.


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bkrantz
post Jun 5 2021, 07:25 PM
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As soon as I connected both battery leads, the headlights cycled and stopped--but not in proper closed positions. No surprise since I installed the motors and linkage randomly.
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bkrantz
post Jun 5 2021, 07:25 PM
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As soon as I connected both battery leads, the headlights cycled and stopped--but not in proper closed positions. No surprise since I installed the motors and linkage randomly.


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bkrantz
post Jun 5 2021, 07:32 PM
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I then started testing various components, with the ignition off and on.

Things that worked correctly:
Fog lights (including switch light)
Hazard lights (including hazard switch)
Horn
Gas gauge and light (assuming correct for now)
Ventilation fan
Wipers
New washer pump
Brake lights
Rear heater blower
Interior light


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