ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
Additional brace to support the rear bumper mount. It is now strong enough that I can lift the body off the chassis with no flexing but still unbolts to aid engine removal.
VWRX Karmann cabriolet
Additional brace to support the rear bumper mount. It is now strong enough that I can lift the body off the chassis with no flexing but still unbolts to aid engine removal.
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
Rear bumper mounts needed to be extended by 35mm to clear wider wings
Now everything is at ride height and, a quick mock-up of the kamei spoiler to my set ground clearance. I will trim this back to the bottom of the valance/wings and flush mount it, this will make it much more subtle and less 'plasticy' and keep the radiator intake clear.
STIDUB Over it.
1,497 posts · joined Jun 2008 ·
lookin gooood 👍
Volkswagen Drivers Club of Queensland - member 🙂
STIDUB - yep its still a work in progress
Vwdcq club car racing/ and crashing while my bug isn't finished.
The above are personal views, no more, no less
STIDUB - yep its still a work in progress
Vwdcq club car racing/ and crashing while my bug isn't finished.
The above are personal views, no more, no less
Bugaru03 Commited Dubber
70 posts · joined Mar 2008 ·
Very nice!
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
Some more progress:
Decided to make up my own spherical top strut mounts.
Mocked up to check the positioning
All welded up
Suspension arm narrowed 15mm to help pull the big front wheels under stock wings (I'll add some more bracing to the join later on)
Another mock-up of spoiler showing better how the wing intake looks
Spoiler now trimmed to fit and roughly clamped to bottom of body panels. This gives me 120mm of ground clearance which is about level with my lowest chasssis point. I'm happy with this as a final ride height too.
It tucks back much more than it would as standard (which is bolted to the underside of the bumper) and looks much less like it's doing an impression of a snow-plough!
Decided to make up my own spherical top strut mounts.
Mocked up to check the positioning
All welded up
Suspension arm narrowed 15mm to help pull the big front wheels under stock wings (I'll add some more bracing to the join later on)
Another mock-up of spoiler showing better how the wing intake looks
Spoiler now trimmed to fit and roughly clamped to bottom of body panels. This gives me 120mm of ground clearance which is about level with my lowest chasssis point. I'm happy with this as a final ride height too.
It tucks back much more than it would as standard (which is bolted to the underside of the bumper) and looks much less like it's doing an impression of a snow-plough!
Flintstones Custom Title Time!
1,077 posts · joined Aug 2002 ·
really starting to come together now Rich.
It's funny when you start modifying you can't stop. Those top mounts look good.
Cutting and shutting the suspension parts wouldn't even get a look in here on OZ. Our local engineers would walk away. What's the go up your way when it comes to registering a modified car, do you have to go through the drama's we have to and consult engineers?
Reason I ask, is that I think the front will look much nicer if you can continue the spoiler line into the wing edge so that it gets rid of that void where you can see the tyre.
Plus it will look more integrated.
i hope I've explained that well enough.
Cheers
D
It's funny when you start modifying you can't stop. Those top mounts look good.
Cutting and shutting the suspension parts wouldn't even get a look in here on OZ. Our local engineers would walk away. What's the go up your way when it comes to registering a modified car, do you have to go through the drama's we have to and consult engineers?
question, how handy are you with fiberglass?ricola wrote:
Reason I ask, is that I think the front will look much nicer if you can continue the spoiler line into the wing edge so that it gets rid of that void where you can see the tyre.
Plus it will look more integrated.
i hope I've explained that well enough.
Cheers
D
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
I've done a fair bit of fibreglass before
The spoiler is plastic but it has been repaired before with a bit of fibreglass paste which seems to have stuck, so I'll see about a bit of blending later on when the body is off the chassis.
It is fairly easy to modify cars here but it is getting harder. We have Individual Vehicle Approval (IVA, used to be SVA) if the car is too heavily modified from stock.
The spoiler is plastic but it has been repaired before with a bit of fibreglass paste which seems to have stuck, so I'll see about a bit of blending later on when the body is off the chassis.
It is fairly easy to modify cars here but it is getting harder. We have Individual Vehicle Approval (IVA, used to be SVA) if the car is too heavily modified from stock.
STIDUB Over it.
1,497 posts · joined Jun 2008 ·
i was about to say precisely what flintstones said about the kamei 👍
offers still there to come finish mine while im at work 😁
offers still there to come finish mine while im at work 😁
Volkswagen Drivers Club of Queensland - member 🙂
STIDUB - yep its still a work in progress
Vwdcq club car racing/ and crashing while my bug isn't finished.
The above are personal views, no more, no less
STIDUB - yep its still a work in progress
Vwdcq club car racing/ and crashing while my bug isn't finished.
The above are personal views, no more, no less
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
Idle air control valve return pipe uses cut down standard pipe.
Header tank is from a Vauxhall Corsa/Tigra as it had the right connections. I didn't like the subaru system as it is based on an external overflow tank. An aftermarket one would have been solid aluminium so levels are not so easy to check. I welded on a couple of brackets to the body to support the standard fitting points on the tank
Fill point is accessable when the decklid is open.
The OBP pedal box had no provision for the throttle cable so this is what I came up with. I also made up the cable from a universal kit using the subaru fittings/adjuster on the engine end. It feeds through the standard tube in the chassis tunnel.
VW polo heater matrix/blower fan will be mounted to access panel and will blow in to the existing ducting behind the dash. I will fabricate an intake for the fan so it draws in air from the scuttle grill.
Header tank is from a Vauxhall Corsa/Tigra as it had the right connections. I didn't like the subaru system as it is based on an external overflow tank. An aftermarket one would have been solid aluminium so levels are not so easy to check. I welded on a couple of brackets to the body to support the standard fitting points on the tank
Fill point is accessable when the decklid is open.
The OBP pedal box had no provision for the throttle cable so this is what I came up with. I also made up the cable from a universal kit using the subaru fittings/adjuster on the engine end. It feeds through the standard tube in the chassis tunnel.
VW polo heater matrix/blower fan will be mounted to access panel and will blow in to the existing ducting behind the dash. I will fabricate an intake for the fan so it draws in air from the scuttle grill.
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
I thought the body line above the trim didn't look quite right and this is what I found under all the filler! NOS VW 1/4 panels are no longer available so I went down to my local VW breakers, angle grinder in hand!
This is what was left after cutting out all the bodged repairs of the past
Donor section clamped roughly in place, it took a bit of searching to find one this good as it is a common rust area, unfortunately it was balanced on top of another car and was full of suspension parts!
This is what was left after cutting out all the bodged repairs of the past
Donor section clamped roughly in place, it took a bit of searching to find one this good as it is a common rust area, unfortunately it was balanced on top of another car and was full of suspension parts!
71-BEETLE-SEDAN AKA Josh
1,058 posts · joined Mar 2009 ·
wow i thought you were nearly finished
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
lol, well I have a few months until the weather is warm enough for paint and this was really bugging me. I'd have really regretted not sorting it out properly...
71-BEETLE-SEDAN AKA Josh
1,058 posts · joined Mar 2009 ·
okay, thats cool then, its looking really good.
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
Had a good couple of days on the rear 1/4 panel...
All hidden areas were treated with Bilt Hamber Hydrate 80, then painted, weld areas were taken back to fresh metal and Roberlo weld through copper primer used.
Tacked in...
Fully welded...
all welds ground down
couple of coats of Hydrate 80 to protect the fresh metal before I get to paint, it will only need a very small amount of filler at the weld seams..
All hidden areas were treated with Bilt Hamber Hydrate 80, then painted, weld areas were taken back to fresh metal and Roberlo weld through copper primer used.
Tacked in...
Fully welded...
all welds ground down
couple of coats of Hydrate 80 to protect the fresh metal before I get to paint, it will only need a very small amount of filler at the weld seams..
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
Bit more done today, sorted the exhaust tip and modified the rear valance to match. Left cutout was filled with section from old panel. I got the panelbeating hammers out and widened the right cutout to match the 3" exhaust..
Flintstones Custom Title Time!
1,077 posts · joined Aug 2002 ·
what, your not going with the stock pea shooters😂
looks like you had fun with the rear qtr panel, she's come up good👍
Cheers
looks like you had fun with the rear qtr panel, she's come up good👍
Cheers
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
Yet more bodgery! Bumper repair panels poorly welded over rusted edges, overlapping the strut reinforcements and internally the bumper mounts have been stuck on with what can only be descibed as pidgeon shit to the reinforcements. It will all be cut out and done properly, I'm hopefull of being able to re-use the repair panels as there is so much overlap.
Finally on to the radiator intake! I cut the valance off and cut out this hole (same size as the license plate). I've shaped a bar hoop the same shape but a bit bigger and will tack weld that on the back side, I will then hammer form a nice rolled edge to keep it looking 'right' and will also weld on some captive studs so I can fit some mesh. I'm also considering bonding some letters to the mesh so it can be the numberplate and not restrict air flow.
Finally on to the radiator intake! I cut the valance off and cut out this hole (same size as the license plate). I've shaped a bar hoop the same shape but a bit bigger and will tack weld that on the back side, I will then hammer form a nice rolled edge to keep it looking 'right' and will also weld on some captive studs so I can fit some mesh. I'm also considering bonding some letters to the mesh so it can be the numberplate and not restrict air flow.
STIDUB Over it.
1,497 posts · joined Jun 2008 ·
nice looking radiator hole 🙂 bout time someone did one thats not just hacked into it, will be curious how it turns out, what are the po-po going to think about the bonded/sprayed on numberplate?
Volkswagen Drivers Club of Queensland - member 🙂
STIDUB - yep its still a work in progress
Vwdcq club car racing/ and crashing while my bug isn't finished.
The above are personal views, no more, no less
STIDUB - yep its still a work in progress
Vwdcq club car racing/ and crashing while my bug isn't finished.
The above are personal views, no more, no less
Joel Now containing 100\% E-Wang
9,368 posts · joined Feb 2006 ·
common trick in the UK 😉
sorry for the hi-jack
x2, looks good Rich 👍
sorry for the hi-jack
x2, looks good Rich 👍
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
I'm not certain of using it as the number plate yet as it may be a bit too hidden to get away with it. Once the bumper is on and the car is on the ground it is going to be fairly well out of view...
I did consider a US style valance but hear the repro ones aren't too good and fancied experimenting with this one first, I like the way it is turning out.
I did consider a US style valance but hear the repro ones aren't too good and fancied experimenting with this one first, I like the way it is turning out.
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
Here's the bar tacked on to the back of the panel after bare-metalling both parts and applying some weld through primer.
I then hammered the metal around the bar, it has created a really rigid panel now and looks much better than a plain cut edge.
I then hammered the metal around the bar, it has created a really rigid panel now and looks much better than a plain cut edge.
ElusiveStranger Officially Full-On Dubber
330 posts · joined May 2006 ·
Really nice work Rich.
When you welded in the rear quarter, roughly how much did the weld line pull in? I've just done my van's rear arch and it pulled in approx 6mm. Using mig I tacked every 5" or so, allowed to cool, tacked again - took ages.
Rear corner I did stitch back with a tig and dressed the weld - almost perfect.
Seeing your shot has made me wonder what/where I went wrong with my arch
When you welded in the rear quarter, roughly how much did the weld line pull in? I've just done my van's rear arch and it pulled in approx 6mm. Using mig I tacked every 5" or so, allowed to cool, tacked again - took ages.
Rear corner I did stitch back with a tig and dressed the weld - almost perfect.
Seeing your shot has made me wonder what/where I went wrong with my arch
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
It did pull in a bit, but it only took a minute or so to work it back out with hammer/dolly
ElusiveStranger Officially Full-On Dubber
330 posts · joined May 2006 ·
Thanks Rich. I think I have the normal "small" amount by the sounds of it. I can't get access to the back so I'm going to tack some washers on & dress it out
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
Made a start on the bumper mount panels, they were a mess!
This is what was under the 'repair' panels...
Small repair done on the 'leg' and the jagged edge trimmed back
Body captive plate needed re-making
This is what was under the 'repair' panels...
Small repair done on the 'leg' and the jagged edge trimmed back
Body captive plate needed re-making
STIDUB Over it.
1,497 posts · joined Jun 2008 ·
looks like your lucky you fixed it 🙂
Volkswagen Drivers Club of Queensland - member 🙂
STIDUB - yep its still a work in progress
Vwdcq club car racing/ and crashing while my bug isn't finished.
The above are personal views, no more, no less
STIDUB - yep its still a work in progress
Vwdcq club car racing/ and crashing while my bug isn't finished.
The above are personal views, no more, no less
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
I had just about finished both bumper mount panel repairs but then my powerfile sander belt broke and threw a piece of metal straight in the centre of my eye! I was wearing safety glasses but they obviously weren't good enough for that sort of angle.
So, last few weeks I have been in and out of the eye surgery and it still hasn't healed properly. My plan was to paint late july but will have to wait and see how my recovery goes as the last thing I need is to get crap in an unhealed eye wound!
Here are some pics of where I got to though:
Main and chargecooler radiator mocked up to finalise mounting.
small section still needs repairing on near side...
I've also decided to redo the bodywork I did a while back over the back of the radiator. Also trying to come up with a nice compact way of ducting hot air flow into the stock ventilation system in the dash. That's a stock polo matrix/blower but I may just use the matrix and the stock bug blower. I also have to cut down the headlight washer reservoir to clear the radiator.
So, last few weeks I have been in and out of the eye surgery and it still hasn't healed properly. My plan was to paint late july but will have to wait and see how my recovery goes as the last thing I need is to get crap in an unhealed eye wound!
Here are some pics of where I got to though:
Main and chargecooler radiator mocked up to finalise mounting.
small section still needs repairing on near side...
I've also decided to redo the bodywork I did a while back over the back of the radiator. Also trying to come up with a nice compact way of ducting hot air flow into the stock ventilation system in the dash. That's a stock polo matrix/blower but I may just use the matrix and the stock bug blower. I also have to cut down the headlight washer reservoir to clear the radiator.
Flintstones Custom Title Time!
1,077 posts · joined Aug 2002 ·
looks real nice Rich, like OEM
Shame about the eye, hope it doesn't take to long to heal.
Can you still fit a spare wheel?
Cheers
D
Shame about the eye, hope it doesn't take to long to heal.
Can you still fit a spare wheel?
Cheers
D
ElusiveStranger Officially Full-On Dubber
330 posts · joined May 2006 ·
Shit mate, you ok now?ricola wrote:threw a piece of metal straight in the centre of my eye! I was wearing safety glasses but they obviously weren't good enough for that sort of angle.
I've had splinters & weld splatter removed on more than 1 occasion
Bolle blast goggles or Sperian seem to be good IMHO. Comfy and don't steam up that much
My worst episode was being allergic to the cream they gobbed in my eye. That was worse than then shrapnel, looked like I'd done 3 rounds with Tyson.
ricola Wolfsburg Wizard
437 posts · joined Feb 2003 ·
I've had bits removed a couple of times before so wasn't too concerned at the time. The problem this time is that the A&E doctor I saw first couldn't get it all out as it was too deep and the eye went and healed over it by the time I got to see somebody in the eye clinic so the 'scraping was made much worse. I've had 4 different doctors scraping so far and am now on steroids to reduce the swelling on the back of the lense which is causing bad light sensitivity. Got to go back again on friday and the steroids seem to be working so I do feel like I'm on the mend now.
Thanks for those recommendations elusive, I've been pouring over the catalogues trying to find some better ones but going by pictures isn't that helpful..
I'm happy with how the rads are turning out. I plan to weld in a round tube to mount the chargecooler off and something that it slots in to at the base to locate the bottom...
Thanks for those recommendations elusive, I've been pouring over the catalogues trying to find some better ones but going by pictures isn't that helpful..
I'm happy with how the rads are turning out. I plan to weld in a round tube to mount the chargecooler off and something that it slots in to at the base to locate the bottom...