Reply to Dozerman51:
Thanks again for more advice. Will have to research this problem further.:confused2:
Hi Team,
just Googled and found this reply to 8v battery conversion on a VW site.
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Hi all.
Another person came by and asked me what they could do to make their old 6-volter VW more drivable without going to 12 volts.
I have sent this out before, but I'll post it again. It is not the most orthodox solution, but has worked many times and is the most simple one I found. I learned this trick from an old-time VW mechanic, one that I started my mechanic career under. It is extremely simple. All thanks to TJ!
Step one: replace the battery. I went to a local battery supply company and purchased an 8-volt battery (4 cells on top), which is most commonly used in farm equipment. It was the same size as my 6-volt battery. Availability depends on where you are, so I can't say how common they might be to find.
Step two: remove the cover on the voltage regulator. If it is good, it should be charging at about 7.2 volts, which is not enough for your new battery. If you watch the regulator operate with the car running and the cover off, you will see that there is a relay arm that clicks on and off to limit charging. Make sure that you know which one is doing this - I don't have pics any more. What you will want to do is (with the car OFF) bend the upper contact arm up a little so that it takes a higher voltage to actuate the relay. This in effect changes the output voltage. You will want to repeat this in small steps, checking the out put with the car running each time until you achieve an output voltage of 9.6 - perfect for your new battery.
Comments: This increase in voltage is enough to overcome the resistance that has built up in the wiring over the years, but is not enough to damage your components. The horn will beep loud again, the lights will be bright again, the wipers will work nicely, the starter will spin faster, and the radio will still work fine. It does have an additional bonus: you can actually jump start it from a 12 volt car with no ill effects, as long as you just jump it and don't try to charge it. It is also easily reversible with a new regulator and your old battery....
I have done this in more than one old VW, and always with the best of results. It is as close to the combination of pure stock and good functionality as you can get without replacing all the wiring, lamp sockets and electrical components.
Let me know if you try this, and what you think. I'll bet you love it as much as I did!
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Hope it helps.
Cheers,
Eddie B.