Alyce the Baja

If you are building a buggy or Baja then please post in here and share your experinces with us

Moderator: manxiberty

User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:22 pm

Hey everyone. I thought it was about time that I started posting my build diary for my Baja on the Manx Club site too. I know that not all of you are on Aussie Vee Dubbers.

IF you're up for a bit of a read here is the current diary I have going http://forums.aussieveedubbers.com/view ... 275&page=1

I did a Kombi box swap on mine just before Christmas, seeing as how Paul has just done one to his Baja I'll copy over what I did on mine so you can all compare :D


It's a long story, but basically I broke the gearbox while offroading last Saturday (10/12/2011). Currently stuck in 2nd gear with broken selector forks :(

So that's put a little bit of a handbrake on proceedings for the time being.

Despite being able to get another Type 3 box for nothing, I've decided to fit a Kombi box instead. I know that I would probably just break another Type 1 box, plus the ratios aren't very good for offroad use.

Luckily enough I happen to have a few Kombi boxes lying around. A 5-rib 1800 box was selected as it has the best ratios for offroad and highway use, remember this car is still my daily (when it's not broken)

Here it is ready for a degrease.


Image


And after I scraped some of the sludge off it and a quick degreasing later.


Image


The bellhousing still has some heavy gunk in it. I have to pull it off to cut the input shaft down anyway, so I'm going to take it to work and run it through the thermojet hot wash to get it nice and clean.


Image




Smiley :)
Last edited by Smiley on Wed Mar 20, 2013 8:11 pm, edited 18 times in total.
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:24 pm

It wasn't long before I had the bellhousing off and the input shaft removed. The box was actually quite clean inside, and the oil wasn't burnt or smelly when I dropped it.


Image


Image


Image


I've spoke to Dave Butler this afternoon and I've ordered a few bits that frequently wear out under the nose cone and are easy enough for me to replace by myself.
I'm also going to replace the CV flange seals and the main input shaft seal.
Another plus is that my Cranky kit bolts straight up to this box so I'll be able to continue using it.

Things are probably going to slow up for a while now, I'm hoping to have the box fitted before new years.

More soon.



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:25 pm

Took my gearbox input shaft into one of the local brake places that happens to be into VWs. He was kind enough to allow me to use his lathe to trim the end down to the correct length for use with the Type 1 engine. Got to love fellow dubbers that are always willing to help out.


Image


I also had a package show up today from Mr Dangerous Dave. Many thanks for the speedy service :D


Image


And I went down to Repco and rifled through their draws until I found some bushings that I liked. They are off a Ford Fairmont I think they said. Soon to be 10° transaxle mounts for a Baja Bug I told them!!!


Image



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:25 pm

Here is the bellhousing after the little clean up it got today at work. It's a shame I'm running on such a tight deadline otherwise I would have smoothed it and gotten rid of all the casting flash like I did on the calipers.


Image


Image


And now all pretty blue!!


Image



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:26 pm

I pulled the nose cone off the box and removed all of the shiftery bits. I have a new pivot ball and the shim plate ready to be fitted. I also picked up a new shifter shaft seal today too.


Image


Image


Hoping to maybe get the box back together this weekend :D

More updates soon.



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:26 pm

I installed a new shifter shaft seal in the nosecone.


Image


And fitted a new swivel ball to the linkage. Plenty of grease.


Image


Here's all the bits greased and reassembled. Ready to fit the shim plate and nosecone.


Image


Image



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:27 pm

I reassembled the thowout arm back into the bellhousing and fitted it to the box. You can also see the cut down input shaft.


Image


I also put new output flange seals and seal caps.


Image


Box is ready to fit :tu:


Image


This was done by about lunchtime yesterday. So I decided to get carried away and rip into the car.



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:27 pm

Didn't take long to go from this...


Image


Image


Image


...to this.


Image



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:28 pm

You can see in the previous picture that I removed the standard gearbox mounting cradle and just left the crossmember that I built in place. This will stop the framehorns from moving around. I'm going to fabricate my own 10° Kombi gearbox mount that will be welded to the top of the horns.

I sat the box in place to see how much clearancing would be required to get the box to fit.


Image


Going to have to trim the framehorns where they are spotwelded together.


Image


Image



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:29 pm

The framehorns got trimmed down and then seam welded.


Image


Image


I also cut the factory front mount off the pan.


Image



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:29 pm

You can now see the gearbox isn't sitting up on the framehorns anymore. It fits in between them and is resting on the two CV output flanges. I took a lot of measurements of where the CVs were located before I took the old box out so I can get the new one in the same location. But I found if I move the box back by 10mm I don't have to trim the shift rod at all. This also gives me a little more room for the clutch and accelerator cables to come pass the box on the LHS.


Image


Image


Image



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:30 pm

One issue I did have was the reversing switch had no clearance to the framehorn and was contacting. I have my reverse light on a switch on the dash anyway, so I decided to cut the terminals and plastic switch housing off. I then removed the plunger from the inside and filled the hole left in the plug with silicon.


Image


Image



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:31 pm

Time to start fabricating a new front transaxle mount. Using those EA Falcon front suspension bushes.

First make one of these to suit your Kombi mounting holes.


Image


Then separate these.


Image


Make some more plates with holes in them.


Image


And voilà! Ready for welding. Make sure you remove the bushes after you tack the pieces in place. Otherwise they get a little melty.


Image


Image



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:32 pm

I cleaned about a kilo of sand each out of the clutch and accelerator bowden tubes. And I fitted the box for about the millionth time to check clearances. I wanted to make sure that the bowden tube was going to have a nice bend in it and not run into the box too much. I'm happy to report that with the gearbox location I've chosen the stock Beetle tube is the perfect length and has the right bend in it and everything.


Image


Image



Smiley :)
If you said I was a Volkswagen man, you'd be right.
User avatar
Smiley
Manx Club Member
Manx Club Member
Posts: 971
Joined: Tue Nov 30, 1999 10:00 am
Location: Yeppoon, Central Queensland

Re: Alyce the Baja

Postby Smiley » Sun Jan 08, 2012 4:32 pm

I go the last of the front gearbox mount fabbed up and welded onto the torsion tube. I'm happy to report that is works as it should and the box is in the right spot.


Image


Image


Image


Now I just need to make up the rear mounts tomorrow afternoon and machine my axles to take a Type 2 CV on the inner side.

More updates as they come, thanks for reading.



Smiley :)
If you said I was a Volkswagen man, you'd be right.

Return to “Buggy & Baja Building”

Who is online

Users browsing this forum: Bing [Bot] and 5 guests