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VW Samba T1 Official Build Diary - Pack 6 Options
delboy271155
#1 Posted : 05 August 2022 22:15:34

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Stage 50

Suspension and Rear Axle

Parts supplied:
Rear axle, Suspension cradle, Support plate, Engine support, Screws BP04. Pic 1


Hi all,

Here we go with pack 6 of the Samba that incorporates stages 50 – 57.

In Stage 50 we will start work on the rear axle and suspension that will be attached to the rear chassis built in the previous stages.

A schematic of stage 50 can be seen in Pic 2.

The support plate will be attached to a post on the rear axle, so familiarise yourself with the shaped hole in the plate as shown in Pic 3.

Fit the support plate onto the post on the rear axle and press the support plate flush against the axle as shown in Pic 4.

Now fit the engine support onto the two open ends of the rear axle Pic 5 and secure the engine support to the rear axle with two BP04 screws as indicated in Pic 6.

Next insert the two posts of the suspension cradle into the two holes in the axle Pic 7 and whilst holding it in place turn the rear axle over and secure the suspension cradle with two BP04 screws as in Pic 8.

Retrieve the rear chassis assembly and insert the two posts and tabs of the suspension cradle into their corresponding holes Pic 9. Whilst holding the parts together, carefully turn them over, make sure that the locating tabs are fully in place Pic 10 and secure the cradle to the chassis with four BP04 screws as indicated 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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delboy271155
#2 Posted : 06 August 2022 15:56:27

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Stage 51

Rear Bumper

Parts supplied:
Rear bumper, Left bumper insert, Right bumper insert, Left bracket, Right bracket, Screws BP06 and BP08. Pic1

Hi all,
In this stage we will construct the rear bumper by adding the corner detailing and attaching the brackets that mount the bumper to the rear chassis rails. A full schematic of this stage is shown in Pic 2.

Before you begin this stage, identify and separate the left and right bumper inserts and brackets, they are all marked with an “R” or “L” accordingly. Pic 3

So, start by mounting the left bumper insert on the left side of the rear bumper Pic 4 and secure it from the inside of the bumper with two BP08 screws Pic 5.

Then install the right bumper insert in the same way and secure it with two screws BP08 Pic 6 and 7.

Now to fit the left bracket, place it between the ridges on the inside of the bumper Pic 8 and then secure it with a BP06 screw Pic 9.
Fit the right bracket in the same way on the right side of the bumper and secure that with a BP06 screw Pic 10.


Stage Complete Pic 11, carefully store any remaining parts in a stage labelled bag.
delboy271155 attached the following image(s):
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2 Stage 51.JPG
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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#3 Posted : 06 August 2022 19:17:05

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Stage 52

Rear Chassis Frame

Parts supplied:
Rear chassis frame, Left drive shaft, Right drive shaft, Screws BP04 and BD04. Pic 1


Hi All,

In this stage the rear bumper is attached to the rear chassis rails, that are then attached to the rear chassis plate. Finally, the right and left rear drive shafts are installed. The full schematic for all this can be seen in Pic 2.


To start you will now need to engage the rear bumper brackets with the ends of the rear chassis frame and press down on the assembly so that the parts are properly joined. Pic 3. Then secure the bumper to the frame with four BP04 screws as shown. Pic 4


At this point carefully place the rear frame and bumper assembly onto the rear chassis plate, Pic 5 and press the rear frame into place to engage the posts with the corresponding holes. Then secure the rear frame with six BD04 screws. Pic 6


We now need to fit the rear drive shafts. The left drive shaft is stamped with the letter L and the right drive shaft is stamped with the letter R. Insert the ball-end of the right driveshaft into the hole in the rubber boot and repeat on the other side with the left driveshaft. Pic 7


Stage Complete Pic 8, carefully store any remaining parts in a stage labelled bag.

delboy271155 attached the following image(s):
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2 Stage 52.JPG
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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#4 Posted : 09 August 2022 18:15:57

Rank: Super-Elite

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Stage 53

Rear Suspension

Parts supplied:
Left rear suspension arm, Brake, Brake drum, Suspension shaft, Suspension spring, Suspension arm cover, Screws BD05, BP04 and BP11. Pic 1

In this stage we assemble the rear/left suspension, a full schematic of which can be seen in Pic 2.

Place the left rear suspension arm onto the post of the rear assembly and the drive shaft. You will need to make sure that the drive shaft is in exactly the right position, because as it enters the arm it has a locating lug that must go into the arm Pic 3.

When fully in place check that the parts are flush and if they are then secure the suspension arm with screws BP11 and BP04 as indicated in Pic 4 and 5.

Now insert the suspension spring into the case Pic 6 and fit the suspension shaft inside the spring with the upper end placed onto the suspension arm. Then secure the shaft to the arm with a BD05 screw Pic 7.

Continue by pressing the suspension arm cover into its recess covering the BP11 screw, Pic 8.

The brake backplate and drum will be used in a later stage. Pic 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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2 Stage 53.JPG
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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#5 Posted : 10 August 2022 15:09:18

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Stage 54

Rear Suspension

Parts supplied:
Right rear suspension arm, Brake, Brake drum, Suspension shaft, Suspension spring, Suspension arm cover, Screws BD05, BP04 and BP11. Pic 1

This stage is basically a copy of the previous stage 53, except on the opposite side of the chassis. A full schematic can be seen in Pic 2.

Place the right rear suspension arm onto the rear chassis assembly, checking that the parts are flush Pic 3 and secure the arm with a BP04 and BP11 screw Pic 4.

Now insert the suspension spring into the case Pic 5 and then fit the suspension shaft into the spring with the upper end placed onto the suspension arm and then secure the shaft to the suspension arm with a BD05 screw Pic 6.

Finally, press the cover of the suspension arm into its recess covering the BP11 screw Pic 7.

As in the previous stage the brake backplate and drum are not used in this stage.

Stage Complete Pic 8, carefully store any remaining parts in a stage labelled bag.
delboy271155 attached the following image(s):
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2 Stage 54.JPG
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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#6 Posted : 11 August 2022 15:48:52

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Stage 55

Left Rear Wheel arch

Parts supplied:
Left rear wheel arch, Screws BD04.Pic 1

In this stage there is very little to do, suffice to test fit the brake back plates and drums, for which a schematic is shown in Pic 2. These will be removed again, so if you don`t wish to do this stage move onto stage 56.

If you wish to do the test fit, then please read on.

Retrieve the brake parts and identify the back plates by their letters. R+L

Test fit the left brake back plate onto the axle of the left suspension arm, noting that the pin at the top of the arm corresponds with a hole in the brake back plate Pic 3 and then fit the left brake drum onto the axle Pic 4.

In the same way, now fit the right brake back plate onto the right suspension arm Pic 5, followed by the right brake drum Pic 6.

So as not to drop/damage the hubs and back plates, now is a good time to remove them.

Stage Complete Pic 7, carefully store any remaining parts (including the brake plates and hubs) in a stage labelled bag.

delboy271155 attached the following image(s):
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2 Stage 55.JPG
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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#7 Posted : 13 August 2022 17:24:04

Rank: Super-Elite

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Joined: 09/11/2012
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Location: East midlands
Stage 56

Right Rear Wheel Arch

Parts supplied:
Right rear wheel arch, Battery, Screws BD04 and BP04. Pic 1

In this stage we will fit the left wheel arch to the rear chassis (from stage 55), fit the battery to the right wheel arch and fit the right wheel arch to the rear chassis. A full schematic of this can be seen in Pic 2.

To begin, retrieve the left rear wheel arch and place it onto the left side of the chassis, aligning the holes and posts. Then press the wheel arch into place Pic 3.
Now secure the left rear wheel arch to the chassis with three BD04 screws as indicated in Pic 4.

Collect the parts from this stage and fit the battery to the rear of the right rear wheel arch, noting it can only fit in one position Pic 5 and secure it from underneath with a BP04 screw as shown in Pic 6.

Now place the right wheel arch onto the chassis, aligning the holes and posts and press it into place. Pic 7.
Then finally, secure the wheel arch with three BD04 screws as indicated in Pic 8.


Stage Complete Pic 9, carefully store any remaining parts in a stage labelled bag.

delboy271155 attached the following image(s):
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2 Stage 56.JPG
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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






delboy271155
#8 Posted : 13 August 2022 19:35:53

Rank: Super-Elite

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Joined: 09/11/2012
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Location: East midlands
Stage 57

Exhaust

Parts supplied:
Exhaust pipe, Silencer (1), Silencer (2), Battery cable (long), Battery cable (short), Screws BP04. Pic 1

In this final stage of Pack 6 we will add the battery leads to the rear chassis and construct the exhaust (to be fitted in a later stage). A full schematic of this stage can be seen in Pic 2.

Take the long battery lead and insert the ends into the holes in the engine and the battery, noting that the thicker/longer pin end goes into the battery and the smaller end with the disc goes into the chassis as shown. Pic 3

Then place the ends of the short battery cable into the two holes as shown, noting that the thicker/ longer pin again goes into the battery and the smaller pin into the chassis as shown. Pic 4

The next part of the build is to construct the exhaust. Start by inserting the exhaust tail pipe into the holes in silencer 2 as shown in Pic 5 (making sure that the locating pin is in the correct position) and then secure the exhaust pipe from inside the silencer with a BP04 screw as shown in Pic 6.

To finish this stage, insert the two posts on the inside of silencer 2 into the holes in silencer 1 as shown in Pic 7, then secure the two parts of the silencer together with two BP04 screws as shown in Pic 8.

Stage complete Pic 9, carefully store any remaining parts in a stage labelled bag.

Pack 6 is now completed, so see you soon at the start of Pack 7.

delboy271155 attached the following image(s):
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2 Stage 57.JPG
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COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"






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