The Classic VW Beetle

As I mentioned in the earlier post – I was chasing down the electrical gremlins with my hand-dandy multimeter. After viewing the Bug Me Videos, I was able to identity a number of wiring issues that enabled me to the wiring system under control. The video answered many questions and things that I simply overlooked.

Which brings me to the brakes.

The brake lights would still not light. After double checking and re-checking the connections, there was something wrong. I used the multimeter and chased the current down to the master cylinder. The current was going in, but not coming back out. Finally, I was able to pinpoint the problem. I was going off the previous owner’s assessment that he replaced the brakes and brake lines, but on closer examination, there was no brake fluid in the reservoir.

So, I filled up the reservoir and prepared to bleed the brake lines. Within seconds, however, i had a nice pool of brake fluid forming in the floor and in the bottom of the hood compartment. I checked the line, and sure enough it was old, worn and cracked. A simple trip to the local auto parts store solved that issue. i reconnected the line, filled the reservoir, and was met with the same result. more brake fluid on the floor. I disassembled the entire assembly up to the master cylinder and inspected everything.

Of course, I should have done that in the first place, as it was the fluid reservoir that was a problem – a nice crack in the side when someone tightened it down to far, breaking the plastic.

Fast forward another few days as I awaited a new brake fluid reservoir like a kids awaits Christmas. Got it, assembled it, the new hose, added the fluid, and everything held. No leaks!!!

NEXT STEP – Bleed the Brakes
I bought a brake bleeding kit, as finding someone to step on the brakes for 20 minutes would be a little difficult. The kit worked wonderfully for the first two brakes, then i dumped the fluid. After dumping the fluid from the first two bleeds, something got into the reservoir on the kit, and it never worked as good as the first time. In fact, it was pretty much worthless. Looking back – bad investment, iIm sure i could have bought something a little more practical and reliable. I did what i should have done. Find a warm body that can count to six and push the brake pedal. It took a while, but it got done.

Next step – be sure your brake lights are grounded. Otherwise, much cursing and second-guessing will happen. Thank you again Bug Me video, for that reminder.

All in all, this part of the project was a tribute to all of the minor detail that were left unattended, and a testimony to how one problem can lead to another, and another, and another.

By the way, the brakes work great. The new brake lights and the upgraded 12 volt system really make then shine bright. This is so much safer than the tiny teardrop lights combined with the old 6 volt system. I never felt safe with this. Especially when some monster truck is bearing down on you when you want to make a left-hand turn.