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.
what new lights did you use? Is it just 12v lightbulbs and the new 12v system? Or did you do something more elaborate?
I’ve got a 1959 the PO converted to 12v, and I’m going to have to spend some time chasing down grounds and getting my brake lights and turn signals working again.
it’s just how it is with ‘older’ vehicles.. there are issues that lead to other problems when not immediately fixed… a cousin owns a vw beetle (which had been passed down to him by his dad, originally owned by our grandfather) that’s been with the family for God knows how long… my cousin also had some problem (i think it was a little clutch problem) that was left unattended, it then started to leak, that’s when he attempted to repair it himself.. he discovered it turned into a myriad of problems and was way beyond his capability to fix..
Well as Kirk allready said. That’s how it is with old cars. But it sure does has his charm! And the modern cars aren’t always better or easier to fix. I have a reasonable new car. And it just stopped! In the garage they connected the car to the computer…and the computer didn’t see the car! It took them 4 days to fix it
MY 68 BUG HAS THE LEFT BRAKE LIGHT AND THE LEFT FRONT PARK LIGHT NOT WORKING. THE BLINKER WILL BLINK BUT THE LIGHT WILL NOT WORK FOR THE LIGHTS. WHAT IS THE PROBLEM?
I know it’s been a couple years since you did this and may not have the bug anymore, but when you went to the auto parts store for the hose between the reservoir and the MC, did you get the proper blue braided hose? Brake fluid will eat away at regular rubber hoses and very rapidly deteriorate.
I gotta hand it to you DIY guys. I wish I had half the courage in getting my hands dirty and fix my own car if it breaks down. I’ve been wanting to get a VW 1303 Cabriolet for years but finding a good VW mechanic is one of my concerns.
Good luck on your bug!
Bob
The tools required to do a total brake rebuild are elementary: wrenches, screwdrivers and pliers are all it takes (and perhaps a braker bar), and if you have the exact parts, this can be effortlessly done in any garage or driveway. Make sure you tag along a few safety methods when placing your car up on jack stands or a lift.