Hello! Sam here with JBugs.com
We're continuing the rebuild of our 1971 Euro Look Super Beetle
and in our two previous videos we installed a pedal assembly,
accelerator and clutch cables, the transmission, and the shift rod.
In this video, we're going to finish up installing the remaining cables in the chassis.
[We] start at the rear of the car where we feed the parking brake cables into the tubes in either frame horn.
The cables are pushed into the chassis until they can be seen in the tunnel at the parking brake handle opening.
Once both cables are pushed through,
they are pulled up and out of the tunnel
and we prep out restored parking brake handle.
We install the rubber stopper and the spring, on the pushrod
thread on a brake button,
and insert the rod assembly into the handle.
We rotate the cats paw at the back of the handle so that the teeth face back,
then slide the rod underneath it
until it sits under the U-bend at the pushrod.
We hold the button down so that the paw doesn't fall out of place
and slide the ratchet into the brake handle, and release the button.
The brake handle is set in place into the tunnel,
making sure that the cables are lined up with the ramps at either side,
and that the notch in the ratchet, is set in place on the pan.
The pivot pin is pressed in place through the chassis
and the snap ring is pressed into place [on] the opposite side.
The parking brake cables are pulled out of the chassis a bit more
and routed through either side of the compensation bar.
The set nuts are threaded on loosely
and we test the operation of the handle before threading on the lock nuts.
We won't tighten the cables fully until the rear brake calipers are installed later.
We finish off the handle by laying a bead of black RTV silicone
and then sliding on a parking brake handle cover
and wiping off the excess RTV.
Next, we'll install the new heater cables.
There are two levers for the heater controls.
The heater box cable has long crimped ends
and routes from the right lever to the rear of the car.
The rear footwell cable has bare ends that are twisted back into a loop
and route from the left lever to the rear footwells where they control the heater ducts.
We'll install the rear footwell cables first, on the left side of the tunnel,
with the longer side of the cable installing into the lower tube,
and the shorter end installing into the top tube.
The top tube goes to the cars left side, the bottom tube goes to the cars right side.
Next, we insert the dog leg on the cable into the left heater lever which bows towards the center.
A plastic spacer is set into the threaded base
and the lever is pushed back into the chassis
and set in place on the base.
Another plastic spacer is installed, followed by the lock washer and an original lock nut.
The lock nut is tightened down and we operate the lever to make sure that it works smoothly.
We cap the lever off with a black heater control knob and tap in place lightly
as it will come off briefly when we install the parking brake boot later.
The heater cables are installed on the right side in the same manner,
with the longer end going into the lower tube and the shorter end going into the top tube.
Then the spacers, lever, lock washer, nut, and knob are all installed just like we did on the left side.
At the rear of the chassis, we use silicone spray on new heater cable tube boots
before sliding them over the heater cables and onto the chassis.
Holding the cable ends with a pair of needle nose pliers helps while pulling the boots over the ends.
Speaking of ends, that's it for this video, but next time we'll begin reassembling the rear suspension.
Thanks for watching! Let us know if you have any questions in the comments below.
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and when you need parts for your vintage Volkswagen, head over to JBugs.com