Alex the Beach Buggy

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Smiley
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Re: Alex the Beach Buggy

Postby Smiley » Sat Sep 19, 2009 4:43 am

At this point I decided to drop the bottom off the tunnel to have a look at what the inside of the tunnel and all the lines are like. I had to make another cut across the back with the grinder, the used a cold chisel to break all the factory spot welds along the sides. Then the plate just lifted off.


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As you can see in the photo below there was a fair amount of rust scale lying in the tunnel. Most of the is from the base plate I removed. The tunnel itself is very solid. I was originally going to clean up and reuse the base plate, but I've changed my mind again after seeing its condition. So it's going to the scrap heap.


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Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:04 am, edited 2 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Sat Sep 19, 2009 4:52 am

A couple more shots of the inside of the tunnel.


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Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:05 am, edited 2 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Sat Sep 19, 2009 5:31 am

The two tubes lowest in the first picture are the old heater cable tubes which come out of the tunnel on the RHS on the gearstick. Neither end is connected so I cut them out to tidy things up.


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At the back end of the car where the heater cables exit the frame horns I ground what was left of them off, a previous owner had hammered them flat. I'll have to fill the hole in the side of the tunnel and one on each frame horn once I've gotten all the old tube out.


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Last edited by Smiley on Sun May 09, 2010 5:07 am, edited 2 times in total.
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Re: Alex the Beach Buggy

Postby MarkMark » Sat Sep 19, 2009 4:14 pm

That's a good way of having a decent look inside the tunnel.

It will be a good time to fit a new shifter bushing before you close up the tunnel again.
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Smiley
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Re: Alex the Beach Buggy

Postby Smiley » Sat Sep 19, 2009 8:27 pm

Yeah. I'll be moving the gearstick back, running new fuel lines and brake lines. Then completely painting the inside of the tunnel before I weld it back shut. That way it should last a long long time.



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Last edited by Smiley on Sun May 09, 2010 5:07 am, edited 1 time in total.
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Re: Alex the Beach Buggy

Postby Smiley » Mon Sep 21, 2009 12:25 am

Did a bit more on the buggy this afternoon.
I picked up a Superbug as a doner car a few weeks ago. I spent most of this afternoon cutting CV bolts that wouldn't come undone.
I'll probably finish pulling the rear suspension out at some stage this week.
I've also got the steering column and switchgear and wiper motor that I'm swapping into the buggy.



Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:08 am, edited 1 time in total.
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OzTowdster
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Re: Alex the Beach Buggy

Postby OzTowdster » Mon Sep 21, 2009 2:33 am

Sounding and looking like a well planned buggy comming along up there !!!.
You'll be suprised at what you will find handy in that new wreck , keep everything you can and sort it as you pull it off and you'll have a good spare parts dept for years to come , but with the Baja etc already i'mm guessing your way ahead of me already .
Working at getting my Towdster and the Baja Bus back on the road !!!
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Smiley
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Re: Alex the Beach Buggy

Postby Smiley » Mon Sep 21, 2009 3:01 am

You're absolutely correct Andrew.
You should see my place, mum has almost killed me on numerous occasions because I keep bringing home VWs. Apparently I've become the local wrecker.
I've got two bay window Kombis absolutely packed full of parts, one is a Camper one is just normal. A '61 6 volt original beetle, that's also chockers with bits and pieces. I'm got a Nissan Vanette that I also use as a shed for all my body panels. Plus the Superbag mentioned earlier which has almost been completely pulled down. And another two floorpans, one completely bare the other is has very rusted halves but rolling with everything on it.

Then I've got my Buggy which is the current project, my daily driver '67 Baja which I drive 500kms a week to work and back. And my favourite, the first car I ever bought when I was 16, a 1968 Semi-auto beetle.

I think my old man has caught the bug too because he has a 1963 bug eye Baja.

Just need to get rid of the 4 Commodores that various other members of the family have and convince mum to get a Golf to replace her SS and we'll be set. :D



Smiley :cool:

PS - If you're in Yeppoon/CQ and are chasing parts, feel free to contact me, always happy to help out fellow dubbers!!
Last edited by Smiley on Sun May 09, 2010 5:09 am, edited 1 time in total.
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Re: Alex the Beach Buggy

Postby Smiley » Tue Sep 22, 2009 1:33 am

Before and after shots of what I got done this afternoon. It's not much but every little bit helps.
I put the pan up on blocks and removed the wheels and drums. Then I undid the spring plate to diagonal arm bolts and removed the large pivot box bolt. I brought them down to the house so dad has two more things to trip over. Plus I wanted to start seeing how easy it will be to swap wide five drums on.


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All I have to do now is pull the spring plates and rear torsion bars out of the super pan, then I'm going to begin fabricating jigs to install the heavy duty pivot boxes.



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Last edited by Smiley on Sun May 09, 2010 5:10 am, edited 2 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Wed Sep 23, 2009 2:35 am

Cut a little bit more off the bottom of the pan today. It was rusted through in a few spots plus I want to run my new sheet further back so it had to go.


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Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:12 am, edited 4 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Wed Sep 23, 2009 2:38 am

A picture of the piece removed, and looking back towards the frame horns.


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Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:12 am, edited 3 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Wed Sep 23, 2009 2:45 am

While I was in there I finished removing the remains of the heater cable tubes, they were fairly rusted through. And while I was going I removed the handbrake cable tubes to check them too. As the second photo depicts, I'll be investing in new ones.


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I then removed the remaining piece of fuel line, the clutch tube, and the brake tube. Of these the clutch tube is the only one in reasonable condition, and it's still a little questionable.

So all I have left in there now is an accelerator cable tube. Gives me a nice blank canvas to work with.

Can anyone recommend where to buy new handbrake and clutch cable tubes from?



Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:15 am, edited 4 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Wed Sep 23, 2009 2:47 am

A couple of pictures showing the empty tunnel.


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Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:16 am, edited 2 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Sun Sep 27, 2009 7:20 pm

Just a quick update.

On Friday night we sat the body on the new floor and aligned it all so I could mark where to cut. I marked it slightly oversized the entire way around cause it's easier to grind it down later than add more on.


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The next picture shows it cut, now I just have to measure and start making the lift kit.


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Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:17 am, edited 2 times in total.
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Re: Alex the Beach Buggy

Postby Smiley » Wed Oct 07, 2009 4:16 am

I had the day off work so I decided to drag the floorpan into the carport and attack with the welder and grinder. Plans for the day - move the gearstick back and weld up some holes and other things.

I decided to go with moving it 4" back, so I measured out two pieces on the tunnel to cut. The piece with the gearstick hole in it and a 4" long piece behind it. Then I just had to cut and swap them around and weld them back in place.


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Smiley :cool:
Last edited by Smiley on Sun May 09, 2010 5:19 am, edited 4 times in total.

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