How about the large wires/connections that plug onto the VR?   They may be 
contacting earth ground on occassion.  Make sure that none of those 
connections are touching anything else or each other, ever.  They're all 
cramped together in that one small space. Maybe a foreign object (jack?) 
moving around in the area?  Or a seat belt latch?  Many people insulate this 
sensitive space as carefully as you've done with your battery.....

Mike B.

----- Original Message ----- 
From: "Potter, Tom E" <[EMAIL PROTECTED]>
To: "Air-Cooled Volkswagen Discussion List" <[email protected]>
Sent: Monday, April 28, 2008 9:01 AM
Subject: Re: [vintagvw] Starting probs in my 68 bug.


> Are the metal springs in the rear seat touching the battery terminals?
>
> Tom Potter
>
> -----Original Message-----
> From: [EMAIL PROTECTED]
> [mailto:[EMAIL PROTECTED] On Behalf Of asad ishaque
> Sent: Monday, April 28, 2008 4:30 AM
> To: Air-Cooled Volkswagen Discussion List
> Subject: Re: [vintagvw] Starting probs in my 68 bug.
>
>
> Hello all,
>
>   The battery has been put in brand new less than a month ago. Problem
> is the car is not giving any problems as far as starting in the mornings
> and operation with headlights on is concerned. The battery is still
> under warranty but unfortunately here the criteria for returns is if you
> encounter any problems, not the fact that the battery reads low.
>
>   I shall discuss this with the battery guy. Lets see if he agrees to
> replace the same, which I doubt highly.
>
>   Couple of more things. I am hearing some occasional 'pops' from under
> the rear seat while driving. It sounds like strong sparking. Have
> checked the terminals and both are nice n snug. Maybe its from within
> the cutout??? It had looked good when I had inspected it a few weeks
> back. The sound is very very occasional, therefore I am unable to
> investigate it while driving. I discussed with my brother Suleman and he
> said it might be arcing somewhere. This may have in fact be what caused
> my last battery to go bad all of a sudden.
>
>    I think a sensible approach (tho a shot in the dark) may be to
> replace the cutout with a brand new unit. What do you guys say???
>
>    Second querry is regarding the Alternator pedestal. The one I got
> *seems* to have been cut from the rear portion (rear of the car/engine).
> Maybe this was done at the factory to help clear the large collar sort
> of flare in the housing? Or maybe its a cheap solution to get around
> buying the correct pedestal?
>
>    How do the alt and gen pedestals differ from each other?
>
>    All input and thoughts are welcome and appreciated.
>
> TIA
>
> Asad
> Karachi, Pakistan.
>
>
>> From: [EMAIL PROTECTED]> To: [email protected]> Date: Fri,
> 18 Apr 2008 10:27:46 -0400> Subject: Re: [vintagvw] Starting probs in my
> 68 bug.> > Bad battery. Any 12V battery should read AT LEAST 12V at it's
> lowest. > Any reading less than 12.0 is bad. If charging system is
> working properly, > and car is driven long enough (20+ mins) to charge a
> low battery, the batt > voltage will come up to or over 12V. If it
> doesn't, it's bad. 12.5 to 12.8 > is closer to normal foe a healthy
> battery.> > Mike B.> > ----- Original Message ----- > From: "asad
> ishaque" <[EMAIL PROTECTED]>> To: <[email protected]>>
> Sent: Friday, April 18, 2008 10:25 AM> Subject: Re: [vintagvw] Starting
> probs in my 68 bug.> > > >> > Guys,> >> > I did check out the voltages.
> The initial voltage at the battery > > terminals before starting was
> 11.68 volts which I think is a bit on the > > lower side. On starting
> the voltage does climb up to over 12 volts and > > goes around 14 volts
> on revving.> >> > This weekend I may go around changing the alternator,
> saying goodbye to > > the 'modified charging system'. That would be
> sweet!> >> > Might need help as far as the connections go. Dont think
> there would > > be much to worry as my current non-VW generator has four
> connections like > > the VW alt has. One connector with three terminals
> and one round clip > > which fits onto a stud connector. The VW unit has
> a three pin connector > > plus a stud connector. Guess I just have to
> figure out where the three > > connections should go.> >> > Would be
> consulting the tech manuals and doing a bit of detective work > > under
> the rear seat to get clues.> >> > Just wait for my shout if I get stuck
> anywhere!!> >> > Regards,> >> > Asad> > Karachi, Pakistan.> >> >> Date:
> Wed, 9 Apr 2008 19:00:28 -0500> From: [EMAIL PROTECTED]> To: > >>
> [email protected]> Subject: Re: [vintagvw] Starting probs in my 68
>> >> bug.> > Hi, Asad,> > If your voltage regulator is working, the
> alternator > >> should top out > around 14 - 14.5 volts after you reach
> the RPM that the > >> alternator can > actually generate at. If the
> voltage keeps climbing with > >> RPM, something > is wrong, and you will
> end up boiling the battery dry > >> after a few days.> > Chuck Kuecker>
>> asad ishaque wrote:> > Guys,> > > > > >> Here is the progress I have
> to report. > > > > Got a new battery. Its > >> rated at 65 Ampere Hours.
> Its in the bug and Im having no probs. Have > >> taken a drive to work
> in the dark and the bug performed normally.> > > > > >> However, I find
> that the readings I take from the voltmeter after having > >> a drive
> are still in the range of around 11.90 Volts. I dont think thats > >>
> healthy as some have already pointed out. The readings with the engine
> on > >> and at idle are in the range of 12.50 volts. On!> > revving it
> goes to above 14 volts. Havent revved it really hard but I > > think it
> would go upto 15 volts.> > > > Got the car rechecked by the > > battery
> shop guy. He took some readings with his voltmeter and said all > > was
> well. > > > > Any checks or readings I should take and report here???> >
>> > > > i have to install the VW alternator soon. The new battery has a
> full > > guarantee for the month of April, then it would be part
> exchange till five > > more months. I should be doing all
> experimentation in this period!!> > > > > > Thanks to all.> > > > > >
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