Two Manx Build, 1 Aussie and lots more days than I wanted

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

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Brad
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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby Brad » Tue Jun 04, 2013 12:05 pm

Beam done and coated ...

By this time the floor pans and 1st batch of powder coating is back and I have begun to assemble the floor pan. When doing this particular care is taken to ensure everything is aligned correctly, greased and ready for use.

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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby Brad » Tue Jun 04, 2013 12:05 pm

The bodies have now arrived from Meyers Manx and the rest of the build can get underway.

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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby Brad » Tue Jun 04, 2013 12:05 pm

And for anyone who wants a read the final build specs are :

Body / Kit Details
  • Meyers Manx Kick-Out Traditional Kit – Canadian Blue
  • Blue\Vented Side Pods – Canadian Blue
  • 2 Piece Rear Deck Lid kit – Canadian Blue
  • Manxter 2+2 Rear Air Box cover – Canadian Blue
  • Meyers Manx Front and Rear Skid Plates
  • Manxter 2+2 Front Bumper
Interior
  • PRP Premier Bucket Seats, Tan trim
  • Custom Carpet Set and tunnel covers
  • Rebuilt Pedal assemblies with cover plates
Electrical
  • Full Custom wiring loom, heat shrunk and sealed
  • Custom 6 Gauge Set with GPS Speedo and Manx Emblem (Speedhut)
  • Custom switching
  • Factory steering column
Floor Pan / Chassis
  • IRS / Ball Joint Floor Pan
  • Shortened 14 ¼”
  • New Floor Pan Halves fitted and shortened
  • Custom Tunnel Gusset and Handbrake reinforcement kit
  • Tunnel Access Kit
  • Heater cables removed
  • Sand Blasted, etched and powder coated
  • New fuel lines and cables fitted.
Transmission
  • Rancho Pro Street – 4.37 Final drive
  • Welded Gear Hubs
  • Steel Shift Forks
  • Super Diff
  • Heavy Duty Side Plate
Engine
  • SCAT 1914
  • Chrome Kit
  • Alternator kit
  • Twin Webber Carbs with hex linkage
  • Pointless ignition and matching coil
Brakes and Suspension
  • IRS Rear end, factory trailing arms fully rebuilt new bearing, and powder caot finish
  • Bilsetin Rear Shocks
  • Ball Joint front end fully rebuilt
  • TRW Steering Box
  • New Tie rods and ends
  • Steering Dampener
  • Bilsetin Shocks
  • Front Brakes – Factory twin pin calipers and new rotors
  • Rear Brakes – Customized EMPI Disc kit with e-brake
  • New brake lines all round
  • Custom DOT Approved braided flex lines
Wheel and Tyres
  • Bruce Meyers Signature Series wheels
  • 15 x 8 Rear with 31 x 10.5 x 15 BFG A/T Tyres
  • 15 x 6 front with 215 x 75 x 15 BFG A/T Tyres
Brad

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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby Brad » Tue Jun 04, 2013 12:06 pm

VWNuts wrote:Oh I know I have really slow builds. That's why I don't put a time frame on them.....

So back to topic..... Where are the updates :P



So now lets see your updates :D
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VWNuts
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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby VWNuts » Tue Jun 04, 2013 5:29 pm

:D
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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby Brad » Thu Jun 06, 2013 3:21 pm

So with the build back and moveing it was time to pickup some more parts.

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Some Buggy Bling from SCAT.

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Some Buggy Bling from Meyers Manx with two sets of Bruce Meyers Signature Wheels.

While I was over picking up teh wheels to drop at the tyre shop for rubber I checked out what I need to get next load ..

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Pimp Buggy !!!
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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby Lovebuggy » Thu Jun 06, 2013 3:54 pm

Sweet. Bolt in Engines :D
Are you a financial member of the club??

Go to "http://www.manxclub.org/phpbb3/viewtopic.php?f=50&t=1667" and sign up today.
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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby Brad » Tue Sep 10, 2013 6:35 am

With the engines in location it was time to fit them to the Rebuilt Rancho Transmissions.

Prior to fitting the engine ,however, you must install the front end with tyres so as to give the front enough weight that it allows the engine to be fitted. These buggies weigh so little that if you have them on a lift without the front end and tyres the engine will cause them to over balance.

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Up front we have a fully rebuilt BJ beam with adjusters, TRW steering box and braided lines. New fuel line is also run and steering dampner and all new seals and bushings fitted.

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Disc braks are fitted along with new callipers. Front discs need to be studded with longer studs to suit the Meyers Manx Signature series Wheels. Although not shown in this picture, light duty Gas Shocks are used up front. The reason for this is that the front does not have enough weight to use heavier shocks and fitting them will make the buggy drive like a brick.

A rear Transmission strap and soft mount kit was used along with all new rubber mounts. Doing it this way significantly reduces engien noise while still gives protection to the nose cone should teh buggy be used offraod.

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Braided rear brake lines are also custom made to suit the rear disc brake kit. We only use DOT appoved brake components to ensure quailty is maintained. Bilstein Shocks are also fitted up back to give years of faithful service and good ride quality.

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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby Brad » Tue Sep 10, 2013 6:35 am

With the front end and engine fitted and checked it is time to move on to the next job.

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From here we fit the Sidewinder exhaust, rear bar and then drop the body on for a test fit.

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With the body in place we can check for any clearance issues which maybe caused by the engine, transmission, front end etc.

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Unlike the earlier Meyers Manx Buggies the KickOuts are made to take Dual Carbies without issue and the Sidewinder exhaust fits nicely with the Rear barwork.

Once happy we spread, insert the gasket and begin bolting it all down into place.

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Once the body is in place the front cowl, dash and bonnet can be fitted. This is a very fidly job and takes a lot longer than expected. It must also be remembered as these are fiberglass kit cars nothing is ever the same and the fit will never be perfect.

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Once happy with their placement and mounting the windscreen can be fitted into place.

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Since these buggies are getting Rear Deck Lids as well I decided now would be a good time to fit it to see if there were any issues.

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With the deck lid fitted the roll bar goes in and then it is time to repeat the process on Buggy Number 2.

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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby Brad » Tue Sep 10, 2013 6:36 am

Buggy number 2 process is exactly the same as number one except the body is blue :D

So we will skip to the pictures.

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Brad

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Re: Two Manx Build, 1 Aussie and 46 Days what could go wrong

Postby Brad » Tue Sep 10, 2013 6:36 am

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Re: Two Manx Build, 1 Aussie and lots more days than I wante

Postby Matt » Tue Sep 10, 2013 11:03 am

Looking good.

Like the look of the blue buggy :)
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Re: Two Manx Build, 1 Aussie and lots more days than I wante

Postby Tratty » Wed Sep 11, 2013 11:00 am

Why don't you run the Billies upside down to reduce your unsprung weight?
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Re: Two Manx Build, 1 Aussie and lots more days than I wante

Postby BlueV2 » Wed Sep 11, 2013 1:12 pm

Looking very nice. Thanks for sharing.

Oh yeah, what part number are the Bilisten rear shocks ?
Sharpbuilt - V2 -http://www.sharpbuilt.com.au
  • Engine - EJ25
  • Gearbox - 5 Speed Subaru - http://www.subarugears.com
  • 4 wheel discs
  • Heated and Air conditioned
  • Cruise Control
  • Rack & Pinion Steering
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Re: Two Manx Build, 1 Aussie and lots more days than I wante

Postby bugman » Wed Sep 11, 2013 7:28 pm

Mark, jump on eshocks.com and have a look, great prices, and plenty of options for vw applications. I got mine from there, came in at 80 each for bilstein 5100 series. They seem like a good shock!

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