Gearbox Re-Build

The Gearbox has been something of a trial in itself! The gearbox that came in the van looked to be the correct one, until we started investigating....... Yes, it was a split-case box, but not a full "crash" box, therefore it had a synchromesh. We assumed this was correct because the Split Beetle (when it became the Zwitter) went to a synchromesh gearbox at the same time (roughly sept / oct 1952). However, the Barndoor kept the full 'crash' gearbox till later on than the Beetle. So, bye-bye gearbox out of van!

Firstly finding a correct barndoor gearbox (yes they are different than a Split Beetle) was the biggest headache. Yes they look physically the same, but obviously by running reduction boxes, the differentials are in the opposite way around (otherwise it goes rapidly in reverse). The only visibly way to tell is that the gearbox code will start 2A-******

The first one we found was visibly perfect, until it was cracked open to reveal totally mashed-up innards.

The 2nd one was a Beetle box that visibly was a mess, but inside was like new.

So, Carl set about making one good Barndoor gearbox out of the various ones we had! Here's how we ended up:

Once the case was split, we had it chemically cleaned and then the case halves were blasted using aluminium-oxide blasting grit, then given a light dusting with glass beads. This takes it back to a factory looking fresh finish.

The very early gearboxes have the oil filler nut located to one side - its the bit with the red blob on it in the photo below:

The two red bolts are the drain bolts.

Sold axle boots complete the correct early gearbox. If you're wondering what the red 'blobs' are, its a paint finish that was added to every part that is opened / undone / drained during a service. Therefore the oil drain plugs and oil fill plugs would have left the factory with a blob of red paint of them to help the service mechanic at the dealership with its routine servicing

All we need now is the van back from the paint shop so we can fit it!!!

Work Starts on the Roof Prep

Straight away the boys at Cotswold Body Shop have made a start already on the roof of the van

They even found some of the original Dove Blue paint under the horrible green!

Arrived at Paint Shop

After leaving our premises yesterday, Bam-Bam has a new home for the next few months whilst the body get its final prep and then painted.

Here's the van in its new home:

Hi-Ho, Hi-Ho, Its Off To Paint We Go.......

Finally, that moment has arrived....... since our 52 panel van arrived back from the blasters in May 2011, its not seen light-of-day since. So after over 12 months worth of body work, the day finally arrived when its leaving us once again bound for the paint shop:

Cotswold group body shop wagon arrives at our premises.

With the wagon fully extended and opened up, we're ready to load.

We put the van onto two dollies, so we could wheel it out.

Carefully guiding it out of the warehouse and onto the wagon

With very little effort, the van goes up and onto the wagon.

 With the tail-lift up, we can push the van further into the wagon

Now it can be securely strapped down ready for the journey to the paint shop

All done and ready for the off!

Bye-bye bam-bam. Next time he comes back to our warehouse, he'll be resplendent in his shiney new Dove Blue paint!

And he's gone out of sight......

Pedal Assembly Fit

One last thing to do before the van goes off to the paint shop is to assemble and trial fit the pedal unit. Just in case any of the floor cut-outs are wrong or anything is slightly out of alignment, we can correct it now:

All three pedals are now in place - showing the greatest extent of travel. They are not sitting upright as no cables are yet connected:

With the centre floor plate removed, you can see the pedals more clearly:

Here you can see the pin that the brake and clutch pedals pivot on and also the small bracket that the accelerator pedal pivots on. These are all fixed to the front chassis cross member.

The view from underneath :

Here you can see the grease nipple that provides grease to the pedal assembly.

With all the pedals fitted and working nicely, they can now be removed so the van can go off to paint!

Finishing Touches to Body Work

We're only a few days off the van going to the paint shop, so some minor finishing touches to the body work before it goes off:

The side cargo doors have gone on and we've been making the locking rods for the doors too.

Arrow-straight body work is what we're looking for:

The back end of the van is now all finished and ready for paint

Just some tidying up inside of the van before its off to paint

In approx 7 days, the van will be on its way to Cotswold Group Body shop for its final prep then paint!