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Which means "Evil Twin". Lets see your projects where you change boring into fun or create the fun from scratch.
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 Post subject: Dune Buggy rebuild
PostPosted: Sun Jan 27, 2019 3:04 pm 
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Joined: Tue Jan 06, 2015 8:09 am
Posts: 107
After 4 years in the garage, my Dune Buggy is back on the road. I bought it running and driving and told my wife, "Don't let me take it apart." Well, that didn't work. The seats were plastic Jaz units and were just horrible. I just wanted better seating. The frame had no room for better seats, so I would lie in bed at night trying to go to sleep but running different plans through my head. I finally decided after several months and one failed attempt, that the frame had to be cut away and a new section installed. I ordered material the new day and started cutting. I was also working part time at night crew chiefing an SCCA Trans Am 2 Camaro. Were we getting new brakes at a really reduced price and that allowed me to order a floor petal set with master cylinders. This meant I now needed better brakes on the car and a hydraulic clutch set up. I ordered a killed brake set up and a clutch slave unit. This led to new steering set up: shaft, quick release, u-joints, box, steering links, tie rods, all of it. Brake lines had to be made, why not do it with AN fittings and 37 degree flare? That means tabs for bulkhead fittings and hand bent hard lines. New lights, gauges, dash, wiring, wire connections, (Deutsch connectors) more tabs for light and connector mounting. Fabbed a steering column for tach and turn signal mounting, new fuel tank with tube fuel gauge welded on the end. New cable throttle set up for a new twin carb set up. All new shifter, with u-jointed shift rod, (all hand fabbed).
I will follow up with pictures.

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 Post subject: Re: Dune Buggy rebuild
PostPosted: Sun Jan 27, 2019 3:08 pm 
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Joined: Tue Jan 06, 2015 8:09 am
Posts: 107
Here is the start of the cutting of the frame for seat mounting.


Attachments:
File comment: Here is the new seat in place
IMG_5250.JPG
IMG_5250.JPG [ 114.81 KiB | Viewed 202 times ]
File comment: I had to cut away the frame that was just in the way of mounting a seat. The frame angled in about four inches and left no room.
IMG_5297.JPG
IMG_5297.JPG [ 130.55 KiB | Viewed 202 times ]

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 Post subject: Re: Dune Buggy rebuild
PostPosted: Sun Jan 27, 2019 3:19 pm 
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Posts: 107
I could not find an exhaust system for a Type 4 VW in a buggy. The Type 4 is like a 914 Porsche and the exhaust is out of the bottom not the ends like a regular Type 1 VW Bug engine. I used the stock flange and machined away the original pipe and fabbed the headers and exhaust. I has a left over 4-2-1 collector that I split into 2, 2-1 units and have two separate headers, left and right.


Attachments:
File comment: Stock flange ready to machine.
IMG_2348.jpg
IMG_2348.jpg [ 99.14 KiB | Viewed 202 times ]
File comment: Machining the flange.
IMG_2349.jpg
IMG_2349.jpg [ 93.02 KiB | Viewed 202 times ]
File comment: Fitting the new pipe.
IMG_2465.jpg
IMG_2465.jpg [ 87.97 KiB | Viewed 202 times ]
File comment: Test fitting.
IMG_2467.jpg
IMG_2467.jpg [ 96.44 KiB | Viewed 202 times ]
File comment: On the car.
IMG_2680.jpg
IMG_2680.jpg [ 126.86 KiB | Viewed 202 times ]

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 Post subject: Re: Dune Buggy rebuild
PostPosted: Sun Jan 27, 2019 3:30 pm 
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Joined: Tue Jan 06, 2015 8:09 am
Posts: 107
The stock Bug transmission needed a new nose and shift fork. Added a better aluminum side cover. The drive flanges were upgraded to bigger CV joints. Machined stepped washer/spacer to attach the flanges. They were held with a snap ring before with a rubber plug to seal it. Added a -6 AN fitting for the vent.
The front mount was on the nose so I fabbed up brackets that were much better than the original.


Attachments:
File comment: Drive flange spacer/washer attachment.
IMG_2595.jpg
IMG_2595.jpg [ 68.54 KiB | Viewed 200 times ]
File comment: New side flange and drive plates with my bolt on option.
IMG_2600.jpg
IMG_2600.jpg [ 117.94 KiB | Viewed 200 times ]
File comment: Nose cover with the AN fitting. New solid mounts fabbed up as well.
IMG_2602.jpg
IMG_2602.jpg [ 85.45 KiB | Viewed 200 times ]

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 Post subject: Re: Dune Buggy rebuild
PostPosted: Sun Jan 27, 2019 3:41 pm 
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Joined: Tue Jan 06, 2015 8:09 am
Posts: 107
Here are some details of the Buggy.


Attachments:
File comment: Oil cooler on the frame.
IMG_2503.jpg
IMG_2503.jpg [ 119.83 KiB | Viewed 200 times ]
File comment: Oil cooler adapter on the engine.
IMG_2502.jpg
IMG_2502.jpg [ 115.7 KiB | Viewed 200 times ]
File comment: Throttle cable mount and fuel line mounting.
IMG_2490.jpg
IMG_2490.jpg [ 137.01 KiB | Viewed 200 times ]
File comment: Engine breather fitting adapter.
IMG_2486.jpg
IMG_2486.jpg [ 105.89 KiB | Viewed 200 times ]
File comment: Engine and trans breather.
IMG_2487.jpg
IMG_2487.jpg [ 125.82 KiB | Viewed 200 times ]
File comment: Air horn pump.
IMG_1923.jpg
IMG_1923.jpg [ 88.26 KiB | Viewed 200 times ]
File comment: MSD box mount behind the drivers seat.
IMG_1919.jpg
IMG_1919.jpg [ 100.89 KiB | Viewed 200 times ]
File comment: Rear shock mount.
IMG_1880.jpg
IMG_1880.jpg [ 105.17 KiB | Viewed 200 times ]
File comment: Dash, seats & column.
IMG_2661.jpg
IMG_2661.jpg [ 130.25 KiB | Viewed 200 times ]

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 Post subject: Re: Dune Buggy rebuild
PostPosted: Sun Jan 27, 2019 7:37 pm 
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Posts: 2519
The welds are just beautiful, but I'm sure you now that.

I saw a tab on the muffler that looks like its for a bracket but no support bracket on the install pic....have you added that? My very first custom exhaust on a corvair engine had unsupported mufflers...that split the pipe after less than 1 week of service resulting in a loud exhaust trick on my way to court for the loud exhaust ticket that prompted the custom exhaust build in the first place :oops:

My other comment is those tires have WAY too much tread....hell they look like theyve never been driven, that needs to change!


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 Post subject: Re: Dune Buggy rebuild
PostPosted: Sun Jan 27, 2019 8:38 pm 
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Posts: 107
The mufflers are currently unsupported, I have 1 inch stainless strap that will wrap around the muffler and bolt to a strap that will then bolt to a tab on a split clamp bolted to the frame rail. I also have tubing to build a rear bumper/engine protector. It will bolt on to the upper frame with two bolt flange and bolt to the trans mount between the engine and trans. Th little custom tabs and brackets eat a lot of time. But that is what makes it cool, and unique.

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 Post subject: Re: Dune Buggy rebuild
PostPosted: Sun Jan 27, 2019 8:41 pm 
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Here is a shot of the front end details.


Attachments:
File comment: Suspension details
IMG_2678.jpg
IMG_2678.jpg [ 147.61 KiB | Viewed 195 times ]

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 Post subject: Re: Dune Buggy rebuild
PostPosted: Mon Jan 28, 2019 10:24 am 
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Joined: Wed Jan 23, 2019 11:13 am
Posts: 24
That looks like a hoot, especially with the predicted power/weight.


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 Post subject: Re: Dune Buggy rebuild
PostPosted: Fri Feb 08, 2019 2:54 pm 
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Joined: Tue Jan 06, 2015 8:09 am
Posts: 107
Waiting for warm weather now. I also ordered parts for a 2257 big bore stroker rebuild next winter with new casting aftermarket heads. Here we go.

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