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Re: [T3] 6V - 12V Conversion

> Hmmm, Tim, your link I have on my page is no longer any good...wassup wit
> dat?

I didn't know you were tied to a link, and I have no idea who had
copied it before - but here is the scoop again.  Toby, let me
know if you want a formatted file to post directly on your page.


Here are the steps to change your type 3 from 6 volts to 12

Change the cast aluminum fan housing, and install the larger 12v
generator.  It is possible to get a 12v generator the same size
as a 6v, so that you do not have to change the fan housing.  Try
Bill & Steve.

Change the coil.

Change the chokes.

Change the idle cut-off solenoids.

Change the flywheel.  Use an automatic transmission starter so
that you do not have to change the starter shaft bushing. There
was a flywheel hub design change, as the older crank shaft end
had a bulge.  The flywheel has a  step cut into it to clear this
bulge.  It is probably easier to have a step machined  into the
flywheel hub than to disassemble the engine to have the crank
shaft end dressed.  Finding the correct flywheel is best. 
Finding the old style hub flywheel with a removable ring gear
(and the correct ring gear to go on it) is next best, but
harder.  A 6v bendix gear in a 12v starter is rare, but I suppose
that you could disassemble a 6v starter, and have the gear welded
and redrilled for mounting in a 12v starter.  You can also put a
12 volt solenoid on your 6 volt starter.  Or don't change the
flywheel or anything else and run your 6v starter until it burns

Change the voltage regulator.

Change the battery.  Your battery cover will not fit anymore.

Change the windshield wiper motor.  Or install a resistor to cut
the voltage.  Or run your wipers really fast until you burn them

Change the fuel gage in the dash.  No need to change the sender
in the tank.

Change the clock.  Or don't worry about it because it won't run
for ever anyway.

Do something with the radio.

If you have an electronic tachometer, you will have to change it.

Change the headlight relay.

Change the turn signal relay.

If you have a horn relay, change that.  Change the horns.

Change every light bulb, everywhere.

That ought to about do it.

Does anybody get the idea that a 6v to 12v conversion is quite a
bit of work, not all of it simple?

The easiest thing to do if your 6v electrical system is getting
tired, is to put a 6v horn relay (from a Karmann Ghia) in the
solenoid circuit, so that your solenoid can get a full 6 volts. 
You can do a similar trick in the coil circuit.  If you think
your wiring is getting tired, try measuring the voltage at the
coil.  When internal resistance drops the voltage to less than
about 5.5 volts, you will have trouble starting the car from weak
spark.  A similar test at the solenoid will tell you that you
will have trouble getting the starter to work consistently. You
can also replace the stock battery cable, which is about 4 gage
(I think), with a heavier 0 gage cable to be certain that there
is no voltage loss going to the starter.  If you change the
positive battery cable, you might also want to secure the starter
ground, by putting a longer bolt through the body where the
battery is grounded now.  Under the car, run a cable from the
longer bolt to one of the starter mounting bolts.  This gives you
a more direct ground, again to avoid voltage drop at the
starter.  This 6v clean up stuff is a lot easier than a 12v
conversion, and lets you keep your car stock because no body can
see your modifications.  Of course, a 12 volt system is not so
subject to tired harness disease, and lets you use a modern

Tim Dapper

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