The Silver Bullet

[ConcreteAce]

This is my wifes car that I am building for her.
Got it a little over a year ago. Installed new beam and all new brakes.
Wife wasnt happy with the color so off to paint it went.
The ride home
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys1960VW018.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys1960VW019.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys1960VW020.jpg

The pic's that Chuck sent that caught our intrest
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/heb068copy.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/heb067copy.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/heb064.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/heb057.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/heb048.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/heb043.jpg

A little damage to the rear fender
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/1961vw.jpg
All in all a pretty damn solid car

[ConcreteAce]

The clean up
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp003.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp005.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp006.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp007.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp008.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp009.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp010.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp011.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp012.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp013.jpg

[ConcreteAce]

http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp014.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp015.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp016.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp017.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp018.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp019.jpg

[ConcreteAce]

getting a new beam. Courtney wants it low
http://i5.photobucket.com/albums/y163/chucky1974/ethan001copy.jpg
http://i5.photobucket.com/albums/y163/chucky1974/ethan003copy.jpg
http://i5.photobucket.com/albums/y163/chucky1974/ethan007copy.jpg
http://i5.photobucket.com/albums/y163/chucky1974/ethan013copy.jpg
http://i5.photobucket.com/albums/y163/chucky1974/ethan015copy.jpg
http://i5.photobucket.com/albums/y163/chucky1974/ethan004copy.jpg
http://i5.photobucket.com/albums/y163/chucky1974/ethan012copy.jpg

[ConcreteAce]

The wife shocked the **** out of me tonight, She is ready for her car to hit the streets. She undid the front brake lines that Bo and Doug put on so that she could put the new wheel cylinders on(we couldnt get them screwed on the back of the wheel cylinder because the hose kept kinking) then she re assembled both front breaks and started tearing into the rear.She painted her new drums with a little help from Randy.

http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61001.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61006.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61007.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61008.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61009.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61010.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61011.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61002.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61003.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61004.jpg

[ConcreteAce]

Danny your killing me with this ten picture min. I gots lots of pic's
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61005.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/Courtneys61013.jpg

[ConcreteAce]

The new look
From this:
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp010.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp013.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/newhome002.jpg


To this:
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/1961Beetle001.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/1961Beetle008.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/1961Beetle007.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/1961Beetle004.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/1961Beetle005.jpg

[ConcreteAce]

Courtney's first trophy
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/TexasNightshow009.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/TexasNightshow045.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/TexasNightshow043.jpg

[ConcreteAce]

Courtney taking a spin.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/65workday001.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/65workday002.jpg

[ConcreteAce]

the tear down. Big thanks to DLK
http://i256.photobucket.com/albums/hh174/fitzoval/100_0404.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0405.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0406.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0407.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0408.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0409.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0410.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0411.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0412.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0413.jpg

[ConcreteAce]

http://i256.photobucket.com/albums/hh174/fitzoval/100_0414.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0415.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0416.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0417.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0418.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0419.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0420.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0421.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0422.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0423.jpg

[ConcreteAce]

http://i256.photobucket.com/albums/hh174/fitzoval/100_0424.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0425.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0426.jpg

[ConcreteAce]

Progress being made thanks for the pic's Billy. They stripped the paint using a razor blade, pretty cool
http://i256.photobucket.com/albums/hh174/fitzoval/100_0433.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0434.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0435.jpg
http://i256.photobucket.com/albums/hh174/fitzoval/100_0436.jpg

[ConcreteAce]

And this is where we are at right now.Hasnt been cut and buffed yet but ya get the idea.
http://i117.photobucket.com/albums/o70/ethandunlap/Silver%20Bullet/SilverBullet022.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/Silver%20Bullet/SilverBullet023.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/Silver%20Bullet/SilverBullet024.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/Silver%20Bullet/SilverBullet025.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/Silver%20Bullet/SilverBullet026.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/Silver%20Bullet/SilverBullet029.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/Silver%20Bullet/SilverBullet031.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/Silver%20Bullet/SilverBullet034.jpg

I gotta say the pics really dont do it justice the silver looks beautiful.



and a big thanks goes out to Billy for blasting the wheels
http://i117.photobucket.com/albums/o70/ethandunlap/Silver%20Bullet/SilverBullet030.jpg

[crankshaft]

Props on the Fema Tarps....LOL....the car really is looking good...

[Jumpin' Joe]

Nice Job! :hail:

[prettinpink]

Very nice! Love the color. Can't wait to see it in person.

[gixxer711]

now this is a readers ride posting!!!! might as well open it up, since it didnt seem to deter you ;) :P i loved her car like below, but the silver looks outstanding and the engine compartment looks really smooth. looks like yall removed all the tabs for the firewall insulation. beautiful!!!

http://i117.photobucket.com/albums/o70/ethandunlap/DLK/1961Beetle008.jpg

[ConcreteAce]

Thanks for all the props.

Yep we removed all the tabs, I have some plans for the engine tin that is going to work well with the painted engine compartment. Figure I will just dyno matt the package tray to keep out some of the noise that not replacing the tar board causes.

[ConcreteAce]

Well the Bullet is home
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/classic09030.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/classic09031.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/classic09029.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/classic09025.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/classic09021.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/classic09027.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/classic09022.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/classic09023.jpg[/

[ThirdCoast]

super nice...

oh and show this to your boy when he gets a girlfriend...

http://i117.photobucket.com/albums/o70/ethandunlap/DLK/CleanUp014.jpg

[ConcreteAce]

Lol I guess I missed that pic. thats not my son that is Billy's son (fitz57 on the dlk board)

[gixxer711]

welcome home silver bullet!!

[ConcreteAce]

some of the bling that came in this week





got five of these
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/61bling004.jpg



http://i117.photobucket.com/albums/o70/ethandunlap/DLK/61bling005.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/61bling006.jpg

front and rear WW bumpers
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/61bling009.jpg

[Jumpin' Joe]

Nice, where did you get the steering wheel? I Like that! :peace:

[vwracing65]

Looks good bro!

[gixxer711]

those popouts look brand new. are they repops? do they make repops? that is gonna be such a bad ass car!

[nomercyambulance]

Beautiful! Oh and the car is pretty nice too. :peace:
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/TexasNightshow043.jpg

[ConcreteAce]

those popouts look brand new. are they repops? do they make repops? that is gonna be such a bad ass car!

yep they are repop pricey but in my opinion worth every cent. I bought around 4 sets for my car before i found some that I could live with and i still am not happy, so with hers I didnt waste the money cuz early pop outs used are a min of 200.

[ConcreteAce]

Beautiful! Oh and the car is pretty nice too. :peace:
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/TexasNightshow043.jpg


I agree on both accounts.

[ConcreteAce]

well here is a little update on the bullet. Got new channels, front wheel wells, new pans, rear apron and rear bummper supports in. It is now sporting a ragtop as well.

Big thanks goes out to Brad, Jeremy, and Jason for helping me with the metal work.

Well the floor pan is now finished 3 coats of POR 15 top and bottom 4 coats of rubberized undercoating. I also seam sealed top and bottom down the tunnel.
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/064.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/064.jpg

http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/floorpan005.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/floorpan006.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/054.jpg

[ConcreteAce]

Well just to catch things up. The heater channels and front wheel wells are in big thanks goes out to Brad Cease for his help.The new orange floor pans are in as well. Courtney's car is now a ragtop car another big thanks goes out to Jason Eubanks (Jeremy's brother) I have never seen a roof put in the way he did it. He skinned the entire roof section. If you look from the inside of the car you can not tell it is a graft all the welds are hidden by the inside skin.
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop124.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop101.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop126.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop125.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop117.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop119.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop109.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop112.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop115.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop130.jpg
http://i900.photobucket.com/albums/ac202/ConcretebyDunlap/1961%20Ragtop/1961ragtop131.jpg

[ConcreteAce]

Final shots of the roof in primer

[asimmons]

im jealous! just had to show me up with the pan didnt you hah, kidding. looks really good

[gixxer711]

fantastic!!! another car soon to bump mine out of the trophies ;)

[Comrade]

Work on the pan was impressive enough, I cannot imagine doing the roof! Great job, will be a real beauty. Now I know who's brain to pick when I do my body off.

[inyakzbug]

any developments with this awesome car? want some more...

[ConcreteAce]

Nothing new just been collecting parts. Hopefully soon I will re assemble the pan, with all four wheel disk brakes. I would like things to go faster but this hasnt been the best economy for my business this year.

Brad did hook me up with a new 6" narrowed beam that still uses needle bearings.
http://i117.photobucket.com/albums/o70/ethandunlap/Mobile%20Uploads/4cfb3190.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/Mobile%20Uploads/661ad364.jpg

[gixxer711]

6" beam crazy!!

[ConcreteAce]

6" beam crazy!!

with the dropped spindles and disk brakes it will be like a 4 inch beam when things are all together

[gixxer711]

ya. i want to get a beam built but i want to keep the shocks. i need to figure out how narrow i can go without modifying the body.

[ConcreteAce]

you can go 4 inches on a link pin and keep the shocks.

[SixPack]

Nothing new just been collecting parts. Hopefully soon I will re assemble the pan, with all four wheel disk brakes. I would like things to go faster but this hasnt been the best economy for my business this year.

Brad did hook me up with a new 6" narrowed beam that still uses needle bearings.
http://i117.photobucket.com/albums/o70/ethandunlap/Mobile%20Uploads/4cfb3190.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/Mobile%20Uploads/661ad364.jpg

so how much would Brad charge to narrow a beam and install adjusters on it ? OR if he can make one, how much would that be ? im looking to get a narrowed beam with adjusters but im only ending up finding a regular one with adjusters that is local.

[gixxer711]

i think brad has retired

[G.K.]

Again:jaw:

[ConcreteAce]

I can ask him for you but like Danny says he has pretty much hung his hat for awhile. You can PM CusinIt (James ) on the DLK board he would probably help you out he has done several ball joint beams.

[ConcreteAce]

to do a little catching up
Back to work :dance:

Since this will be a driver I opted to POR 15 the beam and other suspension parts. more pics coming
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-06221006.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-06223519.jpg
got the drop plates done
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-07212747.jpg

and the disk brake spindles
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-07212715.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-07212653.jpg

also got my garage organized (took me three days) I separated each and every bolt, nut ,washer ect. Now I just need to find some way to lift the pan to waist high while I work on it.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-07212634.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-07212616.jpg

[ConcreteAce]

control arms getting the same treatment
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-07224854.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-07225032.jpg

due to the fact that I will not be running shocks I am using 4 upper control arms. should be a cleaner look.
Got the control arms finished up. Now its time to build the beam up.
http://i117.photobucket.com/albums/o70/ethandunlap/2010-10-08204535.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/2010-10-08204543.jpg

[ConcreteAce]

Although most everything on the pan is going to be covered with carpet ect.. I decided on doing one more coat of por-15
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10022057.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10022108.jpg


Now to tackle this nasty pedal assembly. I have never taken one completely apart before so this should be interesting. Just wish I had the cruiser pedal already. I have a brand new billet pedal that I can throw in there for now, but Courtney doesn't like it so it will get replaced soon.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10022143.jpg
well to start out, due to the fact that I was not sure how the pedal assembly came apart I went ahead and notched it for aliment later on.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10023633.jpg



Only one pin holds the clutch pedal onto the shaft, but it was rather hard getting the clutch pedal off the shaft once the pin was removed, I ended up locking the end with the hook in my vice and was able to twist it off with a fair amount of force. I did bugger the hook up a little I should be able to straighten it out though. Once that was off there is a c clip that holds the brake pedal. That was hidden under a lot of grease.

This first picture is in order of how I took it apart.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10024803.jpg
and some close ups. this is more for me in case I forget
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10024811.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10024817.jpg

[ConcreteAce]

Now the clean up
In this picture you can see that I have already cleaned the plunger for the brake pedal
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10024822.jpg

I just did that on my wire wheel. every thing else needs a little extra cleaning power so I pulled out the trusty
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10025022.jpg

and I put everything in a coffee can and gave it a good coating
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10025200.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10025535.jpg
From this
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10024803.jpg

To this
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10040017.jpg

After seeing how the por-15 turned out on the control arms I decided to use it on the pedals as well
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10041841.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10041850.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10041857.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10041903.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10041907.jpg

I have not decided what to do with the spring yet. it was pretty rusty and I would hate to put it all back together and have it rust again, and I am not sure how well the por-15 will hold up on a spring
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10041916.jpg

[ConcreteAce]

ok here is the finished product.

this is what I started with

http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10022143.jpg


and here is how she is now
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10084801.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10084722.jpg



I think I can live with the results.

[ConcreteAce]

On to the master cylinder
due to the fact that I will be running disk brakes on all four corners. A duel MC with a Volvo top was in order. A big thanks goes out to Joe he took the one off of the 59 that I sold him and he was nice enough to give it back to me. I decided to go ahead and pull it apart to make sure the plungers where still in good condition, plus it really needed to be cleaned It sat around in my garage for ages.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10152245.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10153959.jpg


I decided to go ahead and hit it with some chemical resistant paint. Hopefully it will withstand brake fluid getting on it. after all that is what it is for.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10160224.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-10162446.jpg

[ConcreteAce]

I got all 4 calipers taken apart.

Fixing to head to Gabe's house he is going to hook me up with some powder coating. :dance:
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-11164710.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-11170228.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-11173735.jpg

[ConcreteAce]

Gabe hooked me up with a set of VW covers for the pedals. Thanks Gabe!! He said the calipers should be ready in a few days. :dance:
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-11204548.jpg
Man Gabe didnt waste any time. Here is an oven action shot
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/brake4.jpg

and some finished pic's
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/brakes3.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/brakes2.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/brakes.jpg

[ConcreteAce]

Gabe finished the calipers :dance:
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/caliper01.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/caliper02.jpg

Thanks man!
Moving on to the axel tubes.

these things are nasty and the cleaning process really sux. this is the one time I wish I had one of those little blasting cabinets.
Here is what I am starting with and this is after about an hours worth of pressure washing.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12181319.jpg

You will notice where I hacked off the shock mounts when it was still attached to the car. You cant really clean the cuts up when everything is in the way.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12181327.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12181339.jpg

So I started by cleaning the cuts up.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12184328.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12184323.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12183404.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12183356.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12183350.jpg

Now to finish the cleaning process, and get them painted up. :beer:

[ConcreteAce]

well a whole lotta elbow grease later....

to recap the start
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12181319.jpg

the clean up
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12223054.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12223104.jpg

the finish
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12225626.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12225640.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12225648.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12225700.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-12225709.jpg

:thumbs: I am happy

[ConcreteAce]

How about this. should be challenging. seamless boots :dance: Big thanks goes out to Billy for these beauties. :thumbs:
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-13004345.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-13004404.jpg
Ok Courtney decided to show you MEN up on here. How many of you guys have ever installed one piece axle boots? Courtney will show you how :dance:

The heat up
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/axletubes005.jpg

The install
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/axletubes006.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/axletubes007.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/axletubes008.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/axletubes009.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/axletubes010.jpg


Here is her trick. after several tries with dish soap she pulled out the big gun
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/axletubes012.jpg

With the big gun she got the second one on the first try
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/axletubes013.jpg

[ConcreteAce]

Ive started to bling out the tranny. This job really sux. but it is starting to come out. After I am done with the ribs Ill give it another coat of black to make the lines crisp and a couple of coats of clear.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-16143722.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-16143739.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-16143839.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-16143846.jpg
Ok better pic's

Transmission is done. A lot of work for something you will never see. But hey at least I had fun doing it. :thumbs:
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/transmission003.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/transmission004.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/transmission005.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/transmission006.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/transmission007.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/transmission008.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/transmission009.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/transmission010.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/transmission011.jpg

[ConcreteAce]

Moving along I had to remove the king pins from the stock spindles so that I can clean up and paint the carrier.
I dont have a press so I just used a socket and ext. and banged them out
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-16171745.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-16172701.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-16174307.jpg

now to the trusty easy off to get cleaned
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/2010-10-16172002.jpg
got the carriers and the tops of the link pins done
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/transmission012.jpg

[gixxer711]

looks like i need to stock up on easy-off and por-15. i have the blasting cabinet, next time you need it.

[ConcreteAce]

Moving on to some polishing. Thanks to Kostya for picking these up, and thirty hard earned dollars later I have some nice bolts for my axle's, spring plate covers, and beam bolts.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/polishing001.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/polishing002.jpg
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/polishing003.jpg
my bench grinder is just a little to aggressive for this job so I pulled out my trust rubbing stone.
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/polishing004.jpg
This is what I am trying to remove (letters)
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/polishing007.jpg
I started with some 80 grit
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/polishing005.jpg
then added a little water to some 400
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/polishing006.jpg
Getting close
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/polishing010.jpg
almost there
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/polishing015.jpg
this what I am looking for
http://i117.photobucket.com/albums/o70/ethandunlap/DLK/polishing020.jpg
I have switched to putting the bolt in a drill. doing them by hand is for the birds

[ConcreteAce]

looks like i need to stock up on easy-off and por-15. i have the blasting cabinet, next time you need it.

doubt you would need the easy off with the blasting cabinet.

[gixxer711]

accept for things i dont want damaged. hopefully my compressor can keep up with the cabinet.

[V8SuperBeetle]

Nice work on those bolts.

[mechmark]

Kermit should have a replacement cross shaft with new hook. I have gotten it there before.