It is interesting, and a little frustrating, to see a simple job turn into a major epic, but there you go - the life of the foreign-parts-older-than-dirt, classic car nut.
What started as a simple carburetor rebuild has mushroomed into losing a nut down a hole and pulling the engine from the car, mostly for "ease of access" to get it out. True, it's really nice to have the little mill sitting out in the open so you can get at everything (and how I envy those "Spydah Guys" and their flip up rear cowls), but that easy access also has it's own mermaids, singing their siren songs of "fix me - Make me better". At least I now have a stud-free alternator pedestal for ease of future removal.
So then you get the engine on a shop stand and start looking at it and see a few oil weeps here and there, so you pull the distributor and replace the O-ring seal, then you tighten up the pushrod tubes (mine are adjustable), then you notice that the rear mainseal is a little weepy and could stand to be replaced, too (lucky me - I found a new one in my gasket bin) and on and on and on. I know.....These engines are, at best, a little weepy, but it's right there on the shop stand, right? So there you go.
I started to install the fan shroud and noticed that the thermostat bellows seemed a little too extended for a 40º workshop, so I called Bug City, got the dimension for a cold bellows and, sure enough, mine is toast. Ordered a nice, new expensive NOS German one. While messing with the thermostat, I found that one of the air vanes was binding at wide open so that it wouldn't return to a closed position until pushed just so. hmmmmm..... That might explain more than just the bind, too. Easy fix in most cases - just put a couple of thrust washers on the shaft and you're done. Not with a VW air vane, though. Where the shaft was binding is impossible to get at because the air vane assemblies, a cassette with two vanes each on both sides of the fan shroud, is a welded shut assembly. Solved that with three nylon washers with a cut on one side to allow them to become an open "C" when bent and popped them onto the shaft as spacers/thrust washers. 'Nuther problem solved. MacGyver would be proud.
At least with the engine on the stand I can look all around the sump mating area and see that it's not leaking. Those silicone gaskets from AirCooled really do work! And I'm now looking at installing those spiffy air shields that ALB told us about, along the undersides where my heater boxes aren't - especially on the thermostat side to make it work better.
Then you notice the little places here and there that could use some touch-up paint, or a piece of sheet metal that could be bent back a little for more clearance and...and... and...... I think I'll go have a nice cuppa tea before I find more stuff to "fix".