clodhopper - FIBERFAB.US

CLODHOPPER
D i v i s io n o f V e lo c id a d ,I n c .
FIBERFAB
SANTA CLA,RA,CALIFORNIA95050
2365 LAFAYETTE,
ASSEMBLY
INSTRUCTIONS
CLODHOPPER
Tableof Contents
1.
1
]NTR0DUCT|0N...
2
2. ACQUIRINGAWFLOORPAN..
,....,3
3,
REMOVINGTHEVWBODY.
4.
THEFLOORPAN
. . . . . . . 6
PREPARING/SHORTENING
5.
ONTHE'PAN. . . . . .
THECLODHOPPER
MOUNTING
6. W|RING,ETC..
7.
CoRVAIRPoWER?
..11
......15
8
:l
1.
INTRODUCTION
of fiberglassbodiesfor shortenedVolkswagen
. The Clgdhqppqlis Fiberfab's-entryin the ever-expa$li.ng
-aryay
is manufactured
products-- from the highestqualityglassfi5er,
chassis. The Clodhopper
-- as.areall.F.iberfab
polyesterresin an_d_
gel-coatsthat are commercially
available. ln additionto this highquility y6uwill-note;when
you reccive your Clodhopper,severalu.niquedesignfeatures -- richly and permanenlly
textuied interior suriaces;
integral, heavily-reinforcedbatterywells; one-piecehoodand dashboard;etc. -- wtrichplaces it a notchabove
the competition
andassuresyou that yourClodhopper
is therrbestbuyrtin the fun-vehicle'market.
is very easily assembled
The Clodhopper
ontoa shortenedVWfloorpan.
The instructionsdeal with all asoects
of your Clodhopper
constructionprojectwith emphasifiT'TT6i6ipan
prepaiationand shortening-- the shortening'being
the "toughest"part of the.project. lf yourre-doing
the.shorteningyou'll needan oxy-acetylenewelding,/cuttingoutfit. lf yourrenot, the followinginventoryof tools andsuppliesihould suffice:
HANDTOOLS
VL6u , 3/8tt , 7/L6t' , L/2" , 9/L6n , 5,/8" sockets(3/8u - drive)
and/oropen-end
wrenches
of thesamesize.
3/8" - driveratchethandle
blade
Standard
screw-driver-- medlum
Phillipsscrew-driver
blade
-- medium
Straight-edge
Steeltape(72")
Assorted
rasps,files anddrills
holesaws
Woodworking
2'(for steering
column
cutout)
cutout)
4 L/4't (for speedoheter
tool
Wireterminal
crimping
workshop
variety
Poprivet gun-- horne
TOOLS
POWER
L/4" capacityelectric drill
(Sabresaw andL/2t' capacityelectricdrill are helpful.)
MATERlALS
2 doz. AmericanStandard,roundhead, squareneck, stepbolts , 5/161'- L8,
L L/4 " longwith nuts, washersandlockwashers.
Assortedmachinebolts, nuts, washersand.lockwash
erci L/4" , 5/L6"
3/8" variouslengths l" to 3r'.
Assortedheavy-gauge,sheetmetalsctews
Poprivets, assortedlengths, L/4n to L/2x
Quartof rust-inhibitingpaint
-1-
:
and
N
G V OLK S W A GEFLOOR
PAN
2 . AC Q U IR IN A
bodykit wish to replacethe travel-wornshell of the "beetle"they
a Clodhopper
ManypersonsFurchasing
froma salvageyardandrefurbishthis "outalreadvowh. Otheibuildersplanto acquirea wreckedVolkswagen
parts. ln either instance,thls brief
and perhapsa few "fresh" mechanical
cast" with a newClodhopper'body
builders.
sectionshouldbe of interestto all prospective
familyilcan be dividedinto four groups:1) Pre-1950beetle, 2)
For our ourooses,the "Volkswagen
Post-|961brietie, 3i Variant, 4) Karmann-Ghia.TheVariantandGhiaare not suitablefor use as chassis
ge^arbox.
employ-a4-speed, non-synchromesh
for a Clodhopper.'The earlier beetlesare all 36 hols-epow.er.and
.
and all employa 4-speed,
startingat 5,000,001) .all.haveleast 4O-hors-epower
The latercaii (englnenumbers
gearbox. All the beetlesare suitable, but the later modelsare preferred.
synchromesh
are listed in a
dismantlers
ln the localeof Fiberfab-- the San FranciscoBay Area-- reputableautomobile
oublicationcalledthe PARTSL0CAT0R. The PARTSL0CATORis issuedmonthlyand containsextensivelists
NorthernCalifornia. Most likely, similarpublicationsexist in your
in yardsthroughout
bf all wreckedautomobiles
utilize usedparts. For you reference,the PARTSL0CATOR
areaandwouldassist you sigriificantlyif you choose_to
Avenue, San Leandro,California,94577 ,
addressis: PARTSL0CAT0R, 1696 Washington
Whenbrowsingthroughthe wreckingyards, remernberthat what you needconsistsof four majorpieces:
1.
2.
3,
4.
Floorpan-- the VW 'rplatformframel
unit includingthe steeringcolumn
Frontsuspension/steering
Transaxle-- gearbox,differentialandaxles
En g i n e
(perhaps
partfroma dismantlerand partfroma
You can buv all four piecesin onewreckor buy themseparately
rebuilder). Someminorcompatibilityproblemsarisewhenpre-1960and post-1960partsare piecedtocomoonent
gether, but thesecan generallybe solvedwith little difficulty.
windshieldwiperm-otor
Clodhopper;,e.9.;
can also be usedto.finish-your
Manybits and piecesof VW hardware
assemntyigaugesiignition, headlightanddimmerswitches;wheels(unlessspecialwheelsare goingto be used;
etc.
gas tank (1961or later); weatherstripping;
as they vary considerably.
the requiredVoltswa.ge-n
cqqP-onggt!
It is extremelydifficult to estimat_e_pri-cgs_fg1
fo-r_$_25--$50,
completeand running(not
chassis.se^ll
acrossthe country-.We haveseen1954-1958Volkswagen
for$100-$250.
C
ompl
etepost-1960wr ecksr un
1
9
5
8
-6
0
fl
o
o
rp
a
n
sw
i
thrunni
nggearsel
l
weli. lut r u n n i n q i .
updnage and condifion. Sourcesof Volkswageqp3l!.sother.thanwreckingyardsare
ilo*'SZbO to $6rSO depending
-from
used
yourautomo.bile
VW [totals", local newspaper
insurance
brokerconcerning
cheiper(e. g.', tips
sometimes
car ads and VW repaiishopbare other potentialsourcesof the parts you need.
Unlessvou are equippedwith metricand specialVW tools (andlike to tinkerwith enginesand transaxles)
it i. ot oU i [l i a a u i i a U l t[ri ]n v e s ta l i ttl e m orei nal ow -mi l eagew reck. l nanycase, w henbuyi ngachassiswit h
for iri enginealone),havethe sellerrun the enginebeforeyoucompletethe purchase.
"ngi;e
Alwayskeepin mindthat, if the four itemslisted aboveare intact, the wreckis usable-- DON!TLET A
M A NG L E .D
BOD YF O OLYOU !
-2-
3 , R EMOV ]N GA W FLOOR P A N
withoutthe body, you can skip this section. lf not, readon!
lf you acquireda wreckedVolkswagen
Beforethe VW bodycan be separatedfrom the floorpanthe followingtasks mustbe completed:
I.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
thefrontandrearseats
Remove
loosecarpeting
andfloormats
Remove
the battery
andremove
Disconnect
thegaslines
Drainthegastankanddisconnect
the gastank
Remove
thehydraulicfluid reservoir
fiomth body
Separate
(e.g., coil, electricchoke,etc.)
wiringfromtheengine
all electrical
Disconnect
canbeextracted
fromthe bodyandusedas a sourceof wire.
Thewiringharness
the left frontwheel.
Remove
Unboltsteeringshaftretainer
Unboltthesteeringcolumnclampat thedashboard
thesteering
assemlby
column
Remove
Now you are readyto unboltand removethe Volkswagenbody. Referringto Figure I -- removethe body
retaininqbolts at the locationsshown. Side bolts are accessibleunderthe edgeof the bodyand rearboltsare
is nowfree of the floorpanandcan be lifted-off using
accessiblefromwithin the body(carpetlifted. The body
rrstrong
andwillingil helpers. The VW bodyis extremely
a blockandtackle, chainhoist, or yourselfandseveral
removingit. lt i-sbecauseof this weight.loss,incidentally,
careshouldbe exercisedwhen
heavyand consideiable
performance
fromyour completedClodhopper.
that you can expectconsiderablybetter-than-Volkswagen
-3-
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FIGURE
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4 . P R E PA R IN G/S H OR TE N IN
THGE FLOOR P A N
(di stancefromthe centero f t he
M o s t " d u n eb u g g i e s "a re v e h i c l eshavi ng,nomi nal l y,80" w heel bases
f r ontw h e e l sto th e c e n te ro f th e re a rw heel s). V W ' s have94.5" w heel bases.Therefore
the V W fl oo r panm ust
he C l odhopper
body. In addi ti onto shorteni ng,
be s ho rte n eadb o u t1 4 " to a c c o mo d a tte
the' panshoul dbe cleaned,
andthe frontsuspensi on
t he r e a rw h e e l ss h o u l db e d ,e c a m b e r ed,
bod yis secur ed
" softened"beforethe C l odhopper
t o it .
Th e g e n e racl l e a n -u ps h o u l dc l e arthe fl oorpanof bi ts,andpi ecesof tornfl oor coveri ngandw eather st r ipping.
or sw eptoff. R ustspotsshoul dbe sandedto baremet aland
S t one s ,b ro k e ng l a s s , e tc , s h o u l db e vacuumed
c ov er e d
w i th a ru s t i n h i b i ti n gp a i n to r p ri mer-- speci alattenti onshoul dbe gi venthe areasurroundi nthe
g VW
bat t e rytra yw h e reb a tte rya c i d m a yh a vespi l l ed. A ny hol esi n the ' panshoul dbe pl ugqed
or patched.
g e fl oorpani s decamberi ng
i he V W rearsuspensi on.D ecamberi ng
Th e n e x ts te pi n p re p a ri nth
i s r equir ed
causedby the replacement
to compensate
for the reductionin sprung-w-eight
of the VW steel bodywith the Clodhopper
yourC l odhopper
w i l l ri de severali nchestoo hi gh i n the rear. Decam ber ing
f iber g l a s b
s o d y . W i th o u d
t e c a m b e ring
i s pl anned.
is us u a l l yn o t re q u i re di f C o rv a i r-p o w er
the torsi onbar, i ncl udi ngradi usarm(referred
D e c a m b e ri ni sga c c o mp l i s h ebdy di sengagi ng
to by VW as
fro rrth e s p l i n e sa t th e centerof the fl oorpan,i . e., pul l -outthe barandradi usarm. Nowr ot at e
" s pr in g -p l a te " ),
t he ba ra rrdra d i u sa rm/ a s s h o w ni n F igure2, several" notches"andre-engage
the bar i n the spl i nes . Af t er
bothbarshavebeenrotatedequivalently,the settingis checkedby rolling the floorpanon wheels, backandforth
wit h t w o p e o p l es ta n d i n go n th e re a ro f the ' pan-- the rearw heel sshoul dbe verti calw henthe torsi onb ar sar e set
properl
y .*
\^p aYle o)'\ o-\s,J<- Sgl"'oo'nrl,on ^ u','ic f ldY..urf
.,lo
pull out torsion barsand
-.r
"r,androtateas shown.
radiusarms
LEFT
EAD'd'S
AEPI
F)-----K
.:ir,,;i
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-\-."-*
6/Ls
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2
FIGURE
&6;a/f
e4DtL^t
&1
of
barscomposed
by removing
the fronttorsionbars-- rectangular
Front-endloweringcan be accomplished
six or morestripsof steel-- anddisabling,by cutting, half the strips in eachbar(cut bothsidesof bothbars-the torsionbarhousings-is to drill throu_gh
upperand lowei). Anothermethodof halvingthg front-ehdTpring-rate
w i l l nowact as an
diill t h ro u q ho n es o c k e to n l y (s e eF i g u re1). The torsi onbarrunni ngthroughthe dri l l eds-ocket
w i th a 1'r dr ill- bit
anti -sw aybarcanbe removed.D ri l l i ngi s performed
ant i- s w a y l a ra n dth e " o ri g i n a l -e q u ipment"
securedto the endof a 3-foot extension.
is accomplished
by cutting-outthe piecebetweenthe dotted
Referringfirst to FigureI -- floorpanshortening
the.gearshifr
ftor nt he gear linesa n dre j o i h i n gth e tw o p i e c e so f th e' panas-show inn Fi gure3. To begi n,rem_ove
access. Remove
shift pedestil. Nlxt, uncouplethe shiftinqrod fromthe transaxle-- see Figure1 for couplin-g
t he s h i fti n gro d th ro u g hth e a c c e s sh o leat the frontof therpan. S cri bea 15r' l i ne on the shi fti ngrod p ar allelt o t he
ax is o f th e ro d . R e m o v a
e 1 4 l /4 " secti onof the rbd suchthat 3/8" of the scri bedl i ne appears
on t he t wo
piec e sre ma i n i n gJ. o i n th e s etw o p i e ces,by w el di ng,w i th the tw o scri bedl i nesal i gned.
*T he d e c a mb e ri nogp e ra ti o cna n b e h a stened
Set is
S et . The C am ber
consi derablby
y usi nga Fi berfabC amber
the torsionbars.
adjustment
of camberwithou-tre1m-?ifrf-7ernftT-of
easily installedandprovidescontinuous
-5-
accesshole in lhe tgp of the "tunnel", Startthe holeabout4" behindthe emergency
Now, cut a temporary
brakemounting
andcut as shownin Figure1. Beqdthe tubesrunninginsidethe tunnelawayfromthe sidesof tlie
tunnelso that they will not be damaged
duringthe subsequent
cuttingoperation. Breakthe retainingweldssecuring
brakemounting
thesetubesto the tunnelbehindthe emergency
-- breakall welds includingthoseat the pointswhere
the tubesexit the rearof the tunnel. Movethe brakeline, runningoutsidethe tunnelon the floor, awayfromthe side
of t he t unn e l .
Mark the floorpanwith chalkandcut as shownin Figure1. Use an oxy-acetylene
torchor a sabresaw. Remove
the cut-outsectionby withdrawingit overthe endsof the tubes. Reinsertthe tubesin the holes in the rearsectionof
the tunneland movethe frontand rear piecesof the 'pan togetheras shownin Figure3. Checkdimensions
"X"
(X is approximately
54 L/2") to see that they equal. Nowweld the shortened
'pantogether. Reweldthe tubeto the
end of the tunnelandcut off the excess. lnstall the shortened
shift rod. Shortenthe variouscablesusingcable
aftercutting-outL4 L/4tt, Coil the excessbrakeand gas lines.
spficesor by havingnewendsswaged-on
patching,.shortening,
etc. completed
the floorpanneedonly be paintedwith a rustWith the cleaning,sanding_,
body.
inhibitingpaintto makeit readyfor the Clodhopper
-6-
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5.
MOUNTING
THECLODHOPPER
ONTHE'PAN
The Clodhopper
bodymountsdirectlyto the s.hortened
floorpah. The originalVW body-6-panweather'
using8 step-boltsper side, pasiedthrorr4hthe
strip can be used,ifavailable. Bolt the bo{y !o_th.e
'pan
holes in the rpanand 5/L6" holesdrilled in the mountinglii of the body., Heavyoriginal.body
mounting
gaugesheetmetalscrewsshouldbe usedto securethe bodyto the 'pan alongthe front andrear mounting'
lip -- put washersunderthe screwheads. Generalplacement
of the bodyis shownin Figure4.
Figure5 showsthe mountingof othercomponents
in the Clodhopper
body. The qas tank is placedin the
pre-formed
well in the noseof the bodyandsecuredusingstock-VWgas tank hold-downclamps. Headliqhts
are mounted
on the molded-inpedestalson the body-- the recommended
lampsare manufactured
by:
R . E . D i etzC ompanv
225 W i l ki nsonS tre6t
Syracuse,NewYork L32OL
andcarrypart numbers
820-B and 820-C for blackandchromeunits, respectively.
The windshieldprovidedwith the Clodhopper
kit is boltedto the sidesof the hoodwith the vertical
portionof the frameparallelto the face of the dashboard.Placethe weatherstrip, providedwith the windshield, betweenthe frameandthe top of the dashboard.The windshieldis securedto the hood,as shown
in Figure5, with 5/16" hardware
is gainedusingplated,flat-head(oi filister head)
-- Urebestappearance
machinebofts. With the framein positiondrill throughthe frameandsidesof the dashwith a5/16" drill -countersink
the holes if flat-headbolts are to be used. *
To f it the steerjngcolumn,,boreal-3/4". hole in the firewall 10" fromthscenterof the bodyand4"
downfromthe top of the firewall. Passthe columnthroughthe holeahdsecurethe steeringshaftlo the
universal-jointon the steeringbox. Supportthe columntemporarily
until the hoodis securedto the body.
Mountthe windshieldwiper motorin the ho'odby drilling throughthe pair of mountingbosseswith a
7/I6't drill . Place the wiper shaft bushingsthroughthe holes and securewith stock hardware. Added
supportfor the wiperassemblycan be providedwith a bracketmounted
on the lowerI ip of the dashboard.
on the forwardside of the "firewall" usinga standard3" hose
The brakefluid reservoircan be mounted
clampaffixedto the fiberglassusingpoprivets or small machinebolts and nuts.
the gas tankfillet placethe hoodin positionon the body
After boringa hole in the hoodto accomodate
and securewith poprivets, sheetmetalScrewsor #10 machinebolts. Drill the bodyandhood, to accept
the fasteners,as shownin Figure5. Nowlift the steeringcolumnto the lowersurfaceof the dashboard
and
at[ach it using stock VW hardware(U.-clampand rubbergromme0.
0n to th e w i ri n g .
t
* see pagel5 for the preciselocationof the windshieldif a soft top is to be installed
-8-
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6. WIRING,
ETC.
-Y \rJ
ttt"t
for completing
the basicwiringof your
This sectionof the instructionsprovidesthe ground-rules
described
below is basedon the factory-assembled
wiring system,or
body. The configuration
Clodhopper
to the widestvarietyof engine/instrumentation/lighting
"harness", which has proventhe mostadaptable
harnesses
are available,as partof the Clodhopper
Wiring Kit, from
combinatidns.The factoryprgpared
Fiberfabat extra cost.
To begin,a wiring harnessshouldprovidefor the following:
1. Enginestarting
2. E n g i n ei g n i ti on
Instrumentation
-- engineoiI pressure,fuel level, battery,/generator
condition,etc.
4. lnteriorlighting-- dashboardlights, etc.
tai l l i ghts,etc.
E x te ri o rl i g h ti ng-- headl i ghts,
t.
manyitemsto be wired havebeeninstalled,viz,,
of yourClodhopper,
At this staqein the construction
the starter,startersolenoid,ignitioncoil, generator,voltageregulator,fuel level sender,oil pressure
switchand'headlights.The itemsin the list below, however,are yet to be installed. Additionally,this
and locationsof theseto-be-installeditemsplus recommethods
mounting
list containsremarksconcerning
mendedsources-is gained-1. TAIL LIGHT/BRAKELIGHTS: 0n the reardecklip wherevera pleasingappearance
CorvetteStingray,'55 Chevroletor VW to namea few.
N D IC A T0RLIGH TS : 0n top of the frontfendersnearthe headl i gh t s
2. . F R 0 N T PA R K IN G/T U RIN
or on eachside olthe front licenseplate-- e.9., late modelVVKarmann Ghia.
i nstal l ed
V W w i ndshi el w
d i permotorandmechani sm
W IP ERM 0 T 0 R: S tandard
3. WIN D S H IE L D
hood.
in the Clodhopper
usingthe molded-inmountingbosses
conventionally
4.
DIMMERSWITCH: 0n the rrfirewall"just to the left of the clutchpe{al -- factory-builtcars
all employFord switchesbut anydimmerunit shouldoperatesuccessfully.
I'firewall' nearthe lowerright handcorner-- use a VW horn.
5. H0RN: 0n the outsideof the
6. FUSE BL0CK: 0n the insideof the "firewallt'abovethe centerof the floorpanbrace-- factorybuilt cars use blockshavinga capacityof four fuses:
A. H e a d l i g h ts,parki ngl i ghts, tai l l i ghts
B. Brakelights
C. Turn indicators
accessories,etc.
D. Horn, windshieldwipermotor,instruments,
fuse holders
blocks
be
asry1n[te-d-rping
may
The fuse block is partof the WiringKit. Fuse
availablefroma local electronicspartsstore(e.9., part number57 E3006 as listed in the
Allied Electronicscatalogfor 1968I
body. Boreholes
7. BATTERY: ln the right-handbox moldedinto the rearseatof the Clodhopper
in the sidesof the box throughwhichto passthe cables.
Althoughstock Volkswageninstrumentscan be_used,manyof our customersprefer,touse a more
extensives-etof garges in th-eirnew Clodhopper. The V.DOgaugesused in_factory.-Fltltvehicles are given
il'ih;itFftOni liSf lppendedto theseinsdrlctions. The gausesin the 0PTl0N LIST maybe ordered
fromyourlocalVD0 dealeror directlyfromFiberfab.
majorsections-- hub-to-rearandhub-to{ront--vfiere the
The wiring harnessis dividedinto two
rrhubr''of
the generalroutingof .these
the wiring. Figure6,show.s
instrument
nini,l is .onsideiedlo Uettre
t'ainJsieJrLjitiuJto itu shortenedVolkswagenfloorpan. The hub-to-frontharnessis routedthroughthe
i;ai;;w;li;
At this pointthe harnessdivides in a "T". The
.lrsi i,-rO.ithefuel tank-mountinglurface-.
tefi-nanapdition ot the harnessis broughtto the left edgeof fhe tank-mountingsurfacewhereit fgain .
biancheitii*, onebranchrunninqforwaidalongthe side of the gastank to ihe headlightsand parkinglights.
switch. The right-handportionis routed
Tne otn"r brinilr is routedbackilonq the firewallto the dirnmer
parking
and
light.
headlight
to
the
right
the
left
as
the
manner
in
same
- 11-
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6
FIGURE
/ax Ii^*'
O 4^tutE
l*ot*
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downthe insidesurfaceof thefirewallto thefloorandthenback
harnessis brought
Thehub-to-rear
thefloorandcentralI'tunnel"
alongthejoint between
-- alongtherightsideof thetunnel- lt is passed
lip at the baseof therearseatandfromthereit is extended
to
through
the bodyjust abovethe mounting
thestarter,rearlightsandengine.
shownin Figure6, thewiresin theharnesses
terminate
as follows:
to thenumbers
Referring
REARHARNESS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
L2.
rrhot'rlead (8)* FYik.
Startermotorprimary-- electricalsystemprimary
Startersolenoid(14) F.
Spare(14) F.
Spare(16) F.
(14) F.
coil "BATilterminal
lg-nition
lightpower)
switch (16) F. (warning
0il Pressure
(16) F. (warninglightpower)
Voltageregulator
"61r' terminal
(14) B. (wirein clusterwith3,4,5,6 is grounded
to engine)
Lightinggiound
Tail lisht(s)(14) F.
Brakelight(s) (14) F.
Leftturnlight (14) F.
Rightturnlight(14) F.
FRONTHARNESS
L3.
L4.
15.
16.
L7.
18.
I9.
20.
2]-.
22,
23.
24.
25.
Brakelight switchpower(I4) F. (to oneterminalof the pressureswitchmountedin the end
of the brakemastercvlinder)
Brakelight switchrelurn(14) T. (to the otherpressureswitchterminal)
F u e l ta n ks e n d (1 6 ) T .
Headlightpower(10) F. (to dimmerswitch)
Hi g hb e a mp o w e r (1 2 ) A.
Low beampower (I2) A.
in the sameterminalas wire#I7)
light power (16) T. (terminated
High beam-indicator
wire (14) F.
Holn operating(ground)
HornPower (14) F.
F r o n te n dg ro u n d(1 4 ) A (1 2 ) T.
P a rk i n gl i s h t(s ) (1 4 ) F .
Left turn light (14) F.
Ri g h ttu rn l i g h t (1 4 ) F .
Allwires leadto or fromthe hubwith the exceptionof the rearharnessground(wire#B), low beampower
(# 18) andhigh beampower(#17). The wiring of the.hub,.and
the connection
to it, is
of the harnesses
(viz., speedo-.
diagrammed
in Figure7. The diagramin Figure7 is.basedon the use of VW instrumentation
meier, iqnitionswitch, headliqhtswitch, windshieldwiperswitch, fuel gaugeand3-wire turn signalswitch).
e l o c ka re i n c l udedi nthew i ri ngki t(e.s., 47 E 1876 and 57 E 3005 as
T he t 6r m in abl l o c ka n d -fu s b
listed in the Allied Electronicscatalogfor 1968).
* numbersin parentheses
wire sizes
refer to recommended
#F = f r omh u b , T = to h u b , A = a h e a di n harness,B = backi n harness
-1 3 -
$t
IH
d)t
$$
t:
rl
I
rrJ I
Il
-l
t bs
ir .Q
t Hist
$!$I$
\tr i$ vr "
i$
++
0
i
UR
-L4-
TOUCHES
FORYOURCLODHOPPER
FINISHING
yourClodhopper
can be.accomplished
usingpart or all of the materialslisted in the
Upholstering
0PTION LIST. The principalitemof upholsteryis the carpet-- "stock" VW front seatscan be used
and the rearseat spaceneedonly be coveredwith a pieceof plywoodforminga I'minimumt'
seat.
are:
The materialsrequiredto carpetyourClodhopper
1.
2.
3.
4.
(36rrw i de)
e
ng
4 y d s . a u to mo ti vcarpetti
4 yds. carpetjute for padding
l 0 y d s . v i n y l c a r pet-bi ndi ng
I spraycan of trim adhesive
Use heavykraft paperto makepatternsof the floor area. Transferthe patternsto the carpet
(makingsure it is nodubside-down)'and
cut. Sew on the binding. Cut the jute to matchthe iarpetting.
Spraythe floor with trim adhesiveand install the jute. Thenspraythe jute and install the carpetting
over it.
grabfor interiorfinishingincludeashtrays(mounted
in the dashboard),
Otheritemsto be considered
be yourgui de.
bar s , s c u ff-p l a te o
s n th e " d o o r"s i l l s , etc., etc., etc. Let youri magi nati on
FiguresB and9 showhowthis top
lf you decideto use the Fiberfabsoft-topon yourClodhopper,
is installed. Referringto thesefigures-- the top{ows are assembled
with the small bowto the rear.
brackets,as shown,with#10 self-tapping
The tops of the bowsshouldbe parallel. Installthe mounting
screws.
fromthe centertop edgeof the rearseat
Checkthe positionof the top of the windshieldby measuring
to the centerfrontedgeof the windshield. This measurement
shouldbe 60 inches. lf tlris dimensionis
moreor less tffifi-60 inchesthe top will not fit or will fit improperly.
check, centerthe top on the bowsanddrill throughthe seamsin the top into
lf all measurements
screws. Tuck the frontflap of the top into
the bowsand securethe top to the bowswith chrome-washered
the groovein the windshieldframeand pull the top reanvarduntil it is taut. Then, startingat the center
snap, markthe bodyto locatethe snap-stud. Drill the bodyand install the stud. Workout fromthe center
processuntil all the snapsare affixedto snap-studs. Finally, pull the
repeatingthe locating-and-drilling
top smoothlyoverthe windshieldframeand locate,drill and install the frontsnap-studs.
4
I
60
w
-t5-
Chrome-washered
screws
9
FIGURE
-t6-
7.
C OR V A IRP OW E R
the Volkswagen
For more"G0" fromyourClodhopper,
engineis readilyreplacedwith a muchmore
powerfulCorvairglSilq. GoodCorvairengines.
1962 or later, are availableat mostwreckingyardsfor
engi nes.$f 00.0 0 to $ 3 0 0 .0 0 , d e p e n d i nogn yearandcondi ti on.A voi dthe turbo-charged
the Volkswagen
floorpanif Corvairpoweris usedas the addedweight
It is not necessary
to decamber
of the CoiG-irenginecompensates
for the Volkswagen
camber.
transaxleto a VW shopandhavethemput the ring gearon the otherside of the
Takethe Volksw-agen
case(thedirectionof rotationof the Corvairengineopposesthat of the VW. The ring gearilflopoverl
by one unfamiliarwith settingup automotive
shorrldrrot be attempted
rearends.
Next, lhe bell-ho.using.is
removed
fromthe Corvairenginein preparation
for mounting
a Corvair-toto adapters--w_estronglyrecommend
Vr,lkswagen
adapterplate. With re-gard
the use of the adapterkits
prodrr,:ed
hy CrownManufacturing
Company,651 West Seventeerith
Street, CostaMesa, Califoinia.
T hc Cro w nAd a p te K
r it includes:
N o . 5 0 01
No. 5002
N o . 5 0 03
N o . 5 0 04
N o . 5 005
N o . 5 008
E ngi neA dapter
StarterAdapter
H eavy-duty' Fl yw heel
P l ate
H eavy-duty
P ressure
P l ate
C l utchD i sc
U ni versalThrottl eLi nkage
Crownalso manufactures
a numberof accessoryit_ems
suchas muffler-exhaust
systemswhichcan be
usedtor yourCorvairpoweredClodhopper.Furfter information
is availablefromCrownManufacturing.
l h e ny o uw ri te ,.i f y o umenti on
that the ki t i s to be usedw i th a Fi berfabbody.
I t will h e i re l p fuw
After the bell-housingis removed,removethe Corvairpilot bearingin the endof the crankshaftand
r eplac ew i th th e e x te n d e d -ty pseu p p l i edby C row n-- the-ori gi nal
beari nghasthe properl D butdoesnot
engagecnoughof the Volkswagen
transmission
inputshaft. Bolt the adapterplateto the Corvair(if the
oil seal is not yet installedin youradapterplate, makesurethat whenyou do install it you referto the
or irina l C o rv a i b
r e l l -h o u s i nto
g a v o i dp l aci ngi t i n backw ards).N ext, bol t the adapted
fl yw heelto the
Cor v a i rrra n k s h a ft
a n dth e nb o l t th e c l u tchpl atecover(w i thcl utchdi sc i n pl ace)to the fl yw heel .
Drivethe starter-motor-shaft
bushingout of the VW transaxleandreplacewith the specialbushing
in the StarterAdapterkit. Nowbolt the Corvairto the Volkswagen
transhxle--interferenbe
betweenthe
transaxleand the engineheaterduct is eliminatedby reshaping
the ductsor replacingthemwith Crown
#5012 HeaterAdapters, The Corvairstarteris usedby meansof the starteradapter.
To completethe engineinstallation,the Volkswagen
throttlewire is coupledto the Corvairvia the
Univ ers aTl h ro ttl eL i n k a g ea n da s u i ta bl eexhaustsystemi s i nstal l ed(e.9., C row n#5010).
Us i n gth e C o rv a i e
12-vol t i nsteadof the V ol ksw agen
r n g i n e ,th e e l e ctri calsystembecomes
6-vol t .
T hewi ri n gh a rn e s s edse s c ri b e di n Se cti on5 are, how ever,sti l l appl i cabl e.A l l bul bsgauges,gauge
s lndc r ri n i ts e tc . m u s tb e l 2 -v o l t L r ni ts-- or -- 6-vol t uni tsw i th seri esvol tagedroppi ng
resi stors.
-t7-
CLODHOPPER
OPTION
LIST
finish
Two-tone
solidcoloror Metal-flake
vinyltop(whiteor black)
Covertible
(black,vinyl-textured)
Hardtop
Show-bar0oll barfor looks)
safety)
Go-bar(roll barfor maximum
Carpets(blackonly),set
pair
Frontseatcovers(blackvented-vinyl),
andbackresO,set
Rearseat(cushion
Economy
sidecurtains,pair
(withframe),pair
sidecurtains
Deluxe
Bootfor top
(6 or 12 vol0, complete
kit
WiringHarness
$ s0.00
7 5 . 0 089.00
29.95
59.95
35.00
45.00
45.00
45.00
1 0 0 . 0 0 '-
25.00
39.50
SETBYVDo
CoMPLETE
6 VoLT TNSTRUMENTS,
Description
List Price
VDONo.
gauge
pressure
Oil
De3501
$ 10.97
sender
Oil pressure
L2,30
De3601
gauge
Oif temperature
L3.92
Fe 32L3
sender
Oif temperature
6,78
Fe 3272
Fueffevefgauge
L3,68
Fu 3001
Kit
Tanklnstallation
2,52
Tf 225r
14,22
TankUnit
Tf 220t
Ammeter
6.25
Am1903
gauge
Vacuum
L3.07
Va 0002
gaugeinstallation
kit - 12 ft.
5.30
Vacuum
(764 rev/nild
23.A5
Speedometer
Sp L222
VW-to-VDO
speedometer
cable- 5 ft.
2.80
(4 cyl.)
Tachometer
44.85
aaiqn
SETBYVDo
CoMPLETE
12 VoLT TNSTRUMENTS,
List Price
Description
VDONo.
pressure
gauge
0il
De 3502
$ 10.97
L4.40
sender
0il pressure
De3603
gauge
L6,75
0il temperature
Fe 32L6
6.78
sender
Oil temperature
Fe 3273
L3.68
Fuellevelgauge
Fu 3002
L4.22
Tankunit
Tf 220L
unit
2.52
Tankinstallation
Tf 225L
6.25
Ammeter
Am1903
gauge
L3.07
Vacuum
Va 0002
gaugeinstallation
s.30
kit - LZ ft.
Vacuum
23.05
Speedometer
U 64 rev/milel
Sp 1222
2. B0
cable- 6 ft.
VW-to-VD0speedometer
(6 cyl.)
44.85
Tachometer
zeisA
-t 8 -
{ ,o
,,
si)
2'?'
do
6 d 'a v
DE0II'EERI'{G T}IE F,EA-Ri\IEEEIS
Gene Rj-Ceout, Eeili:ighann, Wash., reports
that after clriving his Porsc,he about 2OTOOO
ni1es, nosily with just hi.nseif in the car, it
developed a port list;
r+e donrt know his weight,
:ut u:rusl,al angles have developed on other cirs
at about the sane nileage.
Gene got out hj-s
shop nurual ard reised the lefi: rear of his car
one degree and lowered ttre right
rear one degree, and reports thlngs are back on arr even
ke e1 .
The operation on the rear torsion bars ca::
be done by alnosi ar{fone who can turn a lrrench
provided sorne guidance is available.
John Snyder, Potorec Region, conducted some adjustEenl
on hri-s rear torsion bars and lrrote up the details and explained a few techalcal
polnts as
he went, along.
Our only preface to Johnts artr
icle ls that you should not play around
'r:ith
the torsion bars just because you have notlring
else to do on a Sirnday afterrroon.
We suggestthat jJ you lo:row there is a li.st,
a droop snoot,
or /cu want the rear end to hold in corpetition,
then go ahead and do the job.
WeLl equinned
=ifriii""r
''"rlani pot"crt"sr.op.t
".-pruru uol
""" neasure the angle
&5A), ttrat will accurately
on lhe rear radius arna.
The radius arm
(uhicb is attached to the end of the rear torsion bar) when hlngJng^free,
should have an
angle of from 6f" to 7, doi.rn from the l.rorizontal.
Many Porsche owners have erperienced the
tendency of thelr car to oversteer,
that 1s, to
follow a path of progres$ive1y decreasing ridiue in any one given turning
position
oJ the
steerjng rheelp requlring
the driver to ropen
uprr on the steering wheel 1n order to steer
around a curve of constant radius.
l'lany have
al-so e:rperienced the tendency of the car to
"wander" at higher speeds, particularly
under
the influence of a crossuind.
These conditions
r€y in large part, and in many case, be eonr
pletely
overcotne by decanrbering the rear wheels.
:
L
^-;
_'.j-r,
^,,+
gc
-^
out
ano
Du;r a nerr pair. of .f;.cnt -uor_
--+
s:c:- :p:'irrgs.
if no*", read
'-::e res-; of tf:is
a l f h c u g h a s l i g n t c e c a n t e : i n g o f th e
: ': -l e; :,e e l s
:-=e
e v e n j J r a n e w c a r : : , a ; , 'b e q u i te .
:3rz:ax]g.
lhe effect of decarnbe:.ing or: the oiers:€er=g teridenc."*is rather +.ecjtnlcai and need
e:i c::-eern us here, suffice it to say that ciec"--::e:irg the rear ;heels of a porscbe, .rdnether
'.::e car be new or used, has a pronounced"iffecl :r the oversteering
tencie::cy and rtrilL decrease j-t in all cases, causi:.g ihe car to have
trcre cr less a neutral_ steering .uendency. ?he
:::cice::tal
effect of decanberGg which causes
..i_ to have greater directior:al
stability
i="
is easily understandable when it is real_ized
'i:at cecamberilg the rear wheels
lov.ers the rear
enC of the car aad that lo"*ering the rear end
of tte car will
tend to create i greater degree of caster of the front
wheels, cester in
*.91f"-being
the anount tha"" th; kin4rjns
are tilted
toward the rear of tbe car at thelr
i.q:per ends. fhe greater the degree of caster,
k-e g:'eater tendeney for the front rfieels to reroirl in or return
to the stral.ght-ahead
positioa,
hence greater directional
stability.
.4lo'r,Ler factor
contributing
to directibnal
sta_
is the proper anount of toe in of the
lielty
lront wheels, rdrich is, of course, a requirenenl mdgl any circunstances.
&'e urlterrs
auJomobile, a J-953 coupe, possessed a great tendency to overdte;r,
a pre
no-,:src€d degreq ,of .directional
instaUi i i ty, and
a.l'so a tenalency- to-shj-rm6r. A1l of
faults -ihese
Here ccrrected by decanbering the fear
'I'he fact that the shfurmying
disappeired "h;;t;.
shous
tlrat there r,l.astoo Little
front wleel caster
bejor.e deeanberilg the rear wheels, since the
frcni
e:rd in all other respects uas 1n gocd
shape.
lecarnbering the rear wheels is a rathel
.
si:Fle. job, although perhaps an hour to ar houtr
and a h-aif should be allowed.
The first
stpn
The ciegree of carnber of the rear lrheels is
5.s to jack up the car and remove o"" oi'ti""lhat degree to which the rear wheels are tilted
rear rreels.
Then r€move the three sets of
outwardly so that their upper portions
nulvs and bolts nhlch connect the bifurcated
are disp_1aced outrardty
of the road contacting po:,tions.
rear end of the trailing
arm to the a:rte hous!,heri lhe rear wheels are perfeerJ-y verl,ilal5
they i.ng, ho of the nuts and bolts also servj_r:p
are said to have zero canber. Because of the
to att€cil the shock absorber lewer bracket"to
rr€rner irl rfrich ihe rear wheels of the porsche
the ar*ie housing.
In the ,*,riterrs car, these
nuis and boLts fitted
are inciepencienlly suspended, lowering of the
a 19 mn, -,rench, a1_
i:cugh z 3nt" soeket rues also used to good
rear enc of the car wiih respect to the rear
ad'":hee1sproduces negative canber.
rz::+.ege. The iraiii.rg
Although
arn is a length of metal
i-he suspension gecr:etry of t,he
car rnay'be
ab:r{+. 5il wide and about
VB" at 3/16', .,hick,
perfectiy proper when new, the front torsion
a::c rtich extends foru:ardly of the rear'ax"le
bars apparen+,Iy have a greater tendency to be
conneciion to the franne.
liu,sine for pivotal
perrnanen'"1ydefo:'rned than do the rear torslon
li:--h -,hese three nuts and bol_ts re"rorrea,
puff
.a rs so i hat af ler pr c longed us e, t h e f r o n t
t-ie rea:. axLe housing reanlard3.y
so as io l-eave
'1ir? rs:i end of
enci of the car nay tre lower to the grou:rd fhan
the trailing
anrr free.
?o do
i'" orirhali;'
was, whereas the rear end nay be
'-:is, ::! nay be necessary to loosen +,ls n1"m
at substar-rfiaii-y< its origir:a1 height, causing
c:r t,:e a-tle housing which serves
,, ;;;;
the ca:" t. h31,iea noscd do'rrnappearanee. It
fc: :he .flexlble
bra_ke hose and to"" nove this
is in such cases tha+. lhe above-neniioned overc1a:e sl-igh.uly ou.urrardly to preve;ri it fron
:teering lendency and lack of dlrec.uional stasir':.ir::.; the heat exchanger fc;r the heater
and
bility
Jf you have ihe
perriii, -"he rear axle housilg to
are nosl noticeabl"e.
be r::o.red back
38
a si:Ji::ien-, a;stance ic :lear
en.d cj -;e l:ailirg
a:,=,
il:
j:
I'
t'
I
l.!
F
r,re forked,rear
rr---h t-: -,:'a11irg a::t t;lus ireed,
it ldll
pr,:ba:-y be '- such a pcs:.-,i-on ,,nat iis
lower
ecige :-s e:ga::i
aga=:ls-L -_:e siop on the frane
jusi r:-rrzrl;
of the F,:=t at which tne trail_
1ng a::-- :s l::-::ecteci t,c --:.s rea:, torsion
bar.
It shc':*rj be roteci at tr:.- point
that tire optfunn ;:sit:::
of the tlaiii.ng arnr will probab1y be =:ch :;:!
when fre:,
iti lower edge vi1l
eit::el ,'::st :-ear Ine s-r:; or be spaced no
more
+-han i a'' ab.:;e it.
!fuc: n:ore ,p""ing
than this
l
wel ;::oab-i; nake it ve:y diffitult
io ,"*o,r.
anci re-;lace :be rear r*te:
since there r+ill be
i.ns'i-fii:ient
clearance bei"*een tle brate Crun
and fe::er.
?ne nerL ste_: is to renove the
four i,rlts -s=:_chseeure :ie dust
for "ure tors:o:r bar Lo f,bg fyene, "orl,
eiit er""pa
17 rm '-:rencbor a 2V32" srencb,iii-dJ.
rhe
dy:l *O vili probably have to be pr5.ei'orf
wl!tr a screl=rivere since it carrles on lts
rnner siCe a resilient
b-:shing drictr ernbraces
the oEtes ed of a boss .drich extend.s transversel-;; thrc:gh and is rigidly secured
to the
ronraFd end of 1;ru 13ai],lng ana, the flt
being ra+.her s:';g. The bcss is fr6ffoin
.na f"-,
terna.Ll.y spJ_i.nedand recelves the splined
outer end of tle torsion bar. Tbe nexl step
is
the bai'lina ara autwardly €o that it
!o-p"y
pur
r-q off frca tbe outer end of -ttre
torsion
-U""l-Oufo""
Eoneve, it n'il"l prcbably t"
!"T.
doing tbls to uark a vertical iine on-tfre
outer,face of t- torsibn bar (nai]. podlf,
q!/ s-o thet rbe original position
of the "fff
torst on ber can be Ce^"errrlnsdo
{
[.
i.j
ii
ir
P.
p
ii
t,
I
t.
F
li
Fr
lt
lz
al
E
n
fi
i!
ll
lV:iJ
F;
it
tr
ft.ere are lrlr splines on the outer end of
the tcrsi.on bar and its ir:ner end is provided
rfith LC gpfir€s'
Since rctating
the freed traiL.
ir.g am, eve! nne spline irith respect io the torston bar so tbe rear end of the arrn 1s moved
uprrerdJ.y f,rcq j"ts orLgiml
position
and then reengagi::g t}:e a:'n rrith tb"e torsion
bar railI effect a ccnsilerable
Cegree of 1or"-ering of the
reaf e:d of the car on tlat side, it wi1J. probably be nec€ssar:/ to rne-nipulate both the inner
end of the icrsion bar a:d the outer end to
adriere the lesired resrlt.
I?ris is rather
easiiy acco=lished
since there are fer+er
s'pli.nes on ,r:ne lnner enri of the bar than there
are o:i rhe c.jter end, a:-; the best rnanner of
proeee:ing is to Cisenga;e the inner end of the
bar a;C rot€-.e j-t one spl1ne il the directlon
which ';oirl"C :a':se raisi-::i of the r:ear end of
the ar: irere it a+-tached ."o ihe torsion bar and
to the: rotz'-e and re-er..gage the arm one spline
fron r:s or:;iral
positi:n
on the bar in a direct:.3:r whlc: wcu]d 'icwer its rear end from its
orj-gj-*ii p:,::.,ion, the :-::t effect of ,,hese two
sieps be'i;rg -ro jus.u ve:-; s1igh.t,1y raise the rear
end ci the a:n wherr ,,he ;arts are all reassenbl"ed. I: othe: w6rds, on :he feft rear wheel, Lhe
torsj.cn bar :s rotaied c:e spii_ne in a counterclcclc;:,se c-ection,
uh1-e the arm is rotated
one spii;re
a cloclcdse directi_on, arrd vice
versa icr +-le
-- ctfier siCe of the car.
These two
steps should be repeat,eci lmtil- the lower
edge
thg.traiii:rg
arn jiist ciea:.s or is no iore
?I
thar 1/bil frcnr tne st,op. Incicentai"ty,
.hnen re_
rnoving fhe ir:::er end cf the torsion bar
.fron
its socket, it is best to first
renove the rub_
ber bushing wirich is slipped i-ntc the frane
and
enbraces the ir^:rer end of the trailj.rrg arrr boss
wnen lhe parts are assenbled.
Thrs nrikes it
easier to grab the iorsion bar anc exert
tne
necessary pullrng force io renove it
fror its
spl-ured socket.
Insofar as ti:e i:rsion
bar is concet-nec.
particular
care shoulcj be taken not to
scratch it an$" although the splirres are ^".-oi
not,
lubri-cated,
there shouLd be a coatin!-of
g""ur.
throughout the internrediate
length oi tne Uar
to protect it fron rust.
Needless'to say, the trailing
_
atrr on both
sides of the car sniirra be so positionea
--ft that,
both wheeLs are identically
camt,erua.
should
be reraernbered that even a very slight
overall
adjustnent
of the trailing
."r,
res,:lt in
very.rewarding
"iii
and noticeable
results,
.o *oJ_f
eration ishould be the keynote.
WitU ifre parts
reassenbled, hop in the car and head
for the
nearest dirt road, and if you canrt
take that
curve faster and wlth less rear end
sliding,
let rne trorou.
WIPTREI"ADES
.
The rrindshields, as well as the rrj-n_
d91s, in Porsches are,rnade pf a specfai glass
whigh.le shatter-proof tho it, is ;;; oi trru
sandrich construption whLch is farn:i.liar a_
rounct uetroit.
tne'bf the dlsadvantases of
the Porsche nildshield material is ttrli it
is sonewtrat softer thsn ordina# gb;r.- son"
of us have discovererl that the irui"i-i"
ti:"
uindshield rriper b3.adeholders will scratcn
the vindshield. If this. scratching beco*es
bad,enough, many state lavs requir8 tfr"t tn.
Ii'r.nosn1-el.cl
be renewed.
One of our rnembers suggests that if the
snall rivets,
uhlch are used to aftaeh the
blade holders to the n-iper arrrs, are kepr
, tight the netal parLs cannot tip over
far
enough to touch the windshleld.
We tried
this on a 'rtiredlr blade holder by tappi-ng
'1 i
f
rr ^^-,^-^
ugrlry
severa_L
-L+1.,
unes uith a snal1 harnmer,
usilg a larger haruner as an anvil on the
other end of the rivet.
This dld the trick
brut we suggest that you be careful the rlvet
is not so tight that j"t vil1 prevent free
movement of the holder as i-t passes over Lhe
curved surface of the rindshleld.
'v{e also
noticed that the viper.s did a bet,uer job
afier the rivets nere tightened"
WIPERSV{ORKING?
E ugene R i deout of B sl l i ngh,,-,
H ,rshi ngr,rn w i ;r,rc i r
D pl S r.ai .n,has some go.d aJ,. r..'.,f,.,r,
.'ri ni ui n,n6
w i ndshi el d w i per machani sms, C 6.6s burne,J.ui
ti ,e
motor duri ng rhe *'arranry peri ,r,_l. \l l i .,n
he rerel v e,l
a new onet he reprtcked the gear case *.j rh
a li .qh:
gradc of Lubri -pl are. Ir w orke,l ...
n!) rj rL\rerr oui rl c .
I hrs w oul d probabl v appl v rr, r,;l ,l rrr_.rrl rcr
, i i nrar,__r
as w el l as rai ny ones.
39/
1'1
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