Establish NVH on air-cooled Beetle

Rear compartment was face-lifted today on VW 1302 Super Beetle. The insulating board were glued to the fire board with some technic.

Some sheet of plywood was set on the surface pressing evenly and shore bars were applied for the purpose. The glue was vinyl acetate, White Bond for wooden material.

Though covering with wall paper would finish this procedure,I determined to put one more layer of rubber sheet material for the purpose of establishing more silent and calm driving, experimental applicaton of the material had proved the enough effects.

The glue for rubber material is Bond G-17 diluted with organic solvent.

Digesting

The distributors exchanged from 009(centrifugal mechanical advancer only) to BOSCH genuine with vacuum advancer(together with CM advancer). Incredible improvement in driving feel was recomended.

009 would not be used any more on my VW 1302 Super Beetle.

Short and far shift lever was modified to compensate these disadvantages, by 45mm extending shift knob positon and 5mm moving back the shift lever base plate position.

Though shift lever strokes were increased a bit, shifting comforts were obtained.

Hitting mark was observed inside of the rear gate being criminal the tip of the air cleaner intake.

Keeping some clearance between them, counter-clockwise rotation of air cleaner was necessary.

Finally 3mm thickness spacer insertion solved this ploblem.

Microflon(fine grain of Teflon powder) application in the steering gear box was performed yesterday inviting satisfaction results.

Today's task is to make up the rear compartment on Beetle, descriptions later.

Interesting attempt

New parts BOSCH genuine distributor equipped with vacuum advance arrived from Mybows Tokyo yesterday.
Comparing with 009 without vacuum advancer only with centrifugal mechanical advancer, the physical property would be far improved especially the transient from idling to medium motor rotation.
Now with 009 lack of vacuum advancer causes some stumbling and hesitation, though high rotation has no problem.
Descriptions later.

Rear window seal rubber was relined with silicon coking material preventing roof leak and rusted floor was cleaned for the next repairing steps.

Clutch wire was lubricated with splay grease and linkages including pedals also.

Amp meter bracket was re-tightened at the original position on the lower dashboard repairing illumination circuitry.
Without this meter activation the ignition relay does not work,so
in case of failure of this meter with open circuitry shortening application is required to start.

Alternator model has no Amp meter,I must consult the difference between alternator and generator, former is alternative and latter's direct currents promptly.

The arrangement of air vents on rear C pillars inside must be considered,because the number of the plastic parts is 6 instead of actual holes are 8 on earth?

The beige color rubber sheet prepared would play a good part of insulation enough form the rear engine room and from the ground.
The steel sheet utilizing the old washing machine case would be adhered finally to the floor panel with silicon coking material.

Vacation started

The roof leak on rear window shield rubber strips would be repaired today with black silicon sealing material.
This working must be done as soon as possible because the rainy season is coming. The inconvenience to parking outside must be overcome at any rate.

The big hole would be closed with 0,4mm thickness plate from the back cover of washing machine holding tapping screw and transparent silicon sealing material.
Some piece of flooring rubber sheet in beige colored for insulation is prepared and this same rubber material may be utilized for more insulation on floor surface of the cabin is prepared for later working.

Minor parts are come from Tokyo already and genuine Bosch distributor with vacuum advance diaphragm is arriving from Mybows in Tokyo also today.

I'm not satisfied with the function of 009 distributor without vacuum diaphragm advancer because of the dead zone of acceleration that should be much more linear and smooth.
009 is useful but not so comfortable as the combination with vacuum advancer and centrifugal governor mechanical advancer.

The original double vacuum diaphragm distributor would be disassembled and the diaphragm case would be cut and separated in two pieces to replace the diaphragm sheet rubber.
Judging from the outside observation of the diaphragm case, it may be possible to repair the defected rubber parts and re-obtain the original functions, very special functions in specific production period, together with advancing and retarding.

As an experiment, also see what will happen if the retarding function only would be killed, probably in that condition too much advancing angle may be observed?

Thermostat functions must be checked this morning, bi-metal should be in shrunk figure and after that the length would be increased to open the cooling air intake doors mechanically. Even now I feel some hot air flows if I do accelerate manually standing behind Beetle, so actually the doors are activated and opened but on closing function for cold starting stage I'm not sure.

On paper?

There are two ways to throw away the automobile, one is permanent killing and the other is temporally killing.
Though my lovely EP82 TOYOTA Starlet is not in our world, she was killed in temporally way on paper, she has already disassembled in parts, so reported in the Web site by the specific wrecker.
I'm going to Hyogo Land Transport Office in Kobe Ohgi to finish the procedure for permanent killing her on papers.
Otherwise she seems like not go to heaven actually, living with me as long as over 10 years.

NVH in automobile

The big hole at rear carrier portion in VW 1302 Super Beetle gave me a good opportunity to think over so deeply about NVH on automobile, the hole had been created after production for the convenience of air-conditioning room equipments.
So the removal of the air-conditioning system means the necessities for several compensations like closing holes at rear compartment.
Also making hole that's unexpected in the original design destroys the balance as a three dimensional body of steel, so to speak the physical property.
Anyway unfavorable conditions must be improved by applying some same kind of material with screws and silicon grue.
The insulating material is needle fuerte insertion between steel floor and the rubber sheet.
This kind of arrangement for preventing NVH would be successful,so I believe.

Thermostat

Water cooled motor has thermostat for the convenience in warming up scenery to stop cold cooling liquid circulation in the motor water gallery. The cooling liquid in the motor is warmed gradually until around 80 Celsius degree, water thermostat opens to let the outside liquid into the motor and the normal liquid circulation including the radiator starts.
On the other hand how about air-cooled motor like ancient VW Beetle?
Deeper investigations revealed that even air-cooled one has thermostat also that looks having nothing to do with over-cooling!
At the very beginning stage thermostat in air-cooled motor shuts the intake door to invite cooling air from the fan to prevent the over cooling in the first idle stage. After that the heat on the #1 & #4 cylinder expands the bi-metal thermostat, then the doors are opened mechanically.
So the malfunctions on this important device cause over cooling in the first idling when it left opened and over heating when left closed. The thermostat plays a greatest part of motor operations, unmovable truth to be payed attentions more on.
The thermostat in air-cooled motor may be an indispensable and a surprising loophole equipment on earth.

Temp. correction

In the cold morning like today complains Solex 34PICT3 on the fundamental lean fuel mixture setting. Even idling speed adjusting is required otherwise AD motor stops.
On the other hand, most of recent computerized automobile has nothing to do with the circumstantial changing,probably intake air temperature corrections are programmed in their ECU.
As for my VW 1302 Super Beetle, all the sensors are included in the driver? And the adjustments are performed by not mechanical devices but by the driver himself.
Anyway much more richer mixture is required in the cold weather, how shall I arrange the carburetor setting to produce the richer condition?
How about inviting fuel from choke line but under the condition of choke butterfly valve fully opened?
Is it impossible to the situation like this with the series connection of 1,000ohm adjustable resister, rheostat?
The Bi-Metal coil spring to control butterfly has 1,100ohm resister value, so balanced resister value may be found?
Whole circuitry is possible to obtain from Web sites,#12 fuse position with the black wiring is the ignition controlled plus circuitry.


Some backlash in the right knuckle ball joint portion was felt this morning,so check it out,the rumor may be the truth,"1302 strut and steering linkage are weak.".

What's next?

What will come on me after the air-cooled WV Beetle?
This automobile is already locked on by my son and will be taken by him without any argument.
This WV 1302 Super Beetle should be used now to enjoy the communication with pure mechanical device, so the tastes may be different from his.
As for his desire, direct connection between the motor and the axle are necessary to run more quickly than torque converter automatic trans-axle automobile.

I'm afraid that he may destroy this extraordinary living VW 1302 Beetle because of lack of experiences.
This machinery is not to run about faster than another cars but to enjoy the machinery constructions and performances as a gentleman's hobby.
Probably he'll not understand this cardinal rule, because he is too young to know this deeply.

Then I'm at a loss what shall I give him as the first manual trans-axle automobile?

How about BMW 320 Coupe 6 Speed Manual Trans-Axle, though I'll take DSG on the same model without any hesitation?

Trifle adjustments

Application of cotton sheet on the rear parcel and the repositioning of original shift lever again almost satisfied my desired performances on VW 1302 Super Beetle.

By the cotton material application between the spaces remarkably reduced so to speak NVH especially high frequency noise.
0,40mm steel plate and 4mm rubber sheet would be applied there for the upper purpose soon.

The slipping resistance in trunk opener wire was eliminated by grease re-lubrication. The result was apparent no more finger itching labor is required.

As for roof leak, black silicon material would be filled utilizing injection syringe,in all the circle of window shield rubber material on both inner and outer ones.

As an experimental trial, 1,000 ohm rheostat and a toggle switch circuitry would be applied in the automatic choke line in order to know the adequate resister value to prolong the choke activating interval that's enough to warm up AD 1600cc motor.

Recent computerized automobiles must have these kind of compensation programs in their ECU ROM, because many sensors were applied in the system, so I imagine.

Mold smell

As mentioned few days ago, rusted plate was found under the room air-conditioning system. I thought the harmful water had come from the physical thermal interrelations by conditioning, but the rain fall and the naked place showed the origin of rusting water did from the roof leak on rear window shield rubber portions.
Additionally some mold growth were found under the needle fuerte insulator, the strange smell must have come from the mold growing in invisible places in the cabin.
In order to eliminate the old strange smell, the inner layer of the cabin in addition to the carpets must be replaced to restore the automobile perfectly.
Though I'm interested in the mechanical restoring, not so much in outer painting nor interior augmentations.
I'm satisfied about the software to the level at not giving discomfort to the others, because I would deny any meaningless decorations on the automobiles.

Shift lever

The replaced shift lever, HURST for VW Beetle never provides me of good shit feel,so turned I back the original one today.
Original one rises upward straight with shorter lever length for me, the shift base setting position was set most backward. Then the knob position comes backward also.
In spite of such kind of knob position adjustment, still now too far for my driving position about 20mm. So much more adjustment would be tried tomorrow with filing method.

The problem of fuel gauge malfunction was solved with an easy task, just pull and push on the terminal was enough to make the fuel gauge system show correct stylus position.

The rain fall today revealed the roof leak again probably it's from the rear window shield rubber seal, some coking must be performed.

Conquring Solex 34PICT3

As mentioned before, '71 VW Super Beetle has very special distributor with vacuum advancer, vacuum retarder and centrifugal governor mechanical advancer and they are affected each other in addition to the "Smog" Solex 34PICT3 Anti-Pollution lean setting carburetor.
The adjustment on this Smog is far complicated comparing with WEBER 40 DCOE side draft carburetors.

The experiment this morning revealed the fact that the opening the vacuum circuitry for retarding ignition timing originally but now closed for the sake of 009, easily causes motor stopping because of too lean mixture.
So the additional air supply intending to prolong the warming up interval is not enough but necessary to supply fuel together.

The expansion of the choke valve activation must be the first by applying series connected 1/4W rheostat in the automatic choke circuitry.

Additionally the retarding orifice on 34PICT3 carburetor may be utilized to know the mixture ratio precisely by closing and by opening with finger tip actions. This nipple goes to a small hole existing in the position between throttle butterfly and intake port.
Of course some keen sense is required to discern the condition if the mixture is rich or lean, in another words the motor wants which one now, air or fuel?

Fuel gauge malfunction

Fuel gauge shows different level, for example shows half and a bit if fulfilled to the utmost on VW 1302 Super Beetle since beginning.

First of all must I do check the voltage regulator body earthing screw re-tightening with the speedometer body.

2nd replacement of the mechanical regulator into electric one like 7812 three-terminal regulator.

3rd adjusting fuel meter mechanically adjusted, stylus positions promptly.

It's very inconvenient for me not to receive good information on the residual fuel amount.
Deceptions are not effective anymore, if this old VW Beetle is going to be used by my son.

Suffered from AD motor

As it is mentioned as "Smog", the combination Solex 34PICT3 carburetor and 009 distributor only with centrifugal governor advancing mechanism makes me nervous recently.
There must be any impossibility to compensate the lack of linearity of ignition timing advancing curvature by enriching the mixture in the carburetor.

Though some fundamental designing of 34PICT3, lean in the all stages would leave problem if the vacuum advance diaphragm equipped distributor may be invited.
The resister value connecting in choke circuitry with series connection should be adjustable resister, rheostat, in order to fix the adequate after idling time interval, probably less than 680 ohm based on an experimental data. The resister value of coil bimetal in automatic choke module is 1,000 ohm.
The wattage is sum upped in 0,15W, so 1/4W resister is enough.
In case of the failure of this electric trial, mechanical treatment is waiting with solenoid valve application in vacuum circuitry for retarding and advancing the ignition timing.
The parts I'm keeping is for electric switched idle up on air-conditioning purpose not for VW.

Judging from the scheme of the carburetor, another way to make mixture rich may be found, modifying function of the choke diaphragm.
The experiment yesterday applying 680 ohm resister in the automatic choke coil heater with series connection prevented the choke butterfly from opening fully leaving one step on the stopper.
The result in impossible condition made the mixture richer leading to remarkable good motor responses.
Once experienced this kind of comfort driving in my VW 1302 Super Beetle, I'm forced that the AD motor should be so adjusted as to operate in upper condition instead of enduring unpleasant lean and flattening performances.

Wreck removed

The wreck of air-conditioner in the cabin of VW1302 Super Beetle was removed thoroughly today leaving big hole on the rusted rear foor.

The construction of the cooling device for setting in the cabin had reasonably two blower fans, one for condenser and another for evaporator.

The weight as heavy as 20kg surprised me so much, because I though it may be about 10kg

It goes without writing that the improvement of steering reactions in relations with rear axle response.

I remembered the saying, "Weight saving on automobile is the most secure tuning up method.".

The lack of warming up interval by the automatic choke system obliged me some experiment, applying 680 ohm resister setting in the heating module wiring serise connection.

The value of 680 ohm made the module action impossible to open the butterfly at fully opened position and the choke diaphragm had been kept in action leading to operation under a bit richer mixture condition.

As the almost of all informations say, richer mixture driving brought so smooth rotation of the AD motor.

The diaphragm for the additional fuel in first idle stage may be possible to control the air/fuel ratio mechanically to seek the best mixture condition on actual driving test running.

There is another way to overcome the lack of warming up ater the first idle stage, utilizing the nipple for distributor vaccum advance and vacuum retarding, I may make bypass air circuitry including solenoid valve on the way, as the parts is prepared already, I can go any time I want.

Unfavorable condition

Internet surfing these days let me know my missing of important points,intake leak on the connecting portions,intake manifold and the parts for intake port.
The material is hard rubber combined with some bands and the purpose for this rubber parts is the measures for the length compensation caused by thermal cycles.

The chemistry between 009 ignitions distributor and Lucas ignition coil must be re-checked, because not a little electric parts were replaced at once?
Though my body condition is not so favorable this morning as to do any work, I'll bring Beetle to my working pit and relatively light servicing would be performed today.

For tomorrow

Today VW 1302 Super Beetle did not move, Opel B-Vectra was used to move to working place, because of my right side knee pain since yesterday. I've realized that I have completely no complaint on this automobile if I would extend the the life interval more ten years from now.
Following tasks would be digested tomorrow if I would be in good body condition.

The original distributor equipped double diaphragms in '71 VW 1302 Super Beetle would be disassembled and diaphragm also be opened to know the functions.
Prior testing revealed the rubber diaphragm themselves has broken already probably because of perforation.
And the adequate resistance value to prolong the interval of choking interval would be decided with some rheostat.
The air volume adjusting screw would be done for the first time seeking for the better(richer) mixture condition on Solex 34PICT3 smog carburetor.

Right knee aches

Knee joint dysfunction on the right side have I today, swelling, redness and pain when standing up and sit down, probably this kind of seasonal disease is brought by the imbalance of electrolyte fluid in connective and muscle tissues. 2 or 3 days later would I recover myself as usual, being not because of age but because of genetic disease, for since young hood I had this seasonal chronic disease.
Judging from the clinical symptoms, this disease has not anything with the newly invited automobile, VW 1302 Super Beetle with no power assist, steering, brake and window, completely no power supports.
With the method to activate the body fluid circulation adequately, I could recover my health condition more quickly, by stimulating the Erector Spinae on both side.

Further adjustment

Now my VW 1302 Super Beetle has passed The Legal Inspection for License and obtained the capability to go on the high way road.
But I feel some inconvenience on the AD motor operations mainly on the 34PICT3 carburetor and retarding diaphragm equipped vacuum advance system on the specially designed distributor based on the concept for the anti-pollution.
Problem is caused on the first idle stage as the motor stopping tendency in relations with too short activated interval on choke system or too lean idle mixture.
Acceleration hesitations is seen sometimes as is notified in the web sites.
I'm considering about the operation of original distributor by cutting the diaphragm module in two pieces and repair the defected diaphragm with some adequate thin rubber material?
Or buy newly the distributor with a single vacuum diaphragm(no retarding but advancing only).

Insulating noises from the ground and engine room, good rubber material I'm keeping was remembered, wrecks of working place floor rubber with beige color, enough thickness and weight has it.
The combination use of this material with needle Fuerte effects of insulation would be obtained.

Stop wishful announcements!

Nose bleeding has increased in number at Kanto Area among the young generation especially the children, what invited the results like these phenomena on earth?
Dose measuring devices even made in Peoples Republic of China have already sold out.
The families of Government officials have already escaped from Tokyo.
Children and young women should get out there immediately now!
Announcement by the spokesman does not tell the truth, because of the responsibility to prevent the riots by panic.

Mixture control

Thanks to the efforts on driver's door hinge adjustment a few days ago, roof leak has disappeared, ill-setting up, upper hinge too much outside must have brought the phenomena from the beginning 40 years ago.
Now the right door is in good condition including rocking construction repaired on last Saturday.
Motor stopping tendency while idling after the first idle stage suggests me to adjust the Solex 34PICT3 carburetor on the mixture, though very precise adjustment technology is required on the way.
Anyway I feel some lean tendency at all stage, no fuel smell is discerned in exhaust gas.
Some considerable change must be carried out if the air-volume adjusting screw may be turned in intending richer mixture.
Initial position of the screws,bypass and volume must be remembered prior to the further adjustment, otherwise I'll be at a loss in case of some confusion.

Enough capability

High way test driving with '71 VW 1302 Super Beetle yesterday revealed the enough and capable performances as a nowadays commuter.
Actually the axle designs are not changed since 1970s even now, so the precisely adjusted Super Beetle in axle geometries and wheel alignments has enough capability to go without any concerns.

The hole after the removal of the stay pillar supporting air-conditioner compressor was closed. This treatment was performed with the intention of prevention of hot air flowing into the room.

Transparently fine today

Just seeing through method for toe-in checking yesterday brought 3mm toe-out, so today frontal axle was precisely adjusted at 1mm toe-in.

The replacement of left lower arm inner hinge bush in normal condition revealed the wheel base adjusting last time was not necessary, because the adjusted value 3mm shortening was the same error value today, so the rear trailing arm length was re-set again as in the original constructive geometry.

As for rear splash guard, I don't want to wear unnecessary decorative vintage additional parts, so I made up my mind to remove them thoroughly.

Around noon departed I for test driving to Tamba City and the way back was the high way, Maizuru Auto Road to Takaraduka, having a lunch time on the way at Akamatsu Service Area.
The test driving proved the steering reaction is almost perfect based on the wheel alignment adjustment performed before noon prior to the testing.

Though the generation of the VW 1302 Super Beetle had the manufacturer's datum with positive camber setting, the test driving today proved that the Negative front camber setting is acceptable in geometric construction of 1302 strut system, no problem it's OK!

Trifles but important

The height of rear splash guard on both side would be adjusted to higher position to prevent some hitting on a bollard,otherwise they will fall down sooner or later.

I just worry about the big hall at the back of rear seat after the removal of the wreck, air-conditioner cabin devices, condenser, blower fan, evaporator and wiring with switches.
Anyway the hole must be compensated with some board considering physical property, noise from engine room and ground.

It will take more time to satisfy my intentions on this VW 1302 Super Beetle,so my contributions to the old automobile will continue for the time being.

Camber correction

Deeper consideration on the application of frontal cambers of VW 1302 Super Beetle led me the conclusion that the value should be more smaller than the datum of recent automobiles, because of lack of power assist on the steering box.
Though the frontal caster angles are fixed at 2 degree and 30 minutes, they are less values considering that the drive train does not exist in the frontal axle. This must be the design on the steering construction without any power assists.
So the value of frontal cambers were set at minus 20 minutes on both sides. Toe-in would be scaled and adjusted more precisely tomorrow and after the removal of the wrecks of air-conditioner, rear wheel alignments would be corrected.

The ignition coil was replaced as a periodical replacement parts into Lucas Golden Coil with a little bit longer shape, first side resister value is set at 7 ohms for the sake of mechanical contact point construction.
AD motor became more vigorous than before again.

Sakura season

Nakayama Sakuradai Park in Hyogo prefecture commands a fine view of Osaka Plane, especially Osaka Itami Airport in this Sakura season.
Famous Osaka Mint pass through Yaezakura Watching Fair is now open.

The ignition coil in VW 1302 Super Beetle's engine room would be replaced into Lucas one for point contact-breaking system this afternoon in addition to the frontal wheel alignment after strut construction disassembling for shock absorbers replacements.


The alignment datum would be referred to those of original 1302, Porche 911 at the same generation and SXE-10 TOYOTA Altezza.
Rear alignments, cambers, total toe and thrust angle would be performed tomorrow.
Consulting the Data sheet on VW 1302S Super Beetle,
positive camber 80-100 minutes,
Toe-in 1,8 to 5,4mm with caster angle 2 degree plus 30 minutes for the front axle.
Toe-in 0 plus minus 15 minutes with minus 60minutes plus minus 40 minutes for the rear axle.

As for my ideal values for my VW 1302 Super Beetle, frontal camber would be applied minus 30 to 40 (negative) with the toe-in 2mm for the front, 60minutes negative cambers with 2mm total toe accomplishing thrust angle 0 degree.

AD motor is in good performance condition after the replacement of distributor into 009 with BTDC 28/3000rpm.

Tension spring

Critical disorder happened on driver's door, sometime fails to lock firmly? As imagined a small coil tension spring that plays a part of engaging the notch with latch in the door striker mechanical construction.
Going without writing, whole disassembling of construction was required and it took me all day long to re-assemble them in original condition, especially some deeper consideration was necessary on mechanical security equipment's reconstruction.

Both torn diaphragms inside of the module, advancing and retarding on original distributor in VW 1302 Super Beetle, central lesion of chronic disease as "Smog", obliged me to replace distributor itself into 009.
Prior calculation on diameter of crank pulley 178mm, the angle positions on BTDC 10 and BTDC 28 were marked on the outer surface of the pulley.
Main adjustment was set at BTDC 28 on 3,000rpm resulting the angle on idling rotation at BTDC 8.
All the performances were satisfactorily far improved like some different motor.
I had realized that the lack of one centrifugal governor tension spring may be some intentional consideration by the manufacturer?

Wreck

Wrecks of air conditioning system in the cabin would be removed today, blower fan, condenser, evaporator and switches with wiring in VW 1302 Super Beetle.

In relation with the replacement of 4 shock absorbers, wheel alignment must be checked and adjusted because of the influences of disassembling strut construction leading to the new geometric construction.

Adjusted backlash on steering gear box provides good results, knocking noise disappeared and dead zone in centric steering position is not discerned.

Adjusted right door hinges upper and lower brought a good result in both the functions and the shutting noise, but the action on door striker fails in some moment, additional striker catching adjustment is necessary. Probably this result was caused by newly deformed rubber weather strips around the door sash.

Plastic insert

The heater lever just beside the hand brake lever doesn't work well on VW 1302 Super Beetle, easily returns to original closed position because of loss of adequate slipping resistance.
Careful checking revealed the fundamental reason was destruction of engineering plastic insert producing slipping resistance to keep the lever at the desired position connected with the door in heat exchanger in the rear muffler.
Similar alternative material of polyacetal plastic with 2,5mm thickness was found, the result would be a later description.

As I guess counterclockwise rotation of automatic choke module could prolong the interval of choke effect preventing idle stop because of lack of warming up by choke device.
The lettering Solex should be parallel to the ground is the matched position in the atmospheric condition these days.
At lunch break time the heater lever plastic was inserted with alternative engineering plastic material resulting in good success.
Though the inconveniences in the Super Beetle are reduced one by one and day by day, comfort while driving would not reach to the revel of those with the automobile nowadays.

Formidable

I'm now setting Solex 34PICT3 carburetor on VW 1302 Super Beetle these days.
According to the information in the Web sites on the carburetor, '71 was the most struggle period because of Exhaust gas regulation for emission control, most confusing time.
Ignition retarding idling system with double diaphragm vacuum advancer, basically lean jets setting smog carburetor with accelerating pump 34PICT3 was adopted.
Displacement of 1600cc and dual intake ports were introduced in AD motor.

Sampling some datum while actual running test on ignition timing, then the results can be pasted into the specially adjustable distributor,such kind of devices are in the Web site market.

Because of upper reasons I feel it a formidable opponent to adjust the AD motor in the highest balanced condition, I'll do that and be sure to overcome!

Not to think over to find the reasons not to do, but to seek over the ways to conquer the difficulty, this is my way.

Emigration?

Japanese Government has recommended today the rate of contamination by the 3/11 accident on Nuclear Power Plant at Level 7 at last, that's the same rate as the miserable Chornobil Accident in 1986.
From their standing point of view, they were informed by US on the rate of the Nuclear Accident, how much severe that was from the beginning, no matter how Japanese Government had recognized actually or not. Some rumor says US helping proposal was refused at the beginning?
But Japanese Government has no experience on this kind of disaster, just laymen or mob?
Probably, this is the last chance to tell the public the Truth, don't miss the good opportunity, now is the time, so advised by US?
It was a good choice for foreigners to escape from Japan at very early stage.
Living in South Eastern portion as I am, may be better to escape to another country, because Japan land and the thing there must be contaminated with any harmful Radiation Materials sooner or later?

Unstable idling

AD motor on VW 1302 Super Beetle has some tendency to stop after first idle mechanism being over for about 5 minutes, but later the functions are no problem OK?

Now the double diaphragm vacuum advancer is alive but retarder one is killed with BTDC 8 degree at #1 ignition timing, may be too much advanced?

Choke module finishes it's duty too quickly before warming up is not finished, in condition that the motor oil inside has much viscosity in cold temperature?

Too much carbon on ignition plug terminal caused by too rich fuel operation by choke phase?

I've some idea to overcome this inconvenience that the additional air circuitry with electric solenoid valve is applied between the vacuum nipples retarding and advancing ones for the purpose of idle speed up bypassing circuitry. The idle up valve by DENSO is utilized for air-conditioner operation, good idea, no?
Or another way to extend the working interval of choke valve, how about applying some adequate value resister in series in the electric circuitry. In another words, insertion of voltage divider in the circuitry to prolong the choke bimetal resistance spring effect. Of course an adequate value must be experimented and the suitable wattage also.

Because of too high idling, bypass screw was 120 degree tightened after the driving this morning.
By touching with finger on mechanical fuel pump and the metal pipe in fuel line proved that the percolation had not happened.

Solex 34PICT3 carburetor equipped Beetle let me know how precisely and perfectly the recent automobiles are electrically controlled on earth.

Countermeasure

The heater flap lever easily returns to inhibited position, though additional tightening were performed few days ago, finding out the breakage of engineering plastic spacer to keep the lever rotational resistance.
I must hold the heater lever connected with heater exchanger flap must be kept in the opened position manually in these cold weather.
I'm going to make the alternative with some engineering plastic material with a physical property of viscoelasticity, how about polyacetal Resin material plate?

The ignition timing set now is too early, BTDC 8 degree. The special distributor equipped in my '71 VW 1302 Super Beetle has two vacuum diaphragms, one is for ordinal advancing and another is for retarding intending emission gas control. There must be some confusions in vacuum advancing mechanism in combination with retarding system. So just killing retarding and applying BTDC 7,5 degree ignition timing may cause too early ignitions especially in acceleration phase, because the value BTDC 7,5 degree is only for the distributor with single diaphragm(advancing only).
Deeper investigation and actual experiments are necessary for sampling on this point for the modifications applied now are all reversible.

The mission for overheating phenomena must be performed on coming Thursday, also noise from the rear seat back modified because of Air-conditioner burdening.

12 hours work

Replacement of frontal shock absorbers in addition to rears yesterday acquired satisfactorily performances on VW 1302 Super Beetle.
A piece of newly replace ball joint boot had some crack, so it was replaced on steering linkage.

Anyway precise wheel alignments would be necessary, if once the strut constructions were disassembled on earth,
It took me all day long from 7 AM to 7 PM until my energy was completely ruined.

Right side door hinge adjustment was performed also resulting the good shutting sound, but main purpose of adjustment is not the sound but the rain water leakage.
Steering gear box backlash was adjusted in condition with cutting off the further connections to know the very gentle slipping resistance precisely.

Thanks to the weight reduction by air-conditioner compressor removal the hip-down profile became better, side steps are almost parallel to the ground.
Unnecessary additives, fog & spot lumps were removed thoroughly, now far better clean face she has.

About over heating prevention, rubber lips replaced but not been adjusted in good position must be done, because I think some heated air must have been inviting fuel percolation leading to unstable idling.

To be overcome

Hesitated energy consuming muscle working, replacement of frontal shock absorbers on both side and frontal lower arm hinge bush re-insertion would be performed today. Indispensable replacement parts with attendance of 2 pin locked nuts, 10 of split pins were prepared yesterday.
Now no barrier is found to prevent the next step except my low back pain. It would take time all day long today.

As previously described the roof leak that I abhor must be removed at any rate. A door weather strips fitting is the most suspicious one, so door hinge must be loosened, be adjusted and be re-tightened, some striker catch re-positioning may be required again. Anyway precise adjustment must be done on the door hinges and the striker catching.

Inner device of an air conditioning system must be removed, condenser, evaporator and switches with wiring.
Then some big hole would be found behind the rear seat that had been done with the establishment of air conditioning system.

Because I'm occupied by VW Beetle these days, Opel B-Vectra is not maintained left undone for long time except engine oil treatment with Microflon.

Secondary air hose replacement.

Replacement of pulleys, timing belt tensioner and timing belt.

X-20 Head cover re-sealing because of oil leakage.

Without any arguments working on any automobiles I'm keeping are waiting for me continuously, so I've no time to put myself in the condition of doing nothing and relaxing.

Sometimes I make careless mistakes recently, how come?
Lack of concentration or too much fatigue makes me impossible to do so? Or just because of age?
Bare in my mind that never make "Irreversible Mistake".

Ignition timing

Following the suggestion by SHELMS representative that the ignition timing is too late, killed I the retarding vacuum circuitry and applied 8 degree BTDC at #1 ignition timing instead of ATDC 5 degree.
As the result great improvement was recommended and I turn back what was the retarding double diaphragm vacuum system, not a single advantage was found except better emission control.

Ugly rectangular fog lamp and driving spot lamp were removed to set them back on another position, but deeper consideration on my style to use this VW 1302 Super Beetle led me to the conclusion that remove away them and no return.
Without any added decorations, looks far better than strange modifications, Beetle's frontal mask.

The door striker catch position was so adjusted as to close without any resistance.

Finding out the rusting on the driver's carpet and the rain yesterday proved the fact of rain water leaking into the cabin on driver's seat portion. Probably door hinge adjustment to establish the fitting of weather strips to body sash would solve this problem.

Recovery

Thanks to the best transactions by SHELMS VW Shop in Ibaragi City, I could compensate the lost two wheel bolt parts last night.

I'm interested in Karman Ghia Type 34 model exhibited in front of the shop for relatively long time, with price tag at 1250,000 yen.
I might buy it if the price comes down to 750,000 yen at all?
Because VW 1302 Super Beetle, almost finishing restoring might be taken by my son as SUBARU B4 BLE 3L 6 cylinder model had been done so.
As a next job is it suitable for me?

2 wheel bolts lost

Two pieces of wheel bolts were lost on the way because of the stupid error to have forgotten the additional tightening at the standard torque yesterday after the pit works on VW 1302 Super Beetle.
This kind of error must be compensated as soon as possible, so the stock of the wheel bolts were ascertained to "HELMS VW shop" at Ibaragi city in Osaka, and I'm sure to drop in there for the genuine parts after work this evening.

The experience this morning revealed the necessity to keep the wheel bolts or nuts at least 2 pieces in the automobile, because the holding on two or three portion of the wheel with emergency parts makes it capable to move to some safe and workable pit.

The adjusted angle position of automatic choke module in 34PICT3 carburetor of VW 1302 Super Beetle shows insufficient performance. The manufacture's standard marking position shows the lack of warming up interval, so idling stop phenomena lasts for a few minutes, after that it's OK no problem.

I should give more longer warming up interval at any rate by adjusting the module angle position. I knew by the actual experiments that the choke butterfly doesn't fully closed if adjusted on the standard punching mark. Most closest angle position is marked by myself, the suitable setting position must be between them.
The datum sampling by actual starting everyday use would determine the adequate position of the automatic choke module.

How to Mechanical WEBER?

I describe how to adjust idle screws on WEBER 40 DCOM carburetors at the level of passing the Legal Inspection Tests.

Closest butterfly positions are evenly set firmly.

Open(or close) the throttle valve stopper screw to the position of obtaining 2,200 rpm to continue rotation without idle splaying only with middle speed nozzle splay.

Close all the idle adjusting screws to the closest position, open the throttle valve stopper to keep the 2,200 rpm middle rotating speed if necessary.

Open the idle adjusting screw 1 1/2 to 2 rotation with counter clockwise until the rotation would gain, then the screw position should be marked and closed.

These steps are repeated on the number of cylinders and the opening position of idle adjusting screws are marked promptly.

These marked positions are the indispensable initial standard ones to be relied upon for later gas adjustments.

These original setting positions are utilized for the Legal Inspections and the 0,5mm opened position on screw outer circular surface is the best set position.

No overheating nor rough idling phenomena would be left far away as a ancient memory.

This description is based on individual experiences, so any questions will do, acceptable for friends.

Careless mistake!

I've experienced wheel bolts loosening while running twice, once on Opel B-Vectra and this morning on VW Beetle.
Both of two accident were caused by my careless and primitive mistakes, just checking the tightening of them after servicing, hating myself now, too old to do?

Again remember here, "Pointing check with finger after any work.".

I've determined to make it a rule to tighten the wheel bolt to the final step with torque setting with special tool, never leave on the way the tightening wheel bolts work, if the wheel were set on the axles.

I'm afraid of the tentacles to reach VW 1302 Super Beetle, with his eyes half opened watching an old but good automobile?
Last night he called me up in bed noticing about that.

About the module rotating position, the requirement are enough warming up interval at any atmospheric temperature and the least smoldering on ignition plugs while the auto choke module is activated by electric coil bi-metal spring. Seeking the best angle position must be checked based on this theory.

As for low back pain, this disease may continue so long as I insist on manual trans-axle automobile, but remember here,some experience sweeps over my cortex storage, yes, manual trans-axle but with no clutch pedal, DSG!

Burn out today

Like appendicitis the residual supporting arm tightened together with #3 exhaust header flange was removed with not a little efforts. The ignition coil that had been implanted on the right side of fun shroud for the sake of air conditioner's compressor's space occupation was repositioned at the original place. As the favorable result, central ignition high tension code length has been shortened with 1/3 length, AD motor acceleration response has been far improved.

34PICT3 carburetor was disassembled on upper half body with the intention that the sticking choke valve center shaft adjustment.
As I imagined previously, distorted center shaft had some shinny spots causing frictional resistance leading to stick phenomena.
Frictional resistance of choke valve shaft was thoroughly removed after hand filing adjustment by myself.

Fuel gauge accuracy was checked and adjusted by bending the float arms(hi and low two arms inside), matching with fuel meter was improved.

Rear shock absorbers have replace as periodical replacement parts, as a natural result steering response and stability increased.
I'm looking forward to replacing the frontal shock absorbers with some expectations to improve the performances in every directions.

Mechanical carburetors

Setting the automatic choke module at adequate angled position on 34PICT3 carburetor of VW 1302 Super Beetle, AD motor has acquired normal performances with satisfactory. I knew how much the choke system affected even after the engine warm up.

Remembering the similar experience on WEBER side draft 40 DCOM carburetor adjustments on Talbot PEUGEOT 205 Rallye 30 years ago. The idle adjustments were the keys to carry out the task on 4 positions, twin carburetor with 4 throttles independently on 4 cylinders promptly. I did it by myself without any vacuum gauges nor special tools for WEBER to the revel at passing the Legal Inspection for the regular continuous survey line(not private but regular one).

Though any precise descriptions were not found on WEBER side draft carburetors even in the professional field including Web sites, I could find out the way by myself to understand the constructions of 40 DCOM carburetor thoroughly with desperate efforts.

The determination of initial position of idle adjust screws promptly is the key to success and to establish the adjustment on earth, so any numbers of cylinders are available.

Now I realize how much easier on single carburetor system on Beetle's 34PICT3 to do those procedures is with the comparisons.

Automatic choke system?

Automatic choke system in 34PICT3 of VW 1302 Super Beetle works unfavorably on earth, how ever precisely I may adjust the tightening torques on the choke module holder. Also I realized the function of this trifle parts is playing a great part of driving comfort.

At the final stage, some rotational friction resistance exists preventing the choke valve return the final position, so the phenomena must affecting the A/F ratio resulting too rich mixture condition.

Though the function of choke system is not well understood, this friction resistance may have something to do with wax pellet heating construction?
Anyway I'll disassemble the auto choke system tomorrow for attaining perfect function of this Solex carburetor.

Coming across to the Web site introducing the way how to set up the automatic choke system on Solex 34PICT3 carburetor.
There exit some certain position to be adjusted with marking on the carburetor body and the round ceramic part.
Also this adjustment and setting are the key to obtain good mixture while the first idling start.

Coming across to the Web site introducing the way how to set up the automatic choke system on Solex 34PICT3 carburetor.
There exit some certain position to be adjusted with marking on the carburetor body and the round ceramic part.
Also these adjustment and setting are the keys to obtain good mixture for the first idling start.

Unusually cold

Considering the date of beginning April, incredibly cold weathers are lasting these days, being inconvenient for many refugees in Touhoku area especially for elderly and wounded patients.
Cherry blossoms are blooming on the way at a half course, it'll get warmer in a few days.

Automatic choke system in Solex 34PICT3 of VW 1302 Super Beetle does not work well requiring finger action helps at the first idle stage and after warming up guiding to fully opened position.
The choke module holding 3 bolts tightening torque applications are the key to the smooth actions, because uneven tightening torque would invite the distortion of valve moving center. The rotating movement does not go well by the factor of frictional resistances. Probably precise adjustment is necessary for tightening 3 bolts there.

The unusual ignition timing introduced since 1971 on the distributer, ATDC 5 degree might have been invited because of very simple idea that the overlap of exhaust valve is 5 degree on the cam shaft design. Are there any communications each other?

As the informations are shown in You Tube on the ignition timing advance,both of vacum and centrifugal and interactions and over lapping in actions, I've some confidence to overcome about this kind of difficulties, also additional parts famous 009 distributor is prepared for the coming experiments.

I have the over 40 years experience to set the 2 cycled 10cc motor in combination with tuned pipes.

I might have some instinctive soul and sense to seek the best combustive performances on internal combustion engines.

1600cc low compression flat 4 OHV motor is not so high barrier as not to jump over myself, with all the tremendous number of informations in the Web sites served by the kind former researchers.

All day long

The heavy,useless and space occupying huge air-conditioner compressor had already been unburdened on last Thursday as mentioned, doubled crank pulley for compressor was removed, belt tension was also sim adjusted at the same time.
As the heavy weights removal on the rear over hung, the rear height increased about 5mm up.

Third party(probably) main muffler was fitting adjusted and fixed firmly requiring 5 hours for precise adjustment.

The spark plugs were replaced from Bosch platinum to ordinal NGK H5SH finding out on the way that #4 plug was not tightened enough inviting gas leaking. The plug gaps for new replacement were adjusted precisely at the value, 0,700mm going without writing.

The spark ignition coil must be repositioned at original place that was displaced into right side on the shroud because of compressor burdening. The high tension center code would reduce the length as the original design, the progress of ignition performance would be desired.

Though the compressor and supporting constructions were removed, the condenser in the cabin and evaporator with hosing and wiring are not removed.

Retarding ignition timing 5 degree ATDC causes rough idling and unstable,so any adjustments of modifying of the distributor system must be invited to keep comfortable VW Beetle driving.

Also stick tendency on automatic choke system must be checked by disassembling the system.
Several inconveniences are left as residual tasks to be continued.

Doubled crank pulley

Additional pulley is with double superimposing on the crank pulley that looks like heavy iron burdening for ill some motor performance.

The first task on the motor would be the removing unnecessary heavy pulley for air conditioner's compressor driving, now over 10kg weight compressor has been already removed so the pulley for driving belt combined with crank pulley should be removed without any arguments.

Actually heavy weight would prevent smooth and quick reactions, so for the purpose of quick AD motor reaction, the light weight with aluminum alloy crank pulley is prevailing by the third parties.

Anyway things unnecessary must be removed and manual trans-axle would be of help to re-tightening the crank center bolt.

Mounts

The mounts supporting heavy mechanical components must have lost their initial physical properties, deformability, movability and adequate viscoelasticity for long time interval over 40 years.

Continuous stress to one direction because of the heavy weight must have enough capability to invite permanent distortions on rubber engine and trans-axle mounts in VW 1302 Super Beetle.
The periodical replacement parts like upper description must be replaced if the parts are already obtained.

The task like these parts replacements are so troublesome and energy consuming ones as to making me hesitate to get into the world.
I'll decide about it tomorrow, depending on my healthy condition.

Tempts

Only 4 big bolt loosening permits the Engine unburdening,so easy so written in the web sites.
So I may remove the AD motor from my VW 1302 Super Beetle utilizing this opportunity and check all the clutch system construction with necessary lubricants applications.
Very light weight 60 kg tempts me to the direction of full disassembling of clutch system, how come?
Problem is how to move backward the loosened motor without body lifting system but just garage jacks.
Necessary lubrication would change the clutch pedal reaction into smooth transient movements.

Cherry

The temperature of the air this morning is a bit cold, but I saw cherry blossoms blooming through the train wind screen realizing myself of Coming of Spring.
Newly graduates are getting out to new fields with cheerful hopes.
I must guide and orient them without discouraging their curiosity and hopes, it's easy to describe like this but actually difficult,because just to teach and to nourish are different each other.

Nagging

I've been suffering from some nagging by my son, he needs financial assist to obtain an another automobile, sport, manual trans-axle and turbine assist?

Just he wanna run about with high speed on the public road?

Just he wanna feel some stupid superiority to pass vigorously another automobiles which are keeping legal traffic speeds?

Just he wanna play with a automobile on the public road?

I do not agree his proposal!

He needs some persuasive explanation to satisfy me and to open my purse for his toy!
I'll never agree young man's opinion, it's too vulnerable and dangerous.

Suzuki Captino 660cc,TOYOTA 86 Collola, Nissan Silvia,Mazda Road Star, Honda S2000 and Fairlady, his desires, front Engine and front Drive layout?

Some convincing descriptions may be necessary to negotiate each other.

Why the name now?

Three weeks after huge earthquake at last the name is fixed by the Government as "East Japan Earthquake",too late no?
This kind of decision takes time as long as 21 days interval?
Very primitive and being just a layman in every field as the Current Administration of Japan now, we must recommend the US saying that Japanese Government rejected the US helpful proposal at the very beginning of the affair because US had realized what kind of phenomena had occurred and the necessity of the early response on destructed Nuclear Electric Power Plants, they are always watching all over the world from satellite.

Muffler replacement

The exhaust header #4 was not locked because of lack of stud bolt length caused by inserted auto air conditioner mount stay, probably from the very beginning of this automobile had been like in this condition, of course exhaust gas leak was found.
This scenery made me determine to unburden the air conditioning system thoroughly from VW 1302 Super Beetle yesterday.

The procedure was not so difficult but not so easy, energy consuming working was required, the result was so favorable as the operation to remove some long lasted chronic cancer tissue.
The accessing to the bypass screw(34PICT3) and distributor have become so easy like nothing going without saying, very natural scenery.

It took time and time upped yesterday on fitting at exhaust portions with new muffler parts. With unnecessary distortion containing internal stress to cylinder head, setting muffler is not my way, so precise fitting with bolt hales modifying were performed promptly.

In addition, the removing of heat exchanger obtained fine view of stater motor and easy access to the clutch release construction, planning the application of Microflon to the release linkage and release bearing with the grooves of splines, they would be the tasks for coming Sunday.