'73 Volkswagen Squareback

[Seanz0rz]

or

"why you dont give z0rz money"

pictures speak for them selves. got a great deal, minimal rust, history of it being purchased in germany, taken on vacation, and brought back as part of the tourist program VW had back in the day. spare set of wheels and front bumper, plus some of the random trim bits

http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2436.jpg
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2422.jpg
http://s103.photobucket.com/albums/m141/hamiltoncomputers/square/

and the 4runner with its new little sister:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2437.jpg

here's a list of needed fixes in a sortof order of importance:
passenger window off track
starter? (whatever it takes to get it running)
parking brake
check and bleed brakes
adjust clutch
fix slop in shifter
ignition switch (currently uses a push button)
leaking frunk seal (not a typo)

stay tuned for updates on how it's ruined my life.

[Obi..]

*At least it's a 12 volt, that's half of the work. :D

As far as ruining your life, well it is all about how you deal with it, FWIW I ended up selling my '68 auto stick, with a blown #3 cylinder, that I had barely $6000 into to a Japanese collector for..












$15,000. No that is not a typo, early numbered and cleaner than even this one! http://www.collectorcarads.com/Volkswagen-Beetle/33031

*I should've kept the black-yellow plate. ;(

[DHC6twinotter]

What's a frunk seal?

I still think that spare tire windshield washer squirter contraption you were telling me about is the coolest thing ever. :hillbill:

[Obi..]

Frunk=Front Trunk. The seal at the front edges goes south and even when new they sometimes still leak/whistle..

Really annonying.

[kregg]

"why you dont give z0rz money"

leaking frunk seal (not a typo)

stay tuned for updates on how it's ruined my life.


I only remember these parts of the post above...
LAWL!

[Seanz0rz]

the seal that goes around the front trunk. i was sitting in the car while it was raining and noticed a drip just right of the tunnel under the dash. this is my assumption of where the drip is coming from. although it could be something to do with the fresh air system.

goal for the car is a daily driver. 4runner is killing me on gas and wear parts. i think i can get this running for a little bit of cash and just enjoy it as it is, fixing it up as i go. the way i figure it is, i dont think i will ever lose money on this vehicle.

[Obi..]

*Thing needs a set of Surf Racks. ;)

[DHC6twinotter]

LOL...that's what I figured. I was thinking "rear trunk", "front hood", "rear hood", etc; but "front trunk" didn't cross my mind. :laugh: The rear hatch seals on the buses seem to wear out too.

[Seanz0rz]

after further reading, im being led to believe that the leak is from the fresh air vents (louvers in the cowl)

friday ill have all the paperwork done and pick up a new starter and charge the battery. this thing needs to get on the road!

[YotaFun]

You sure this thing isn't gonna nickle and dime you as much as the truck?
I feel like mine is, though I finally figured out my trans leak is a mixture of the cooler and the need for a new pan and gasket.

Be interesting to see where you go with it Sean.

[Seanz0rz]

i figure with about 300 bucks i can have it back on the road, from there its just fixing stuff because i want to, not because i need to.

besides, the 4runner is "done" just some loose ends to tie up on it and then i can just maintain it and enjoy it. time for another project vehicle!

[strykersd]

Very nice! My uncle has had one of these sitting in his yard up in Salinas for almost a dozen years, I've often times thought about taking it off of his hands...

[Terracoma]

*I should've kept the black-yellow plate. ;(


I've got a black-plated '68 standard-trans Beetle, but it needs more work than I can give it... :(

Always wanted a Squareback!

[Seanz0rz]

first weekend i got to work on her, got alot done.

my first priority was tackling the passenger window. it had come off the regulator and the PO had messed with it a little bit. to get to it, the door panel had to come off. a few screws and alot of NICE metal clips (they sure dont build them like the used to...):
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2440.jpg

the door panel is pretty shot, lots of water damage from not having a plastic seal. what i found underneath is exactly what i expected, a pretzeled regulator:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2441.jpg

nothing that coulnt be fixed with a hammer, torch and a welder:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2443.jpg

also found that the pin on the end was kind of messed up, so i filed the slot smooth so the clip would operate properly:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2444.jpg

i reinstalled the strip to the bottom of the glass. some soapy water really helped get this accomplished without fear of shattering a 40 year old window in my hand. everything went back in after a thorough coating of grease on the metal on metal parts and a good coating of silicone lube on the window tracks. this was also done to the drivers side, and both work GREAT!!!

while i was working on the door, i removed the exterior handle, as it was broken. unfortunately i cannot fix it and will have to find a replacement:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2442.jpg

after completing that, i set about fixing the emergency brake. that was fairly simple and took just 5 minutes! i now have a parking brake that works!

i took a break from real work and started to sort through the random parts strewn about the frunk. took stock of what was good and what was simply trash.

next was the starter. i knew the battery was completely flat, so i hooked up one i had lying around that was fully charged. i put the key in the ignition and nothing happened. i looked at the back of the key cylinder and found no wiring attached to it. the PO had installed an on/off switch and a momentary switch. this was to start the vehicle, you dont even need the key! (except for the steering lock) but even those didnt work. im fairly sure the problem is purely wiring related. after looking at the hack job from the PO, and the general terribleness of 1960's wiring, especially european wiring...

didnt take any pictures of the process, but here is what it looks like now:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2450.jpg

i most certainly have my work cut out for me. im thinking it is not worth the 200 or so for a main harness replacement. i will order the wire next week and hopefully get started on it in a few weeks, stay tuned!

[Seanz0rz]

so this car has become a bit of a time vampire. (like i knew it would)

here is an update (cross post from thesamba.com)

started on the rewiring of the square on wednesday. here is what i started with:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2477.jpg

left headlight harness half done:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2478.jpg

frunk completely wired:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2479.jpg

right turn/head lights, horn, left turn/head lights:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2480.jpg

through the bulkhead with forward lights, fuel gauge, fuel pump, and brake lights:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2481.jpg

here is my fuse/relay box (ignore the lack of fuses and relays, they are out to be properly wired to my needs):
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2492.jpg
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2493.jpg

and what my dash looks like now:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2494.jpg

my methodology for this is pretty simple. keep brown as a ground, so at the very least that is somewhat OG VW. other than that, im choosing colors that make sense for stuff like headlights. low beams are yellow and orange, high is white and grey. striped wire was too expensive so there are some identical colors in some harnesses, but i try to differentiate with different sizes or twisted pairs.

so the front is done, some of the dash is done. im trying to figure out the best way to wire the headlights. i dont like full current running through the switch, but i know the switch was designed for it. so ive been kind of stalling on that front. most everything is pretty straight forward, just power and ground. im trying to separate out the fuses a little more than stock. i never liked how the fusebox had more than one or two things on each circuit.

all in all its going well. taking today and tomorrow off of working on it, then back to work on tuesday, wednesday, and thursday. trying to get it done and hopefully get the thing started, as i needs to be off the driveway by monday.

[corax]

Hey Sean, forget fixing the outside handle - get a cheap "door pop kit" and shave it off completely. Extra bling and smoother lines unless you're tryiing for a near original resto

BTW, since you're not doing striped wires, I found a cheap label maker works great for marking wires (future reference - if you ever need to go back over something, it'll save your sanity)

[Seanz0rz]

thanks keith! i have a label maker, just need to find it and get some more tape for it! ill have to do that before i do any more work!

i fixed the door handle, bought a used but good one from a guy in the classified and swapped over my lock cylinder. works great! also got a new ignition switch, it also works great, but most of the rest of the wires are toast, hence the rewire. i think i will add electric door locks in the future, along with an alarm system (i just love keyless entry, plus the lock cylinders and key are showing their age, so id like to cut their usage down a bit)

[Bob98SR5]

sean, man you got your work cut out for ya! enjoy reading this so far, reminds me of my rehabing of my mercedes. the wiring scares me though. good luck!

[Seanz0rz]

thanks bob! hopefully i don't have the rust that the 'benz had! how is that project going? i haven't heard anything, though i haven't looked or asked either!

got some work done this past weekend. the fuse box is nearly done being wired. fuses for headlights (4 total), fuel pump, EFI, horn, brake lights, and parking lights are done. Instrument panel, turn signals/hazards, wiper, radio, and security/interior light fuses are left to be wired. i ran out of connectors, so i need to raid the junkyard again! here is the back side of my cut down fuse box with the 4 relays, one for headlights, high beams, fuel pump, and fuel injection each:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2558.jpg

here it is in the stock location:
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2559.jpg
http://i103.photobucket.com/albums/m141/hamiltoncomputers/square/IMG_2560.jpg

those pictures do not show the last two relays, but i did confirm that everything fits with them installed. i will have to make a mounting bracket for it, a cover for the rear and a cover for the front. you will also notice im not soldering my harness directly to the fuse box. i am planning on either putting disconnects or a full on complete plug between them, so the fuse box can be completely removed if necessary.

this weekend im hoping to get the starter in and wired to the ignition, completing the dash wiring this weekend would be my ultimate goal, but i still have some work ahead of me. i think i might go on and do what i can with what i have and continue to wire the rest of the vehicle and save finishing the fuse box (and the dash wiring) until i have all the correct fittings for the fuse box. new battery cables will be going in this weekend for sure, but i am going to wait until i am done with the wiring to get a new battery (i have a spare from my truck i am using to test with.

rear fenders may have to come off to do the wiring of the tail lights (doing my best to avoid this, im thinking i can abandon the wire that is in there and run my new stuff with a fish tape and some luck! the original stuff is clamped in there with steel tabs, so i doubt i'll be able to pull it through with the new stuff attached to the end. that's a question for a different day.

thats all for today folks! that fuse box took me an entire day! hopefully i can pick up the pace soon, id like this running by the end of the month.

also, i've had a few people ask me how i printed out my wiring diagrams on multiple sheets of paper. i use this program discussed here:

http://lifehacker.com/5468489/easy-poster-printer-...d-printers [LifeHacker.com, links to download pages]

[Seanz0rz]

So wow! It has been almost exactly 7 months to the day from the last time I posted in this thread!

The last couple of weeks I cleaned the garage enough to get her in and start working on finishing the wiring. Today, it rained, so it was a great day to toil around in the garage.

First, I cleaned out the square and organized my tools and supplies, and threw away a lot of trash! I looked at the wiring I had done and my notes, and realized I didn’t take enough notes! I’ll have to spend a bit of time and decipher what I had done and take careful notes. I have already relisted all my color codes for things, so that should help. I will be doing a final schematic in Eagle when I am all done.

After looking at the daunting task in the dashboard, I turned to the rear of the car. 6 months ago I ran wires up the passenger D pillar and down the door for the license plate light and for a future 3rd brake light. I started here and added a new ground wire (and cleaned up the grounding spot for a better connection), turn signal wire, brake wire, parking light wire, and reverse wire. I cleaned up the contacts on the housing with a bit of electrical contact cleaner and a qtip, and then applied some dielectric grease to the connections to keep them corrosion free for the foreseeable future.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3052.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3055.jpg

Did the same on the left side:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3057.jpg

I ran the 4 wires in split loom through a hole I drilled and then through the stock hole in the body through to the engine compartment.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3056.jpg

I tested all the wires and they work! I installed my new lenses from ISPWest. Taillights are officially done (except for LED bulbs, but that’s another a topic for another day)!
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3058.jpg

Feels good to work on it again. Tomorrow the plan is to finish all the wiring through the firewall. Under the rear seat will be my splice section, not sure if I’m going to do something like a patch panel here or if I am just going to do a lot of soldering here.

Thanks for reading!

[conigirl]

Ahhh sean you make me feel bad for letting my 73 bug sit outside in the snow....my daughters friend has a 71 standard bug kinda was a project car, so some stuff done....she is off to college and wants to get rid of it.....??? if you know anyone....

[Seanz0rz]

all of my friends think i am absolutely crazy for buying an air cooled vw, so i dont really know any one specifically.

put it up on the classifieds on www.thesamba.com (http://www.thesamba.com) it should go pretty quick if you want to get rid of it.

taking a break for lunch. the engine compartment wiring is nearly done, just a couple of connectors left to crimp.

here is my writeup for today:

Today I set out to finish the engine compartment. Along with the tail light wiring, there are the wires for the ECU, the oil sender, generator, a future tach, and the coil.
All of these wires have to go towards the front of the car:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3060.jpg

Measured, cut, crimped, etc until it was all done, then I pushed it through the firewall and through the cabin. Using a piece of pencil steel really helped get through that no-man’s-land above the transmission.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3061.jpg

Once through, I went inside and pushed the original protective sleeve on to my split loom.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3062.jpg

I neatly finished the connections on the engine:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3063.jpg

Inside the cabin, I have a lot of wires that are a few inches shorter than I had intended. Guess I under estimated the length of wire needed to go from the engine into the cabin. It’s not anything that can’t be fixed, it just puts my splices a little further up than I had wanted.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3064.jpg

Now I have a major question (that I think I will end up answering myself anyway). Back when I wired the fuse box, I ran the feeder directly to the battery (pretty much as I have always done on other vehicles.) but the original wiring schematic calls for it to be pulled from the voltage regulator at the same point where the battery attaches. It appears to me that I am just saving myself some wire doing it this way.

[DHC6twinotter]

Sweeet! Looks good, Sean!

[Seanz0rz]

now that all my projects are done, and most of my finals as well, i can turn back to the vw.

yesterday i got a package:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3068.jpg

from top to bottom, left to right:
3rd Brake Light (new)
License Plate Light (retrofit existing housing)
2 1156 sockets (possible retrofit front housings for markers)
2 front turn
2 front marker (possible)
2 rear turn
2 brake/parking
2 reverse

cost me a bit of money, but i think it will be very much worth it for the current savings and the longevity of the bulbs. plus i think they look darn cool, especially having this older vehicle with a new technology. i am sure this is what VW would have done had they produced the car today. ;)

hopefully some updates of actual work this weekend, hopefully!

[Obi..]

Noooiiiicccceee :D Lemme know if/when it's all done and if you decide to sell it off. I'm still on great terms with a couple oversea's collectors. Sold off my '69 Bug, Autostick, Shaved/Cal-Look, with a deleted dash pad, all with a blown 3rd cylinder for way too much. I showed one of them this and he got all hyper and big eyed drooling. :thumbup:

[Seanz0rz]

So today I decided it was time to tackle the license plate light.

First, I removed the stock lamp assembly.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3070.jpg

Then, I polished up the lens with rubbing compound. A bit of elbow grease and a dremel really made it shine! looks almost new!
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3071.jpg



I then desoldered the connector on the LED strip, and soldered in my 20AWG wires.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3072.jpg

The LED strip I purchased fits perfectly at the back of the lens.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3073.jpg

The strip got silicone into place, with the help of an unused club card:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3074.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3075.jpg

Man is it bright!
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3077.jpg

So that is one task done. soon I'll get to swapping in all the new bulbs and testing those systems. I got my electronic flasher the other day, so now I can complete the turn and hazard circuit. Need to figure out how to mount my 3rd brake light, but that is a job for another day.

Thanks for reading!
-Sean

[Seanz0rz]

I just wanted to write something to the regulars of this site, and to the people that might come across this in a search someday.

people have asked me why I post vintage VW stuff on an offroad Toyota website. I am a member of this community, this family we call UltimateYota. The people that frequent here, I consider them my extended family. Beyond sharing my little project with my family, I am posting these images and words so that maybe someday when someone is working on wiring an offroad vehicle from scratch, they can borrow some ideas from me, and read about my experiences. Maybe someday when someone is restoring an old truck, they will look at some of the methods and materials i have used and be helped by that. Hopefully it inspires someone to get out there and do something, either with an old car, truck, or motorcycle. Whether it be a lowrider or a SCORE truck, we are all members of a much larger community, and we all have things to learn from and teach to each other.

We can talk and WebWheel all day long, but what really matters is going out and doing something. Hopefully these pages will inspire you to do something. Even if it is just mounting a pair of fog lights, you can do it! Don't be afraid to do something, just make sure you do it right!

I have little formal training in the things I do. I never went to school for electrical work (though i have had a few classes AFTER I had figured it all out), I never had any formal welding classes. What I know I learned from other people or the internet and trying, making mistakes, and learning from them. You can too.

If you have any questions about anything I do on this vehicle, please post up! Even if it sounds stupid, I rather you learn than make a simple mistake that will cost you money, or hurt you or someone else, or damage your project.

I really appreciate your interest in my progress on this little car.

[4x4mike]

I just wanted to write something to the regulars of this site, and to the people that might come across this in a search someday.

people have asked me why I post vintage VW stuff on an offroad Toyota website. I am a member of this community, this family we call UltimateYota. The people that frequent here, I consider them my extended family. Beyond sharing my little project with my family, I am posting these images and words so that maybe someday when someone is working on wiring an offroad vehicle from scratch, they can borrow some ideas from me, and read about my experiences. Maybe someday when someone is restoring an old truck, they will look at some of the methods and materials i have used and be helped by that. Hopefully it inspires someone to get out there and do something, either with an old car, truck, or motorcycle. Whether it be a lowrider or a SCORE truck, we are all members of a much larger community, and we all have things to learn from and teach to each other.

We can talk and WebWheel all day long, but what really matters is going out and doing something. Hopefully these pages will inspire you to do something. Even if it is just mounting a pair of fog lights, you can do it! Don't be afraid to do something, just make sure you do it right!

I have little formal training in the things I do. I never went to school for electrical work (though i have had a few classes AFTER I had figured it all out), I never had any formal welding classes. What I know I learned from other people or the internet and trying, making mistakes, and learning from them. You can too.

If you have any questions about anything I do on this vehicle, please post up! Even if it sounds stupid, I rather you learn than make a simple mistake that will cost you money, or hurt you or someone else, or damage your project.

I really appreciate your interest in my progress on this little car.


Why would people care? Heck we have a general vehicle tech section so if anything it belongs. All forums have threads that get way off topic and in the end probably belong in a chit chat spot. Whatever.

Sean, you've got a big project on your hands and I give you 2 thumbs up for your work as it's more than I would want to tackle. Just like Bob's veggie mobile I enjoy reading your progress and have no problem with it.
Wrench on.

[Seanz0rz]

Thanks Mike!

here is the finished assembly:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3078.jpg

and here is it all lit up! she lives! she lives!
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3080.jpg

today i found out that the rear turn signals will require a tiny bit of grinding on the housings to fit, and the reverse bulbs will simply not fit into the housings. the problem is the angle of the head of the bulb. from the top of the socket, it angles out to capture the 30 LED array, but the housing's socket is recessed quite a bit. guess ill have to figure out a way to remedy that. also my plan for the front markers wont work either. i will have to install strips much like i just put into the license plate light.

[4x4mike]

Can you post a picture of the housings? The license plate strips look like Superflux leds which are really cheap and bright. Paddlenbike used them for his footwell lights and runs them at something like 82 ma with a simple circuit. I imaging you only need a couple and you can run them a little brighter and be golden. Superflux are in the mirrors of VW and mercedes and tail lights of the 2nd gen prius, from what I've seen. I bought a box of 20 for a couple of bucks.

[Seanz0rz]

ill grab some tomorrow when i can get a chance to get out there.

i really dont mind buying the boards, since they are soldered and sealed and easy to use, mount, etc. they are also pretty cheap.

[paddlenbike]

I like the LED retrofit. Nice work!

[Seanz0rz]

eventually, the 4Runner will get it too. ive been trying to figure out a way to do the taillights without ripping them open, but ive run out of ideas.

[paddlenbike]

I thought about converting my taillights too but if and when the money ever becomes available I will just buy those 01-02 lights aftermarket lights that already have the LEDs in them.

[Seanz0rz]

here is my update, the led project is on hold for the time being, but i'm getting stuff done on the wiring under the dash now.

looking back at the fuse box, it was a complete mess. i organized it a bit better.

of the 10 circuits, 5 i have put hot from the battery, the other 5 will be IGN switched.

the battery section is fused 30 A, as is the IGN section. with all the LED's and such, it should be plenty for the draw even at max use (wipers, blowers, all lights, etc). the relays for the headlights and high beams are there, you should be able to tell what i did if you look closely at it.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3088.jpg

there will be another fuse box under the rear seat for the EFI ECU, reverse lights, interior lights, and a few other circuits.

i will be cleaning up alot of the under side of the dash, it's a mess. goal is to have the wiring done by the end of the year. we will see how that goes. at least it is in the garage and i dont have to work in the rain.

the turn signal circuit still does not want to work on my desk, maybe the resistance of the long wires will allow it to work, we will see. i know i have it wired right, maybe my flasher is kaput, or my power supply cant crank out enough power (though i doubt that is the cause).

the wipers should wire super easy, most of that wiring is staying, along with the blower.

work continues as long as it rains. more updates to come!

[Obi..]

^FWIW on my last VW build we ended up going to the HD Flasher instead b/c the new wiring has less resistance that the factory german stuff. Grabbed a length and measured the new against the old yet? *This should go without saying, but have you checked the relay's wired correctly and you didn't reverse two of the wires on accident? Basically, with a '73 you're dealing with all the weird crap they were also using in the Super Beetle.

[Seanz0rz]

it is an electronic flasher, not a thermal, so it really shouldnt matter about the resistance, the only thing is with 12" leads versus 12 foot leads maybe that is the problem. i know the circuit is wired correctly (actually cant mess this one up too bad...)

up early today so i can finish up the fuse box today. and i think get the dash wiring all finished.

[Seanz0rz]

Today I got up early (or at least earlier than I have been!) and went to work on it.

First, I tackled the wipers and blower motor, finished up the loose ends in the wiring, and completed the hazard/turn circuit (sans flasher).

"old" fuse box out, sorting all the wires, etc.:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3089.jpg

tucked the fuse box up there, but the wires are still a bit of a mess at this point:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3090.jpg

came out pretty clean. I am strongly considering under dash panels of ABS to finish off the wiring and interior, maybe another day... this is still before I cleaned up all of the wires.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3091.jpg

here it is all cleaned up with just a few little things left to do:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3096.jpg

I then ran my wires under the sill to the rear of the vehicle, these included the brake lights, parking lights, the gen and oil senders, among others. I also ran 4 wires for future projects.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3092.jpg

Reinstalled the sill:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3093.jpg

and connected some of the wires and mostly finished off the voltage regulator.
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3094.jpg


one issue I have is the large (10mm or 3/8") spade terminals on the v.reg. where can I find these? the one or two I had are long gone now (long story, but they were not salvageable in the least), any ideas where I can get them? I've looked around a bit but no luck so far.



so the dash is 98% done. need to attach the grounds and find my lights for the inst panel, speedo, and clock. the brake warning light might get wired up too.

under the rear seat, I still have to wire the EFI and reverse lights, as well as the coil. after that, the wiring is done for the time being. I will be doing full tests on all the circuits individually for shorts, and then test for functionality (do the wipers work, do the turn signals work, do the wipers come on when you hit the brakes, etc)


after that is bleeding brakes, replacing fuel lines, and changing the oil. the shifter needs work as well, and I will be asking questions as I find them.

Thanks for reading as always, and hopefully someone can help me out with that electrical connector!

[Seanz0rz]

I am officially declaring the wiring finished!!!

there are a few things that remain, like wiring a stereo, finding some new bulbs for the gauges, and installing a working flasher.

here is the fuse block and relays under the rear seat:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/Squareback/IMG_3099.jpg

after this, i put the heater muffler back into place, and finally installed it correctly (it was not when i removed it nearly a year ago.)

to come: fuel lines, bleeding brakes, and tons of loose ends to tie up. i have alot of parts in the mail, should be here next week just in time for me to go back to school and have zero free time!

[strykersd]

Sean, how's the Squareback coming along?



Very nice! My uncle has had one of these sitting in his yard up in Salinas for almost a dozen years, I've often times thought about taking it off of his hands...


I'm picking it up Sunday :D

[Seanz0rz]

no time or money. can't even sell it because ill end up losing money on it! some day it will get finished. someday.

[04 Rocko Taco]

I saw this thread bump Sean, and I was really hoping for more tech, but boy, do I understand no time and no money. lol. Keep your head up!!

[Seanz0rz]

i have another project im starting in a couple of weeks (more about that later) that takes major priority over the vw. the vw will get kicked out of the garage and put under a tarp until i can find some time to work on it again. really hate doing that but its a necessary thing for the next 12 months.

[Crinale]

Sean, how much would u have to sell it for to not lose money? just curious.

[Seanz0rz]

ive got 900 in the car, 100 in wiring, and probably 150 in parts ive acquired for it. basically, if i cant get 1100 for it, im losing money. problem is it is further from running than when i got it, a completely untested electrical system that isnt 100% finished is the biggest problem.

[Crinale]

ah. i thought u had already replaced a lot of the wiring? and how much wiring do those engines really need to run? id be surprised if much at all..

[Seanz0rz]

the wiring is 95% done. the starter needs to be hooked up, as well as the reverse lights. the headlights need to be rewired. the gauges need to be illuminated, and the entire harness needs to be tested. i dont know if the engine runs at all, ive never tried to start it.

i have fuel line that is waiting to go in, and some of the rubber for the intake tract. i have collected alot of parts, but just no time to work on it. i still plan on putting in a few days into it, but really cant afford any new parts for it. if i can get it running, i may consider selling it. if it runs well without much other stuff needed, then i will keep it. i love the car, it just comes with alot of needed work and time.