Alex the Beach Buggy

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

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Smiley
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Re: Alex the Beach Buggy

Postby Smiley » Wed Oct 07, 2009 4:19 am

Both pieces removed. You have to be extra carful when you're making the cuts on the LHS of the tunnel to make sure you don't slice the accelerator cable tube at the same time.


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Last edited by Smiley on Sun May 09, 2010 5:20 am, edited 2 times in total.
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Smiley
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Re: Alex the Beach Buggy

Postby Smiley » Wed Oct 07, 2009 4:27 am

I gave all the edges a clean up and made sure that they fitted as best that they could. Then tacked them into place so I could give them a tweak with the hammer where required. Then I fully welded the pieces back into their new spots.


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Please excuse the shoddyness of my welding, it's been over a year since I've picked one up.



Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:22 am, edited 4 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Wed Oct 07, 2009 4:29 am

I had to make up a small plate to fill the hole where the heater control knob used to be on the RHS of the tunnel. After I welded the plate in I built up on top of it with weld then ground this back to try and match the curve of the tunnel as best I could.


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Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:24 am, edited 4 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Wed Oct 07, 2009 4:30 am

While I had the welder and grinder fired up I filled the holes where the heater control cables used to come out on either side of the frame horns.


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Then ground the welds down and smoothed them off.


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Last edited by Smiley on Sun May 09, 2010 5:25 am, edited 2 times in total.
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Smiley
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Re: Alex the Beach Buggy

Postby Smiley » Wed Oct 07, 2009 4:35 am

All that was left to do was grind the welds down flush and smooth them off with the flapper wheel. I hope to do a tech article up on moving the gearstick hole back when I have some spare time.


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I think it almost looks factory, and will be much easier to reach.



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Last edited by Smiley on Sun May 09, 2010 5:26 am, edited 2 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Thu Oct 08, 2009 1:39 am

So I got in and did a little bit more this afternoon, every bit helps!

These pictures show before and after shots of the handbrake bracket, I decided that spot welds weren't good enough and ran some beads all the way around. Then smoothed the welds into the tunnel so it's all one piece. Came up rather nice.


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Last edited by Smiley on Sun May 09, 2010 5:27 am, edited 2 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Thu Oct 08, 2009 2:01 am

002 5-rib Kombi gearbox, weapon of choice for changing gears in my buggy. It needs a few minor mods to get it to fit in the Beetle floorpan.


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In order for the gearbox strap that came with the mounting kit I bought to fit, some of the metal needs to be ground into a more rounded shape. It's hard to see the lumps in this picture because of the mound of sludge built up against it.


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Last picture shows the lumps ground down and smoothed.


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Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:31 am, edited 4 times in total.
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Smiley
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Re: Alex the Beach Buggy

Postby Smiley » Thu Oct 08, 2009 2:05 am

First picture shows the gearbox after I rounded both corners off.
In the second picture I sat the top strap from the front gearbox mount in place to see how it fits.


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Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:30 am, edited 2 times in total.
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Huffypilot
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Re: Alex the Beach Buggy

Postby Huffypilot » Sun Jan 17, 2010 1:03 am

Hi Smiley
Your buggy is going to be one smick ride !
I have a 5 rib and was just about to order what looks like the same gearbox mount . Can you tell us where you got this one and if you think its ok. Id also be keen to see how your build is coming along .
Cheers
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Re: Alex the Beach Buggy

Postby dbryar » Sun Jan 17, 2010 4:26 am

Wow, that is one seriously sh*t covered gearbox.
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Smiley
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Re: Alex the Beach Buggy

Postby Smiley » Sun Jan 17, 2010 4:38 am

Wow. There hasn't been any activity on here in ages. I really need to get the Baja done so I can get back into this old girl.

The gearbox mount in from Custom Vee Dub in Brisbane.
It's very well made, fits beautifully (though I haven't welded the crush tubes in yet) and I would hightly reccomend it. Have a talk to the fellas there, they were quite helpful in explaining the best way to mount to etc.

The gearbox is a little crud coated. Obviously been weeping a little oil.

Will be getting cleaned up and rebuilt before going into the car.



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