Dave's Meyers Manx Buggy - Barwork, Seats and a Fuel Ta

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Dave's Meyers Manx Buggy - Barwork, Seats and a Fuel Ta

Postby Brad » Mon Dec 13, 2010 2:52 am

Dave's Meyers Manx Buggy is in the shop for some work.

Being the 1st Buggy in our new workshop it is taking a little while to get cracking but we are aiming at having it done by early Jan 11 ( If this rain goes away long enough to get the sheet metal shop extension roofed so we can use the folders and guillotine )

Main Work to be undertaken:

Meyers Manx Front bar.
Fabricate seat mounts to fit supplied seats.
Meyers Manx 6 Point Roll bar.
Meyers Manx Dash support bars.
Meyers Manx side bars ( 3 Bar design).
Meyers Manx Alloy Fuel Tank (65L)
Supply and fit QLD Tpt Blue Plate plate for Roll Cage, Seat and Seat Belts.
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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Mon Dec 13, 2010 2:55 am

The start of the 6 Point roll cage. From here we will bend up the front hoop and add the centre braces. Once that is all in place and tacked the seats will be fitted and we will ensure there is enough room to clear head and arms space.

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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Mon Dec 20, 2010 8:30 pm

Before the front roll bar hoop can be made the seats need to be fitted so as to ensure that the correct head clearance and seating position can be obtained.

The seats use in this case are from a Mazda NA MX5. These are a great seat, very compact and very comfy. They are not too hard to fit and we usually use a seat runner jig. In this case the pan had pre-existing seat bars in place so the MX5 runners needed to be modified to allow fitting at the correct height. Once modified they bolt in and out like a normal car, are fully adjustable and very comfy.

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Once the seats were in place the fuel tank was next on the to-do list.
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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Mon Dec 20, 2010 8:54 pm

The Manx is getting one of the new Meyers Manx Australia Long Range Fuel Tanks. These tanks are designed to optimize fuel capacity while not effecting, steering, up travel or reliability. They are a fully tig welded pressure tested unit made from 2mm aluminum with internal baffles.

As the lift kit on this pan is not one of the current designs we wanted to ensure that the fuel tank would fit correctly and not fowl on anything.
To do this we removed the front wheels, removed the centre adjusters and fully compressed the front suspension.

Once compressed, we fitted a K&L limiting bar and started measuring.

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When doing this it is very important to check ALL measurements as full compression and lock to lock. What you are doing is making sure that the steering column is not going to hit anything and also the long tie rod is going to clear on both locks and full travel. The long tie rod in this case is a stock unit which looks as though it has been bent and straightened a few times. The Manx Tanks are built to clear a CORC Heavy Duty unit which is thicker than stock.

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Once measurements are takes using various edges, jigs and string lines we can confirm the a Long Range Manx Tank will suit the buggy.
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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Tue Dec 21, 2010 5:00 am

Well after we had all the mesurements I checked them against the tank spec and it will be all good. Based on that I confirmed the file and printed out a Fold sheet for Dave to sort tomorrow.

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Once we are done with the folding of the main section we baffle it, check out the column space and then cap it. It holds up to 60L depending on the filler location.
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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Thu Dec 23, 2010 7:04 am

With the CAD Design confirming the tank would fit it was time to let Dave do what he does best and turn specifications into reality. So the aluminum was cut, folded and tig welded into shape the end result being a nice shiny Meyers Manx Australia Long Rang Fuel tank (Available off the shelf in 2011). As you can see we don’t waste much space in the fitment.

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The bonnet fitment is tested under load and flex as best we can. Fuel cap design is snug and recessed.

Checkouts and folds are made to clear the steering column and custom internal baffles and used to keep the fuel where it should be.

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The log tie rod is tested on full up travel on left and right lock. This is done without the bump stops fitted to ensure that on stop compression no contact is made. This space is optimised as to big a hole would be a waste of capacity.

You will also see twin fold corners so that the fiberglass does not need to be cut and this the integrity of the rolled lip is maintained.

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The fuel tank has an internal surge setup with draw via the lowest point. The fuel tank can be setup for EFI or NA. This one is just NA Carbs at the moment but we will be changing that as with all new tanks we make them EFI Ready so if the customer ever changes their mind it is simply a case of taping in the return line.

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All up they are a very nice fit and I will be confirming capacity once we finalise the filler placement with Dave.
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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Fri Dec 24, 2010 2:51 am

Work will slow over the next week or so as apparently it is Xmas time and Buggy Building goes on hold for fattening food and family cheer.
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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby VWNuts » Fri Dec 24, 2010 9:43 pm

Looking good, Dave shouldnt have any excuses for not having this at Fraser next year :D
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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Fri Dec 24, 2010 9:49 pm

VWNuts wrote:Looking good, Dave shouldnt have any excuses for not having this at Fraser next year :D


There will be none from our end he will have it back early in January 11 so has plenty of time, hell he should make Dubs by the Pie. :lol:
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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Thu Jan 06, 2011 4:41 am

Well with those pseky holidays out the way and work on Dave's buggy back underway I don't think Fraser will be an issue at all.

Dave's front bar is one of the New Meyers Manx Australia Offroad versions. These bolt onto the front beam with custom brackets and provide great protection, they also come fitted with two spot light mounts.

They have an option for full bash plate and recovery hooks and also work in well with the Meyers Manx Australia front tow bars (these allow you to tow your buggy LEGALLY behind your car).

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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Thu Jan 06, 2011 4:43 am

With the bar fitted it was time to fit the new Manx Dash Frame and BBA Dash, Dave decided to go with the BBA unit as he wanted to get the extra space and stereo location.

To fit the BBA dash to a Manx you need to modify it as it is to long to fit correctly. You can still use a Meyers Manx Australia Dash frame though which means you retain all the factory supports and mounting points.

I will get some pictures of this when I go back to work.
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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Fri Jan 07, 2011 7:10 am

Ok the Dash has been in and out a few times now, it is amazing how much time it takes to fit things in the old bodies where nothing is square and they have years worth of "mounting" hole sfrom past attempts and great ideas.

Anyway it is in and looking good.

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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Sat Jan 08, 2011 12:02 am

Dave's front bar was removed today so it could be finshed off and have the optional bash plate and recovery hooks bolted on.

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The bash plate is 3mm Aluminium Checker plate which is CNC cut and then folded to ensure a great fit. It can be done with checkers in or out, Dave has opted for checkers out. Bash plate locates on the mounting flanges which are welded up the inside of the bar. This means when the bash plate is in place it gets support from the full bar not just the tabs.

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Last edited by Brad on Sat Jan 08, 2011 12:06 am, edited 1 time in total.
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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Sat Jan 08, 2011 12:05 am

Th erecovery hooks are a 10 000 lbs unit with retaining clip. We fine these particulare ones to perform quite well compared to some of the cheaper ones. Held in place by two 12mm high tensile bolts and fitted to the 6mm lamainated front bar brackets.

Nice and tidy and easy to access, should he come across a bogged baja that needs assistance.

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Re: Dave's Meyers Manx Buggy - Barwork, Seats and a Fue

Postby Brad » Wed Jan 12, 2011 4:19 am

Rail, Hail, Shine or flood it ain't that easy to stop a buggy build, we need the space for the next one.

Anyway Dave's 6 point cage got welded out and is now done. He has one of the new Meyers Manx Australia units which also has intergration for the side bars to ensure maximum protection.

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When we make these the side mounts get slotted to allow for alignment when fitted as you ofetn get a change in angle from side to side and pan build type.

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Side bars are a 3 bar design slightly longer than most to allow them to tie into the front and rear roll cage.
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