We have a slight problem…
Having had the electrics gone through in the re-fit process, there turned out to be a small charging gremlin to get sorted before I was happy with it all, as the red generator light was coming on at the dashboard, which normally means the battery is not charging properly as we discovered out on our first test run! I was advised to double-check the earthing strap from the gearbox to the chassis as well as checking the regulator and dynamo.
The earthing strap looked like it was probably the original item from 1969/1970, and subsequently was covered in 40+ years of accumulated dirt and grime! So I removed it and gave it a thorough clean and de-grease, as well as cleaning up up the bolts and connection points on the chassis and gearbox.
This way I could go through items one by one and make sure they had all been checked off. The earthing strap rather than looking like a piece of discarded dusty rope now looked as good as new, so this could be ruled out as being a problem.
Now to check the regulator. A friend had an original German-made VW stamped regulator that I could try as a replacement. Nice to use original parts wherever possible. This was used and all the connections were double-checked…
To make sure all electrical connections were correct, I found a copy of the original wiring diagram. This was really helpful and was found in the Technical archives of the really helpful thesamba.com website. Great to have a resource for things like this. An invaluable resource for air-cooled VW enthusiasts the world over.
Lastly, with the new original VW regulator all wired up, we double-checked the dynamo connections and made sure all was good. The live feed from the regulator to the dynamo had a small amount of movement in it. My eagle-eyed friend noticed that this had also caused a small loose connection on the internal connection. This was also tightened up and so now, all should be good to go!
So I jumped in the cab seat, turned the ignition and bingo, the engine fired up and the red generator light immediately went out! A happy ending to the evening work!