Some notes on reworking the VW generator

To dis-assemble the generator, I loosened the two long bolts that go all the way through the generator, end to end.  I left a full thread engagement into the end cap and I broke the end cap loose buy  tapping the slotted end of the bolts.  This made a nice gap to insert a couple of pry bars in between the end cap and the generator body.  I just tapped on the end of the armature shaft with a bronze hammer until it slid out from the bearing.  I did almost the same thing to the opposite end.

Next, I released the springs that apply pressure to the brushes and I loosened the screw that connects the end cap to the electrical contact in the body and the whole assembly just slid apart.

I removed the two screws that held the bearing into the end cap on the fan end and the cap came right off.  Next I pulled the bearings off the armature shaft using a small puller.  They were not on very tight, they slid right off.

I sprayed all the parts with cleaner and pushed the bearings back on the armature.  I just reversed the disassembly process and it was back together and ready in no time.

I used a piece of 400  grit sandpaper to clean the commutator.  Make sure there are no burs left that can cause excessive ware to the new brushes.
Pay close attention to the brush spring positioning upon reassembly.  The coil spring should be positioned so that pressure is applied to the center top of the brushes.  This applies a nice straight even linear pressure on the brush so it is being pressed against the commutator.  Be sure to check the travel of the brushes to be sure they do not bind.

A couple of notes here, this procedure applies to a generator that was previously working, it just needed the bearings replaced.  The coils were fine and the generator produced power, it just had noisy bearings.

It really isnt possible for a DIYer to repair bad windings. The parts should just be replaced if that is the case.  Used parts are out there, just be sure they are good.

Be sure to polarize the generator before you reinstall it.  To do this, connect a jumper wire from the D- terminal to the ground screw. Connect a +12 volt DC source to the D+ and the D- terminals.  The generator should spin up like a motor.  Only allow this to run for a couple of seconds, that's all you need.  This magnetizes the iron/steel cores between the windings and the hysteresis in the system (trace amounts of magnetism left over in the plates) will allow the generator to produce power.  Generators that have been sitting for long periods of time will eventually loose their trace amounts of magnetism in the plates and will "forget" how to make power.  The polarizing  restores this magnetism and you are off and charging.
Good luck!

Spring Once-Over

First I would like to start out with an apology; it has been far too long since I have posted anything.  No excuses, just too lazy to get it done.  I will try to do better.  I have gone from ready to sell the bus to, I am certainly going to keep it.  I am pretty solid on the keep it decision at this point.  I do have too many projects going, but the bus still holds a special place in my heart.
I don't know why, but the weather this spring has been a gift.  Way too warm, way too early.  While the farmers are in a bad way, it does afford us an opportunity to dig the toys out nice and early. 
After getting the bus out of storage quite early this year, I noticed after driving it a few days that it was leaking a bit of oil.  I had just recently gotten back from a big engine builders show in Lansing Michigan a couple of weeks ago and I was holding a spiffy new electronic ignition module in my hand.  I have a Bosch 009 distributor all reworked ready to put it in and a nice new set of plug wires to go with it.  I also have a set of “J” tubes to install, a new Gene Berg oil pump cover that needs to be installed along with a drill and tap of the block for full flow.  My intent is to have a full flow oil filter system on the bus.  So, out came the engine!

It came out very easily.  It took me about 30 minutes just taking my time.  I mounted the stand adapter to the front end and my neighbor and I lifted it in place.  This is pretty nice; I have never had the luxury of working on an engine up on a stand.  I think it was worth the $40 investment and some welding to make that work.

Another thing that has bothered me about the last time I did this engine is that I had painted all the parts up nice and pretty and when I painted the bus, enough overspray got all over the engine to make it look like is was all hazy.  This removal gave me a chance to repaint all the tin ware as well.

I started in on the oil pump.  As anyone who has ever attempted this on an early bay knows, routing the hoses and fittings from the pump and block past the exhaust, through the cooling tins, past the pulley, around the supports is a major pain in the butt.  I spent the better part of a day and about $50 making this work.  (big drill bits and brass fittings are expensive!)

 

In between working on the plumbing, I sprayed the tin ware and it all had a couple of days to dry over Easter.  I got back at it the next week and while attempting to install the upright cooling shroud, I noticed a small “clunk” in the cooling fan.  After a bit of wiggling and Jiggling, I concluded the generator bearings must be bad.  I knew the generator was working fine, and I could not hear any bearing noise, but that clunk was unmistakable.  So off it came.

Better now than once it is in the bus I guess.  Parts are on order now.
Actually the generator was pretty easy to dis-assemble to get at the bearings.  It will give me a chance to clean the years of dust and crud out as well.  If you ever get a chance to dig into one of these, don’t use a strong petroleum based cleaner to do the job.  The problem is the windings inside the generator are delicate.  They are a series of, seemingly, bare copper wires all wound into nice neat coils.  This copper wire actually has a clearish coating to keep them from making contact (electrically) with each other.  This coating is a form of varnish.  Any solvent that will soften, or otherwise attack varnish is a no-no.  I think the best option is to stick to a spray can of electrical contact and parts cleaner available at most auto parts stores.
It looks like the generator parts will be here before the weekend.  That will be nice, as I would really like to have the engine all back together and put back in the bus this weekend if possible.  Hmmm.  That’s a tall order.

A nice little bus trip

It was my first “real” show of the summer, not because there haven’t been others, but life just kept getting in the way.  On Sunday June 26, in South Haven, MI our local V-Dub-Club held a fund raiser/car show.  The weather could not have been better.  It was in the mid 70’s, low humidity, and a beautiful sunny day with a gentle breeze blowing off the lake.  It just doesn’t get much better than that.

The ride down was made better by the fact that I finally got the stereo/CD player installed and working.  A bit of Jimmy Buffet to set the tone, a hot cup of coffee and a nice ride along the lake Michigan shore was a very pleasant way to spend a Sunday morning.

About 35 cars showed up this year, It seemed a bit lighter than in years past, but a nice group of folks to be sure.  We wandered around, looked at each others cars, and chatted for hours about VW’s, road trips to come, and adventures past, you know, the stuff that seems to happen at all car shows.

As is usually the case, each of these trips affords the opportunity to add several “to-do’s” to the list.  I have discovered that I would really like to lower the front of the bus a couple of inches to make it sit level.  I have a set of Avis adjusters for a link pin beetle, I am sure I can make those work, but it will be a pretty big job.  While I am under there, the ball joints really need to be replaced.  If I just order the ball joints, I bet that will motivate me enough to get going on this.

Show over, door prizes dispersed, things packed up, good-by’s said, and back on the road for home.  About half-way back, Saugatuck, MI, I am lured in by a fresh Michigan strawberries sign.  Strawberry season in Michigan lasts about three weeks,  I couldn’t help myself!  Like I said, A great day.

A nice ride on a nice Spring day!

Just got the itch to take the bus for a ride the other day.  I ended up down at the beach for a quick pic, and an ice cream on the way home.  It feels good to be driving the bus again.

First visit of the season

I got up to the storage garage the other day to visit the bus.  It's starting to get nice out once in a while and it is getting close to car show season.  I wanted to be sure it would start and everything looked good before move back home day.  All was well.  I couldn't resist installing the little piece of "Grill" I bought for the bus this past winter at a show!

New winter project!

As I mentioned a while back, it's time to park the bus for the cold and salty Michigan winter.  I decided it was time to start looking for a new winter project.  My first thought was a rat rod beetle, but I could not find a suitable donor.  I did, However, run across this nice little 67 Beetle that was just begging to be brought back to it's former glory.  I decided to start a new blog for the beetle project.  I will start posting back to the bus blog when I get it out in the Spring.  For now, it's Beetle time.  I hope you enjoy the project as much as I will.

Good times just driving the bus.

I have been having a great time driving the bus and just tinkering with the hundreds of little things that one must do when you own a 40 year old car.  There is always a little clip that needs to be replaced or a seal that needs to be removed and reinstalled, the list never ends.  I have been spending a bit of time working on a hard cover photo book of the bus project.  I found a site that makes this pretty easy to do.  It's called Blurb.  I haven't bought anything from them yet, so I can comment on their quality, or service, however, their software for making the book is pretty good and it's free.  I will be sure to let you know how it comes out.  I thought this would make a nice thing to have sitting in the bus when I take it to shows.
As a part of that project, I needed some pics of the bus in it's finished (current) state.  I headed out to the park and shot a few pics before the weather gets too cold.  Have a look.

Some plans for next summer include a new awning that is a bit more authentic looking than my Walmart pop-up, Maybe a roof rack, I have the front beam adjusters on order so I can lower the front to match the rear, a new stereo, and maybe a new air cleaner and some stainless push rod tubes.  Then it's on to some more shows.  My brother in law and I are talking about making it to Road America this coming June for the big show there.  Sounds like a good time.  Maybe I need a tow dolly or a trailer?