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VW Samba T1 Official Build Diary - Pack 5 Options
delboy271155
#1 Posted : 27 August 2019 14:22:23

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Stage 36

Cab Rear Panel

Parts supplied:
Cab rear panel, Screws BP06.


Retrieve the cabin assembly and unused parts from stage 35.

Line up the pins of the handle with the holes in the bulkhead and press the pins into the holes. Now locate the three holes in the top of the spare wheel housing and note that they correspond with the two pins and hole in the ashtray, which means it will only fit in one way. Next place the ashtray into position and secure it with a BP07 screw from the inside of the housing.

Locate the two posts and two notches on the bulkhead and the two posts and two tabs on the spare wheel housing. Now place the spare wheel housing against the front bulkhead and press the spare wheel housing against the bulkhead aligning the posts of both parts.


Stage complete, carefully store any remaining parts in a stage labelled bag.

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delboy271155
#2 Posted : 17 November 2019 15:19:07

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Stage 37

Front Floor

Parts supplied:
Front floor, Screws BP06.

Collect together the cab rear panel and the BP06 screws from Stage 36.

Now insert the three posts on the underside of the panel into the corresponding holes in the cab floor and secure the panel with three BP06 screws, checking that the parts are flush as you tighten the screws.

Next align the holes in the front floor with those at the front of the cab floor and press the two parts of the floor together, then secure the parts with five BP06 screws.

Stage complete, carefully store any remaining parts in a stage labelled bag.

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delboy271155
#3 Posted : 17 November 2019 15:23:46

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Stage 38

Front Floor Carpet

Parts supplied:
Front floor carpet. Accelerator cable (01), Brake cable (02), Gear lever, Handbrake lever, Accelerator pedal, Clutch pedal, Brake pedal, Accelerator plate, Brake plate, Pins, Starter knob, Heating knob, Heating controller, Screw BP06 and BP08.

Place the posts on the underside of the front seat floor carpet into the holes in the front floor and press the carpet into place.

Insert the accelerator pedal into position in the front floor, then turn the assembly over and insert a pin through the aligned holes (smooth end first) and using a pair of pliers press the pin into the hole.

Next insert the brake pedal into the front floor and fix it in place in the same way as the accelerator pedal with a second pin.

Now insert the clutch pedal into the front floor noting that the clutch pedal is not secured from underneath, so check that it is properly positioned.

Stage complete, carefully store any remaining parts in a stage labelled bag.


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delboy271155
#4 Posted : 19 May 2020 20:23:12

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Stage 39

Spare Tyre

Parts supplied:
Spare tyre.


Identify the labels on the two cables: Accelerator cable (01) Brake cable (02) and make sure you handle the two cables carefully as they can be easily damaged.

Turn the cab over and install cable 01 into position underneath the accelerator pedal. Then mount the accelerator plate onto the two posts and fix it in position with two BP08 screws.

Next insert cable 02 underneath the brake pedal, now fit the brake plate into position paying attention to its orientation and secure the plate with two BP08 screws.

Temporarily secure the two cables to the floor with some masking tape.

Stage complete, carefully store any remaining parts in a stage labelled bag.
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delboy271155
#5 Posted : 19 May 2020 20:27:12

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Stage 40

Spare Wheel

Parts supplied:
Spare wheel.

Retrieve the rest of the parts supplied with Stage 38.

Insert the starter knob into position, with the heating knob in the hole next to it and the heating controller in the next hole along.

Insert the gear lever into position, noting that the base of the lever is D-shaped so can only fit in one orientation and secure the gear lever from under the floor with a BP06 screw.

Next, insert the end of the handbrake lever into the floor in front of the gear lever and finally check that the buttons under the floor are properly engaged when you press on the pedals.

Stage complete, carefully store any remaining parts in a stage labelled bag.

delboy271155 attached the following image(s):
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delboy271155
#6 Posted : 19 May 2020 20:32:34

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Stage 41

Engine Block

Parts supplied:
Engine block (left), Engine block (right), Left push rod tubes, Right push rod tubes, Engine block (rear), Screws BP06.

Take the spare tyre, along with the spare wheel and insert the wheel into the tyre by pulling the side walls of the tyre over the wheel. Check that the side walls are properly seated on the wheel by rolling the assembly back and forth.

Now slide the driver’s seat forward and tilt the passenger seats forward so you can place the spare wheel into the space behind them. Then check that the spare wheel is positioned correctly.

Stage complete, carefully store any remaining parts in a stage labelled bag.


delboy271155 attached the following image(s):
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delboy271155
#7 Posted : 19 May 2020 20:35:42

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Stage 42

Cylinder Head

Parts supplied:
Cylinder heads, Left cylinder head cover, Right cylinder head cover. Left air pipe, Right air pipe, Valve covers, Screws BP06 and BP08.

Retrieve all the parts supplied with Stage 41.

Fit the rear part of the engine block onto the post on the right engine block. Then place the posts of the left engine block onto the posts in the right block and secure the assembly with two BP06 screws.

Now identify the two push rod tubes R and L and insert the left (L) push rod tubes into the holes in the left half of the engine and the right (R) push rod tubes on the right side of the engine block.

Stage complete, carefully store any remaining parts in a stage labelled bag.

delboy271155 attached the following image(s):
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delboy271155
#8 Posted : 04 August 2022 14:56:52

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Stage 43

Hi All, BigGrin

This build is being resumed due to the re-release of the Samba. Originally, I was far behind with parts supply and had tendonitis in both wrists, but I`ve got the rest of the kit now (plus my wrists are “better albeit not perfect”) so I`m up and running again. I also hope to be able to try and resolve previous problems that were encountered, for example the steering.

So here we go:

Engine Mount

Parts supplied:
Engine support, Tube, Screws BP04 and BP09. (As shown in pic 1)

To begin, retrieve all the parts supplied with Stage 42 (Pic 2) and the engine block assembly from the last stage.

At this point I`ve inserted a snip of the overall objectives of this stage so you can cross reference for parts and part numbers. (Pic 3)

First task is to fit the cylinder heads into the two holes in the engine block (Noting that it will only fit one way, due to the pin/hole sizes). (Pics 4 and5) I found the pins to be quite a tight fit, so take care and make sure the parts are square to each other when you apply pressure.

Next you need to insert the left air pipe into the corresponding hole in the left cylinder head cover and secure the pipe with a BP08 screw. Repeat for the right cylinder head cover and pipe in the same way and secure that with another BP08 screw. (Pic 6)

Place the right cylinder head cover onto the right side of the cylinder heads and secure with two BP06 screws and repeat for the left side parts. (Pic 7)

The final task for this stage, is to mount one of the Valve covers into the holes in either side of the engine by carefully pressing the covers into place. (Pics 8 and 9)

Stage complete (Pic 10), carefully store any remaining parts in a stage labelled bag.
delboy271155 attached the following image(s):
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delboy271155
#9 Posted : 04 August 2022 16:50:12

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Stage 44


Hi All, BigGrin


Here we go with the next stage of the Samba:


Cooling System

Parts supplied:
Fan housing, Top cover, Tube, Screws BP03 and BP04. (Pic 1)

The first thing to do is prepare all the parts supplied with Stage 43. (Pic 2)

As before I have added the schematic of the stage objectives to help. (Pic 3)

Fit the tube into the hole in the engine support and secure the tube to the support with a BP09 screw. (Pics 4 and 5)

We now have to place the two holes in the support plate onto the two corresponding posts of the engine assembly and secure the support to the engine with two BP04 screws. (Pics 6 and 7)

Next, we fit the tube into the fan housing (noting it can only fit in one position) and fix the tube in place with a BP03 screw. (Pics 8 and 9)

Finally fit the fan housing to the top cover (Pic 10) and secure the parts together with a BP03 and a BP04 screw making sure you orientate the screws correctly, as shown in Pic 11.

Stage complete (Pic 12), carefully store any remaining parts in a stage labelled bag.

delboy271155 attached the following image(s):
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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#10 Posted : 04 August 2022 19:15:55

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Stage 45

Welcome back to the Samba build. BigGrin

This is where we will start to detail the engine. Cool

Engine Parts supplied:

Intake manifold, Oil filler tube, Pulley (large), Pulley (small, part 1), Pulley (small, part 2), Carburettor, Throttle lever, Distributor, Fuel Pump, Pulley plate, Belt, Oil filter cover, Alternator, Screws BP03, BP04 and BP10. (See pic 1)

The schematic overview for this stage is shown in pic 2

So, the first thing to do is retrieve the engine cover and fan housing assembly.

Now, insert the central post of the intake manifold into the hole and secure the intake manifold with a BP04 screw. (Pic 3 and 4)

Install the oil filler tube into the L-shaped hole (Pic 5) and fit the carburettor onto the top of the intake manifold (Pic 6).

It’s at this point that I think there is a choice as to what you do.

a) As per the instructions: insert the ends of the throttle lever into the holes in the carburettor and fan housing. (Pic 7)

b) You can leave the throttle linkage off for now, making it easier to fit future parts and fit it later.

If you choose option “a” and find it gets in the way, just be careful when you remove it and replace it. I went the “a” route, ended up removing the linkage and replacing it but like I say be careful.

Next assemble the two parts of the small pulley noting that they can only fit together in one position (Pics 8 and 9) and then insert the small pulley onto the alternator (Pic 10) and fix it in place with a BP10 screw (Pic 11).

The next job is to insert the alternator into the D-shaped hole in the housing. (Pic 12) This I found to be a snug fit, so please be careful how much pressure you apply.

Finally fit the fuel pump into the hole in the cover base (Pic 13) and insert the two short tubes of the fuel pump into the indicated holes in the housing (Pic 14). More detailing continues in the next stage.


Stage complete (Pic 15), carefully store any remaining parts in a stage labelled bag.
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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#11 Posted : 05 August 2022 10:33:32

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Stage 46

Engine

Parts supplied:
Engine cradle, Carburettor vacuum system, Starter coil, Carburettor, Fuel line, Spark plug cables, Screw BP04. Pic 1

Retrieve the unused parts from Stage 45. Pic 2

In this stage we will add more details to the engine and fix the top and bottom of the engine together. A full schematic of this stage can be seen in Pic 3

Start by fitting the distributor into the hole in the housing as shown in Pic 4

Position the end of the large pulley into the slot in the base, Pic 5 and mount the pulley plate over the end of the pulley to hold it in place, securing it with two BP03 screws. Pic 6

Now the belt can be installed over the two pulleys. Pic 7

Retrieve the lower part of the engine and mount the upper part by inserting the ends of the manifolds into the four holes as indicated in Pic 8.

Holding the parts together carefully turn the engine assembly over and insert the oil filter cover into the hole Pic 9 and secure it to the engine with a BP04 screw from above as shown in Pic 10. Now turn the assembly round and check that the four ends of the intake manifolds are still properly engaged in their corresponding holes.

Finally insert the long free end of the hose from the fuel pump into the hole in the side of the engine. Pic 11

Stage complete (Pic 12), carefully store any remaining parts in a stage labelled bag.

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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#12 Posted : 05 August 2022 12:08:48

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Stage 47

Rear Chassis

Parts supplied:
Rear Chassis, Screws BD04. Pic 1

Retrieve the pieces from Stage 46. Pic 2

This stage of the build sees more details added to the engine. The schematic can be seen in Pic 3

Position the engine cradle to the rear of the engine assembly Pic 4, now carefully press the cradle in place by inserting the two pins into the holes. Pic 5.

Next identify the four different locating pins of the spark plug cables noting that these fit into specific holes in the engine assembly. When you are sure of the orientation pass the spark plug cables between the carburettor and the alternator as shown in Pic 6. Once in position insert the locating pins (1–4) into the corresponding holes as shown in Pics 7 and 8, then insert the four ends of the spark plug cables into the holes, (two on each side of the engine). Pic 9 and 10

Now install the carburettor fuel line between the two mounting points. Pic 11

Then fit the starter coil to the corresponding points as shown in Pic 12, securing the starter coil to the housing with a BP04 screw.

Finally, fit the carburettor vacuum system to the two points, as shown in Pic13.

Stage complete Pic 14, carefully store any remaining parts in a stage labelled bag.

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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#13 Posted : 05 August 2022 13:28:13

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Stage 48

Transmission

Parts supplied:
Transmission upper, Transmission lower, Right cables, Left cables, Screws BP05. Pic 1

Retrieve the parts form Stage 47. Pic 2

So, in this stage the engine will be installed in the rear chassis, the transmission is then added along with the rear cables. The full schematic can be seen in Pic 3

Carefully pass the engine assembly up through the opening at the back of the rear chassis. Pic 4.
Make sure at this point that the engine plate lays flat with the rear chassis. (It`s a snug fit and if incorrect, the fixing points won`t be in contact) When in place, carefully turn the chassis over and secure the engine with four BD04 screws at the points shown in Pic 5. Turn the chassis over and check that the engine is correctly located. Pic 6

Next fit the two parts of the transmission together Pic 7 and secure them together with two BP05 screws Pic 8. Now insert the three posts on the top of the transmission into the holes in the chassis Pic 9 and secure the transmission with two BP05 screws Pic 10.

At this point in the build, two lots of cables are added under the chassis, each of which has numerous fixing pins that are pressed into the chassis. To aid you in this process I have added a couple of clipped images from the instructions showing the locating pin positioning.

With the chassis upside down refer to Pics 11 and 12 to fit the right-hand cables and Pics 13 and 14 to fit the left-hand cables.

That`s all for this stage, with one more stage to finish pack 5.

Stage complete Pic 15, carefully store any remaining parts in a stage labelled bag.

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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#14 Posted : 05 August 2022 14:27:33

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Stage 49

Heating System

Parts supplied:
Heating system tube upper, Heating system tube lower, Boots, Left heat shield, Right heat shield, Screws BP03 and BP04. Pic 1

In this stage we add parts for the heating system, a schematic of which can be seen in Pic 2.

Start the assembly of the two parts of the heating system tubes by pressing them together Pic 3 and secure the ends with two BP03 screws and the rest of the tubes together with three BP04 screws as shown in Pic 4.

Place the right heat shield into the holes in the chassis as shown in Pic 5 and then fit the left heat shield into the holes in the other side of the chassis. Pic 6

Now fit the rubber boots onto the shafts on each side of the transmission, pressing the boots flush up against the transmission. Pic 7

Retrieve the heating tubes and position the posts on the top of the heating tubes into the three holes in the chassis Pic 8. Finally, whilst hold the heating tubes in place turn the chassis over and secure the tubes with three BP04 screws. Pic 9

So that`s it for this stage Pic 10.

Pack 5 is now complete, carefully store any remaining parts in a stage labelled bag.

See you soon for the start of pack 6.

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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






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