JBugs Video Series

1971 VW Super Beetle - Brake Line Installation:

Brakes Routing

Video Overview:

We are almost ready to drop the body in place onto our restored 1971 Super Beetle chassis. Before we do we are making sure that everything that we can install is installed! It will be much easier to do now while the body is out of the way. Follow along as we finish up the installation of our VW Brakes with new stainless steel brake hard lines along with stainless steel braided brake hoses to plumb the brake system of our Euro Look Beetle.

Front to rear brake line installation: 0:53
Trailing arm brake line installation: 2:24
Left to right rear brake line installation: 3:29
Front brake line installation: 4:24


Video Tips:

Tools used in this video:

3/8" Drive Ratchet
3/8" Drive 3" Extension
3/8" Drive 10mm Socket
Flat Blade Screwdriver
10mm Wrench
11mm Wrench
14mm Wrench
17mm Wrench
Adjustable Wrench (x2)
Brake Tubing Bender
Hammer
Chisel

Video Transcript:

Hello! I'm Sam with JBugs.com
We're working on our 1971 Super Beetle and while the body is out of the way, 
we're installing as many of the parts on the chassis as we can. 
In our last video, we installed the rear suspension and brake components, 
and now we'll work on installing new stainless steel brake hard lines.
For shipping, the long front to rear brake line is looped over, 
so we begin by straightening the line. Then, we install a brake line grommet on the line and then slide the brake line through the lower hole at the rear of the left floor pan. 
A new brake line "T" is threaded onto the end of the line, 
then it's shaped and bent using a brake line tubing bender and gentle thumbs. 
The brake line grommet is installed into the chassis, 
and the "T" is lined up with the chassis tab and bolted in place. We check the alignment with our original brake line and "T" and then tighten the brake line down.
Next, we gently bend the brake line back so we can install it through the front of the chassis. 
We continue to bend and shape the line carefully until it can be lined up against the chassis. 
Once it is, 
the line is pressed into place under the brake line tabs at the tunnel, and the tabs are bent down with a hammer and chisel to secure the line. 
At the front of the chassis, we bend and shape the line so it's clear of the pedal assembly. 
Then, we install brake line grommets at the inner and outer portions of the chassis bulkhead. 
The brake line is bent and shaped there so that it threads into the rear port on our master cylinder and the fitting is tightened.
At the rear left of the car, we thread in the previously installed stainless steel brake hose into the brake caliper, 
and we loop it up to the brake hose tab that we welded onto the trailing arm. 
A brake line clip is tapped into place temporarily to hold the hose 
while we shape the trailing arm line. 
We bend and shape the line so that it rests into the stock metal tabs on the top of the trailing arm, 
and then bends down to the stock brake hose tab.
The stock replacement braided brake hose, at the front of the trailing arm, is threaded onto the "T" and tightened down. 
It is installed onto the brake hose tab on the front of the trailing arm, 
and a brake line clip is tapped into place. 
The new brake line is threaded into the hose, 
routed up to the tab on the trailing arm, and then threaded into the hose at the rear of the trailing arm. 
The brake line is shaped a bit more so it sits against the trailing arm, 
the tab is bent over to hold it in place, and the brake line clip at the rear is tapped into place once again. 
Both ends of the line are tightened, 
and we can get to shaping the left to the right rear brake line.
Fortunately, this line can be shaped just like the stock 
and since we kept the original, we use it as a guide to bend and shape the replacement piece. 
Once one side is ready, we set it in place at the chassis 
and thread the line into place and tighten it at the left "T". 
We thread the brake union in place, at the opposite end of the line, 
and bend and shape the line there until the union can be bolted in place at the chassis tab. We then tighten the fitting and bend over the securing tab in the middle of the chassis. 
The installation at the right trailing arm is just like the left; 
installing the hose at the caliper, the chassis, and then bending the line to fit between the two.
At the front of the chassis, we have all the original brake lines to use as templates, 
and we start by bending the front brake line. 
Then, we bolt the front brake line "T" in place, 
thread the brake line into it, and then route the line to the passenger side, tapping the securing tabs in place as we go. 
The front left line is shaped using the original line as a template again 
and then threaded into the brake line "T". 
Finally, we bend and shape the line that runs from the front part of the master cylinder to the "T" 
making sure that it's clear of the control arm mount and it's installed. 
The rest of the front brake lines will be attached once the front strut housings are in place, 
but we still have a few more things to do before then. The main thing of course will be bolting the body back in place.
But before then, we'll go back and double-check that all of our fittings are tight 
as they are never as easy to get to as they are right now.
Thanks for watching!
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and when you need parts for your vintage Volkswagen, head over to JBugs.com