It is perfect VW driving weather Mike

Yep it sucks being stuck back here where all I can do is look at it...

Just had a chance to load test it. With a 300 amp load on the battery it holds pretty stable at 5.03 to 5.1 Volts. However, when you crank it the starter puts almost a 500 amp load on the battery and takes it down to 3.23 volts. So time to double check all connections, replace the battery cables, and look for any bad wires. Could still be the starter itself though since it wont start when hot.

I'm sure your battery is low on electrolytes. Top it off with distilled water....

Just a quick update...Car starts fine now. Upgraded to 1 guage battery cables and that seems to have fixed the issue. Of course now that it starts, it won't stop. Seems like a bad master so a dual circuit conversion is in the works. Got a 67 master cylinder and a Volvo reservoir and looks pretty straightforward. Gonna get started on that tomorrow evening. Been staying busy with the "other" car and keeping it going.

Did your adapter work for the switch?

Nope. Overthinking the problem as usual. Tapped the master with 1/8pipe tap and new switch threads in perfectly. Got everything soaking in PB blaster right now so it hopefully all come apart no problem.

Out with the old



And in with the new




Biggest headache was getting the old metal lines to line up with the dual circuit master cylinder. I think I spent 2 1/2 hours doing the swap, and probably 75% of that was making the lines fit. Now I just have to bleed and adjust and hopefully all will be well

Good job

Mike you taking her to the classic this year?