Project Posca January Update #4 (Official Return)

No new photos at this stage, but I am posting an update for very important reasons.  Posca has just had a check up by the mechanic and the mechanic is more than happy.  So, it is official.

 

Posca is back on the road!!

 

Keep an eye out for more updates soon as there are some outings to be had and more work to be done.

The project continues….

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Project Posca January Update #3

Just a half day spent working on Posca  today.

The door windows are now both back in and just need some time for the rubber to settle before the excess is trimmed off.  The door panels are now back on with their new ‘stud’ look.  The new chrome and black window winders are now on too.  I am rather pleased with the way the doors have now turned out.

The carpet is now all but done too, although I need to get to an upholsterer for some sowing before I can install the last two strips of carpet that run under the doors.  Sadly, they are on holidays till Monday so I will try them then and hope they can do it on the spot since it is just to short straight runs of stitching.  Apart from them,  the front carpet is in. (Please excuse the chalk marks on the carpet.  I need to clean them off yet.)

Oh, and I forgot to take pictures, but Posca has two new side mirrors too.  They are the same as the old one on the drivers side, but I now have a new one there and one on the passenger side too.  I shall try and remember to take picture for the next update.

Also, as I promised in the first update for the month, here is my full list of tasks again.  I have updated it to reflect the current status, and I must say, I am amazed at how much of that list that I have accomplished.

 

Full Summary of Tasks (those in blue italics are done.);

  • Rust holes cut out, repaired and painted.
  • Surface rust cleaned up and painted.
  • Replace the back window rubber (as this is where the water got in to cause most of the rust).
  • Replace the heater boxes in the exhaust system.
  • Fix/repair High Beam, Driving Lights and Reversing Lights. (Turns out that Posca has no reversing switch or some wiring yet, so no Reversing Lights yet.)
  • Replace the fuse cradle as it looks a little dodgy.
  • Replace the L/H lower ball joint.
  • Replace R/H inner tie rod end.
  • Replace rear brake cylinders. (Pads were not needed at this time.).
  • Replace pop out window seals, rubbers and latches.
  • Re-key left passenger door lock.
  • Install new sun visors.
  • Repair roof lining.
  • Repair back seat.
  • Clean/renovate the carburettor.
  • Clean/renovate the distributor.
  • Replace hand brake rubber shoe.
  • Give the interior a good clean.
  • Replace front and side window rubbers.
  • Replace missing parts to get the heater system working. (Almost done.)
  • Replace air vents in dash. (Almost…just waiting on some parts.)
  • Repair/replace ducting for front air vents. (Almost…just waiting on some parts.)
  • Repaint the wheels.
  • Repair some small rust issues around luggage lid.
  • Repair/replace/repaint bumpers.
  • Repair/replace engine lid.
  • Put a new (none standard) carby and dizzy on Posca?
  • Repaint parts/all of the body.
  • And a million more as yet unknown ones……..

More to come soon…

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Project Posca January Update #2

Well, another day spent working on Posca.  Not too much to show this time though.  Today was mostly cutting and glueing.  Still,  slowly slowly, and we are getting there.

So, to start with we discovered a little more hidden surface rust under the back window.  We quickly wire brushed it, cleaned it out and the applied the good old 3M Rust deactivator and primer.

Pre cleanup – Deactivator applied

The resprayed glovebox door was fitted and I personally am very pleased with it.  Please excuse the finger prints all over it though.  The whole car will need a good clean once everything is back together though.

With that new bit of rust cleaned up, the underlay and carpet started going in.  It was not quick work, but we have the back done and the back seat back in.  The front it almost done and should be finished tomorrow.

Carpet going in the back – Carpet in – Back seat in

So, we are almost there.  Tomorrow the plan is to finish putting the driver side door windows back together with the new seals and bailey channel, finish fitting the front carpet, fix the door panels with their new ‘studded’ finish, and put two new revision mirrors on.

Stay tuned….

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Project Posca January Update #1

Another couple of months has slipped by with no update. The difference this time is that lots has happened.  Wow, lots has happened.  We are getting there now.  I actually had not realised how much had happened since my last update, but let me recap it all.

New (proper) door rubber seals have been installed.

Old seals – New (proper) seals

I got a new fuel cap as I suspected the old one was not sealing properly and adding to the fuel smell in the luggage compartment.  I may yet need to replace some fuel lines as well, but we shall see.

Old at top – New at bottom

The gear shift shaft was painted matt black and a new “fancy” shift knob added.  The new shift knob has flames and a chrome skull embedded in it.

Old – Painting – New

After much trouble and several failed attempts by an Auto Electrician, I managed to find some instructions on the internet and got the new High Beam Relay working.  In fact it works like a charm now.  As well as that there was a fault in the old fuse cradle that prevented the driving lights working.  A new fuse cradle has solved that problem.

High Beam Relay – Fuse Cradle

The original glove box had already been replaced by a fibreglass one, but the inside of this glove box looked….drap.  So, I painted it a lovely matt black.

Glove Box pre-painting – Painted Glove Box in place

The vent windows are being dismantled and new latches and rubbers fitted.  In the process the scrapers and bailey channels are also being replaced.  We are now one door down (though the rubber between the vent window glass and its frame will need to be trimmed once it settles) and should have the other door done tomorrow.

Dismantled Vent Window – Passenger window back together – New latch and rubber seals

While the inside of the Bug was gutted I cleaned the floor pan up.  3M rust deactivator and primer was was applied to the pan and any other areas of surface rust that I could get to.

The heater cable channels were cleaned out and the new cables were installed, though we have not attached the cables to the heater boxes yet.  New nylon bushes were fitter to the control leavers and the handbrake was adjusted.

I then applied a matt black top coat to most of the inside of the floor in the Bug.  It looks more finished and if the floor pan is ever seen through gaps in the carpet it will be black at least.  We have started installing underlay to deaden and soften things as well as sorting out the jigsaw puzzle that is a carpet kit (this is the underside in the pic…not tha actual colour).  Hopefully the carpet will go in tomorrow as well.

Top shows the matt black floor – fitting the underlay – sorting out the carpet

When I bought Posca the glove box lid was orange like the rest of the bug and had a horrible green writing on it.  It said VW Superbug.  BUT, Posca is from 1970 and so pre-dates the Superbugs.  So naturally, this had to go.  The glove box lid is now matt black and shall be fitted tomorrow.  Likewise, the speakers that were fitted below the dash in the foot well were white.  I think I shall leave their fronts and the brackets white, but the rest of them has also been made matt black.

Sanding the glove box lid – the white speakers – painted glove box lid – painted speakers

I am sure there are other things I have missed as well, but that will do for now.  I will try and update again when the windows are done and the insides are back together.  I might try and look at that long list of things to do again then as well so we can see where we are up to.

Anyway, stay tuned…

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