WCSTA -06- 56 T1

Share progress on your 356 related project or full restoration with others!
Message
Author
User avatar
Harlan Halsey
356 Fan
Posts: 345
Joined: Fri Mar 02, 2012 2:05 pm
Location: No Cal SF Peninsula

Re: WCSTA -06- 56 T1

#46 Post by Harlan Halsey » Tue Jul 09, 2019 5:31 pm

In order to install the races in the front drums I made two race drivers, one for the inner race and one for the outer race. I heated the drums to 325F in my garage oven and put the inner race in first. Then inverted the drum on the driver and installed the outer race. It seemed that the drum didnt grab the outer race until it got down to under 200 degrees. I think this will work for a street car.
IMG_0303 FW Bearing Drivers.jpg
IMG_0303 FW Bearing Drivers.jpg (3.28 MiB) Viewed 396 times
I polished the spindles and installed the seal race using the tool on the right in the above picture. That tool is a bored out race installed in a thick wall tube. I recall that in the old days we used to heat the race and it just slipped on, but this time I chose to just drive it on at RT. That worked OK but some force was required. It turns out that the seal race installer is also the rear bearing installer.

IMG_0300 LF Suspension.jpg
IMG_0300 LF Suspension.jpg (1.97 MiB) Viewed 396 times
IMG_0301 LF Drum Installed.jpg
IMG_0301 LF Drum Installed.jpg (1.74 MiB) Viewed 396 times

Next I polished the rear axle ends and installed the axle tubes. Both the bearings and the drums are tight, the bearings will require the VW tool to remove, and the drums, a puller.
IMG_0302 L Axle Tube.jpg
IMG_0302 L Axle Tube.jpg (1.03 MiB) Viewed 396 times
This is a temporary installation just to make a roller of the car so that I can trailer it home where I will complete the assembly.
The next steps are to install the rear torsion bars and the spring plates, do a rough alignment of the front wheels, and figure out how to get the car down from the rack it is on and onto it's wheels.

User avatar
Harlan Halsey
356 Fan
Posts: 345
Joined: Fri Mar 02, 2012 2:05 pm
Location: No Cal SF Peninsula

Re: WCSTA -06- 56 T1

#47 Post by Harlan Halsey » Thu Jul 18, 2019 10:35 pm

The new KONIs arrived yesterday and a minor mystery is solved.
Since it is nearly 50 years since I bought a set of KONIs I had wanted to see if the currrent offering is still good or if the shocks had been cheapened. The mystery was that none of the usual vendors could answer the simple question: "Are the current KNOIs screwed together and so rebuildable, and modifyable; or are they now crimped together as are most shocks." All you had to do is to extend the shock fully and look...
Not so! KONI has estended the dust shield about 2" so you cannot see the top of the shock tube.
IMG_0306 Old and New Koni.jpg
IMG_0306 Old and New Koni.jpg (2.38 MiB) Viewed 347 times
The black shock is a 1959, probably original to the '59 Carrera. It has a fill port on the side, a feature which didn't sruvive much beyond 1959, but is otherwise identical to 1960s production, except for the black color. ( At some point those black shocks will go back on the car.) The two tools at the bottom are the KONI disassembly tools made by Dean Lyon for Chuck Forge in the 1960s. The top one is a spanner wrench and the bottom one tightens the rod packing.
IMG_0308 KONI Shock Tool.jpg
IMG_0308 KONI Shock Tool.jpg (1.61 MiB) Viewed 347 times
As you can see, those tools wil no longer work unless the new dust shield is shortened. Also, the old KONIs had information stamped into the dust shield. No longer. And the new shock tube is 2mm smaller in diameter than the original. New tooling would be needed to disassemble the new shocks. Originally, the adjust ment range was a little more than two turns, but now it is a little less. However, KONI assures me, via e-mail, that the new version is still of twin tube construction, and rebuildable and modifyable.
IMG_0311 KONI Components.jpg
IMG_0311 KONI Components.jpg (2.48 MiB) Viewed 347 times
The brass filter is another '59 and earlier feature which didn't survive.
I am tempted to take one of these new KONIs apart to see exactly how they are built these days, but right now getting this '59 together is a better use of time.

User avatar
Harlan Halsey
356 Fan
Posts: 345
Joined: Fri Mar 02, 2012 2:05 pm
Location: No Cal SF Peninsula

Re: WCSTA -06- 56 T1

#48 Post by Harlan Halsey » Wed Aug 14, 2019 2:17 am

Major milestone today, I got all four drums on. I struggled with the rubber donuts, apparently they aren't all the same size. some are too big to get the cover on even with 50mm bolts. However the ones from Wofsburg West are slightly loose in the cover. These expand when forced over the spring plate tube and still allow the cover to be put on with the long bolts. I've only cinched the covers down to within about 1/4" of contact because that's all I need for now.

The right axle seemed a little too tight, both the bearing fit and the brake drum, but the left axle had about the right bearing fit and the drum slid on. I'll try switching the drums when I get to final asembly. The left front spindle required polishiing with the Cratex wheel to get the outer bearing on. Once I polished the outer edge of the bearing seat, the bearing went on the way it should. The left went together just right the first time. Never Been Together Before, 50 year old used parts. This sort of thing is to be expected.

I seem to be having trouble with the front wheel seals. I have several spares, but some seem to be just a bit too large to press into the drum. Maybe I have VW seals mixed up with the Porsche ones.

Looks like a couple of days more work over at Bruce's in Bonny Doon and the car will be a roller and i can bring it home. It's an hour and a half theough the Santa Cruze Mountains each way and this cuts down the work time considerably.

User avatar
Vic Skirmants
356 Registry Member
Posts: 7021
Joined: Tue Oct 27, 2009 5:02 pm
Location: SE Michigan

Re: WCSTA -06- 56 T1

#49 Post by Vic Skirmants » Wed Aug 14, 2019 7:58 am

Front wheel seals should be same as VW.

User avatar
Harlan Halsey
356 Fan
Posts: 345
Joined: Fri Mar 02, 2012 2:05 pm
Location: No Cal SF Peninsula

Re: WCSTA -06- 56 T1

#50 Post by Harlan Halsey » Wed Aug 14, 2019 7:31 pm

Vic,
Are the drum brake seals the same as the disk brake?

User avatar
Vic Skirmants
356 Registry Member
Posts: 7021
Joined: Tue Oct 27, 2009 5:02 pm
Location: SE Michigan

Re: WCSTA -06- 56 T1

#51 Post by Vic Skirmants » Thu Aug 15, 2019 8:28 am

Harlan Halsey wrote:
Wed Aug 14, 2019 7:31 pm
Vic,
Are the drum brake seals the same as the disk brake?
Definitely not.

Post Reply