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Last Updated 7 Jan 08

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Step 3

First I drain the tank and remove the fuel sender unit and the wires hooked up to it. While the tank is draining, I can remove the battery and put it on a charger.

The battery must have been leaking acid for a while which rusted the battery tray and part of the tank. It's not a real problem as the tank gets repaired anyway but it pays to check from time to time what the battery is doing while hidden behind the seat.

I'm taking the tank to the sandblast people before I reweld the cracks on the top of the tank. After that I make up a bracket for the other side and weld it on the tank with a plate to make it stronger.

When the tank goes back in the trike I weld another bracket on the left hand side of the torsion bar so it is mounted how it should be. I fit rubber washers on all 6 bolts who hold the tank in place. The washers stop any vibrations to go from metal to metal and the tank has a bit of free play to move in the frame.

Step 4

The next step is removing the rear-crash bars and the shock absorbers to get to the Motor and Gearbox points. I put all the bolts I remove in ice-cream containers and have different containers for different parts of the trike.

The best containers are from Paul's rum and raison ice-cream or plain vanilla with a bit of Bundy poured over it. 

Now the motor can come out so we we can get to the Gearbox. I drain the oil before I disconnect the oil cooler. Something I learned the hard way... put a sticker on the fan housing telling me later there is no oil in the motor.

After the wires and the throttle cable are disconnected I unbolt the motor off the gearbox.

The beauty of the VW aircooled motors is it is very easy to remove the motor, which hangs on the Gearbox like an outboard motor on a dingy. 4 Bolts and it's out.

The Trike is getting shorter and I can see poor Margaret thinking that it is never going back together.  Just wait when we get down to the bare frame... that's a scary look!

After disconnecting the brake lines the gearbox mounting bolts are removed and the mounting points near the wheels. The gearbox lifts out and is ready for a good scrub.

I pumped all the old brake fluid out of the lines, I bet the brake fluid has never been replaced since new. It should be done at least every two years anyway. I replace mine every 12 months so I can be sure there is no moisture in my brake fluid. I like brakes to work well when I need them .

Tomorrow I will take the Gearbox to Leon's workshop and he will pull it apart to see what needs doing to it. The brake drums come off at the same time and the axle tubes get powder-coated black.

While the Gearbox is gone I will check all nuts and bolts and wires and hoses to see if anything needs replacing. The frame gets a good clean and I can fix the tank.

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