byronmcmanus59 Seriously Crusin Dubber
199 posts · joined Apr 2008 ·
love the oval mate, super clean.. screw the ball joint tool, try using two hammers 👍
Ian's Oval
reub VWRX is gone...
2,054 posts · joined Sep 2002 ·
Very envious of your oval!
I look forward to seeing the progression of the build.
I look forward to seeing the progression of the build.
Reub
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Trial fitted the beam up to make sure there were no issues. All went in easily and there is actually more clearance to the inner wings than on a stock beam.
Dropped out the engine also so another step done before splitting the body.
Dropped out the engine also so another step done before splitting the body.
Airkewld 2010 Learner Dubber
5 posts · joined Oct 2009 ·
Car's coming along great Ian
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Body off time. Made some lifting frames to help the process. Forks get bolted on to the bumper mounts.
Trolley jack goes under, lift to desired height and lock off with a bolt. Made some wheel trolleys too so that the chassis could be pulled out the way.
Rolls around easily and ideal to work on the shell.
Trolley jack goes under, lift to desired height and lock off with a bolt. Made some wheel trolleys too so that the chassis could be pulled out the way.
Rolls around easily and ideal to work on the shell.
FROSTY Insano Dub Head
744 posts · joined May 2009 ·
holy shit, that is the best lifting jig I have ever seen....Nice work
Dasdubber DAS Resto Haus
5,746 posts · joined Aug 2002 ·
Nice work Ian, nice setup mate!
Al
Al
dangerous 23 Windows of Awesome
5,901 posts · joined Jan 2005 ·
Wow, cool jig and trolleys,
almost looks like some kind of engineer designed it!
almost looks like some kind of engineer designed it!
westi wrote:That's mad Alan.
type_one Custom Title Time!
1,161 posts · joined Sep 2002 ·
How stable is that Jig? Looks like the legs might fold in a bit. I'd be super keen on plans if available. Space saving when you aren't using them for sure.
Blank
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Yeah pretty stable. I was a bit worried about this when I built them so I kept the upright outer sleeves long to help stop the legs from flexing. The legs are quite thick gauge box tube and are a snug fit to the outer sleeves so no movement there.type_one wrote:How stable is that Jig? Looks like the legs might fold in a bit. I'd be super keen on plans if available. Space saving when you aren't using them for sure.
Really happy with how they turned out - definitely makes this an easy one man job!
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Time to get dirty! Spent the last 2 days up to my neck in grease and oil getting the chassis cleaned up - easily the worst job so far. Still can't complain - all this crud has kept the rust at bay for a long time. I am still amazed at the condition of this car after the last 2 tea strainers I restored in the UK 🥲
Here is a pick of the front end after a grease down:
Check out the original chassis paint - not bad for 50+ years.
Here is a pick of the front end after a grease down:
Check out the original chassis paint - not bad for 50+ years.
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Next the rear end got the same treatment. Dropped out the old split case + axles & tubes.
Cleaned up nice. The whole assembly will be stored and can be bolted back in if the car ever goes back to stock. Another handy use for one of the wheel trolleys has been found.😂
Next job will be a trial fit of the new gearbox. The jury is still out on what front nose cone will be needed to get it fitted.
Cleaned up nice. The whole assembly will be stored and can be bolted back in if the car ever goes back to stock. Another handy use for one of the wheel trolleys has been found.😂
Next job will be a trial fit of the new gearbox. The jury is still out on what front nose cone will be needed to get it fitted.
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Well, I managed to bugger my back over xmas while moving the floorpan around in the garage🥲 That will teach me for not bending the knees😂
Anyway, to help me out going forward (Doc says I have to take it easy) I decided to modify my lifting frames to work with the floorpan. Using a few bits of scrap I made some additions to the original frames and now I can raise or lower the pan to whatever height and also spin it 360degrees. The pan can be mounted with or without the gearbox in place to help me weld in mid mount tabs etc.
Next job........
Anyway, to help me out going forward (Doc says I have to take it easy) I decided to modify my lifting frames to work with the floorpan. Using a few bits of scrap I made some additions to the original frames and now I can raise or lower the pan to whatever height and also spin it 360degrees. The pan can be mounted with or without the gearbox in place to help me weld in mid mount tabs etc.
Next job........
dangerous 23 Windows of Awesome
5,901 posts · joined Jan 2005 ·
Looks awesome Ian.
Hope your back gets better soon,
I cant wait to see you driving this thing around again, even if it is only with a 36hp engine.
Alan drove his oval with 36er,(and now with 40hp) and a tall first gear,(3.33 with 3.88 diff) and it drove fine.
So your 3.444 with 4.125 will be no wuckers.
Still amazed how rust free this car is.
Your not planning to paint it at all? (hope not).
Hope your back gets better soon,
I cant wait to see you driving this thing around again, even if it is only with a 36hp engine.
Alan drove his oval with 36er,(and now with 40hp) and a tall first gear,(3.33 with 3.88 diff) and it drove fine.
So your 3.444 with 4.125 will be no wuckers.
Still amazed how rust free this car is.
Your not planning to paint it at all? (hope not).
westi wrote:That's mad Alan.
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Thanks Dave. Don't worry - not planning to paint anything that will be visible. Will paint the underside of the floorpan + framehead etc, inner arches body colour, bottom of heater channels for protection and thats probably about it. 🙅dangerous wrote:Looks awesome Ian.
Hope your back gets better soon,
I cant wait to see you driving this thing around again, even if it is only with a 36hp engine.
Alan drove his oval with 36er,(and now with 40hp) and a tall first gear,(3.33 with 3.88 diff) and it drove fine.
So your 3.444 with 4.125 will be no wuckers.
Still amazed how rust free this car is.
Your not planning to paint it at all? (hope not).
Euro_67 Wolfsburg Wizard
690 posts · joined Oct 2003 ·
Dave,
What is the lowest rpm you would expect at 110km/h in a 'box setup with the tallest 4th gear possible, assuming 195/660/15 tires.
What is the lowest rpm you would expect at 110km/h in a 'box setup with the tallest 4th gear possible, assuming 195/660/15 tires.
dangerous 23 Windows of Awesome
5,901 posts · joined Jan 2005 ·
195/60/15 tyre measures 24.21" in height according to google.
If Ian was using such a short tyre his rpm would be 3636rpm at 110km/hr.(4.125 diff with 0.931 fourth).
With Ian's proposed 205/70/15 tyre this would be 3346rpm.
The tallest gears VW make are the 3.875 diff and a 0.821 from an early bus.
This would be 3012rpm with the same speed and 195/60/15 tyre.
Albins DO make a 0.696 fourth gear and this would be 2554rpm, but these are very impractical,
an the huge gap from 3rd to 4th would be bogus.
If Ian was using such a short tyre his rpm would be 3636rpm at 110km/hr.(4.125 diff with 0.931 fourth).
With Ian's proposed 205/70/15 tyre this would be 3346rpm.
The tallest gears VW make are the 3.875 diff and a 0.821 from an early bus.
This would be 3012rpm with the same speed and 195/60/15 tyre.
Albins DO make a 0.696 fourth gear and this would be 2554rpm, but these are very impractical,
an the huge gap from 3rd to 4th would be bogus.
westi wrote:That's mad Alan.
Euro_67 Wolfsburg Wizard
690 posts · joined Oct 2003 ·
Thanks for the info.
I imagine higher load and lower rpms may also have a negative effect on engine cooling with the fan also dropping rpm.
I imagine higher load and lower rpms may also have a negative effect on engine cooling with the fan also dropping rpm.
66brm Seriously Crusin Dubber
140 posts · joined Nov 2009 ·
Cant wait to see more progress on this one😎
cam070 Custom Title Time!
1,332 posts · joined Jul 2009 ·
Nice progress on this project. Hope your back gets better soon so you can really get stuck in again. And very envious of those jigs, man they are the sh*t.
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
K & L time....... Stripped all the grease and crap off the K&L assembly ready to have new stuff fitted throughout.
Labelled it all up and packed it ready to have the new pins and bushings put in. So paranoid about mixing up all the bits......its like a chinese puzzle!
Came back all shiny and nice and ready for a bit of paint. Didnt paint the carriers first as they would likely have got chipped during putting in the King's. I had painted the CB spindles back over in the UK to protect them from rusting during the boat ride over.
I taped it all up ready for a splash of gloss black. How good are the WD40 lids for masking off the Link pin holes?? 😂
Labelled it all up and packed it ready to have the new pins and bushings put in. So paranoid about mixing up all the bits......its like a chinese puzzle!
Came back all shiny and nice and ready for a bit of paint. Didnt paint the carriers first as they would likely have got chipped during putting in the King's. I had painted the CB spindles back over in the UK to protect them from rusting during the boat ride over.
I taped it all up ready for a splash of gloss black. How good are the WD40 lids for masking off the Link pin holes?? 😂
Scarab Wolfsburg Wizard
646 posts · joined Jul 2009 ·
nice work!! love your painting trolley!! 😂
Scarab (aka: Paul)
Scarab (aka: Paul)
Wannavee Insano Dub Head
729 posts · joined Sep 2008 ·
Ah shit,I just threw one of those 'painting trolleys' out! Coulda used that this week painting my wheels
Damn it
Damn it
donn Wolfsburg Elder
3,515 posts · joined Nov 2005 ·
Never throw those painting trolleys away, I've got one withthe seat still intact but without the backrest, great for sitting on while tinkering under the bonnet of the buggy.👍
I dream of a day when a chicken can cross a road without being asked for it's motive!
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Had a few issues getting the new box to mount into the correct position and finally chased it back to the front mount. I have two brand new front mounts and both of them are wider than a stock mount which does not allow the box to sit as far into the chassis as it needs to to retain the stock geometry. 😠 Bloody repro crap 😬
The front mount on the old split box was in pretty good shape so was decided to reuse. Only issue is the new ERCO nosecone has 10mm stud holes and the old mount has 8mm studs.
To sort this I "machined" up some sleeve's and installed them as a snug fit into the mount holes.
Job done!! 🙅
The front mount on the old split box was in pretty good shape so was decided to reuse. Only issue is the new ERCO nosecone has 10mm stud holes and the old mount has 8mm studs.
To sort this I "machined" up some sleeve's and installed them as a snug fit into the mount holes.
Job done!! 🙅
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Really wanted some detailed fuch rims to go on this car so ordered some Flat 4 wheels in 4.5 and 5.5 inch widths. Went over to Das Resto Haus for some detailing action over the weekend to get things moving along. 🙅
Al was good enough to let me do some of the labour to offset the cost and also see what the process was. Started out masking things up and then working out where we wanted the paint to cover vs what remains polished.
Infill taped all the remaining areas we didnt want the paint. 400 grit wet and dry then keyed in the surface.
Masked up the rest of the wheels and then lined up ready in the spray booth.
Primer applied then 2 coats of direct gloss black (no clear coat needed).
Take off the masking and we're done!!! Look awesome and can't wait to get them fitted up. Will leave for a few weeks now though to fully cure and harden up. 😂
Al was good enough to let me do some of the labour to offset the cost and also see what the process was. Started out masking things up and then working out where we wanted the paint to cover vs what remains polished.
Infill taped all the remaining areas we didnt want the paint. 400 grit wet and dry then keyed in the surface.
Masked up the rest of the wheels and then lined up ready in the spray booth.
Primer applied then 2 coats of direct gloss black (no clear coat needed).
Take off the masking and we're done!!! Look awesome and can't wait to get them fitted up. Will leave for a few weeks now though to fully cure and harden up. 😂
trickysimon 100km/h is only 9 seconds away
1,473 posts · joined Dec 2007 ·
Mmmmm fuchs 😵
chippy Slammed & Awesome Dubber
94 posts · joined Jan 2010 ·
They are SEXY AS!!!! I dont know many beetles that wouldnt look good sitting on those!
Cheers Todd 😀
Cheers Todd 😀
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Got back to the Gearbox again and lined things up for a final fit. Didnt like the fit of the rear cradle as when bolted up it did not sit fully under the rear mounts. To fix this I welded a plate onto the back of the cradle which pushed it out to sit squarely under the bell housing.
Now bolted up it all seems to line up properly again. Probably not 100% necessary but I just like things to look right.
Now bolted up it all seems to line up properly again. Probably not 100% necessary but I just like things to look right.
Aussie Officially Full-On Dubber
296 posts · joined Sep 2006 ·
Next up was the mid mount which needed brackets welded onto the frame horns.
Here is the kit as supplied:
You need to replace the 4 stock length studs under the box with longer versions to allow for the thickness of the mount plate.
Next a trial fit to make sure there is good clearence to everything. Not sure how much these things flex under load but the design is good with plenty of room for a bit of movement.
The only thing I didnt like about the kit was the profile of the mounting face where it is welded to the frame horn.
So I grabbed the grinder and file and shaped things a bit for a more snug fit. Should help to make the welds a bit neater at least!
Here is the kit as supplied:
You need to replace the 4 stock length studs under the box with longer versions to allow for the thickness of the mount plate.
Next a trial fit to make sure there is good clearence to everything. Not sure how much these things flex under load but the design is good with plenty of room for a bit of movement.
The only thing I didnt like about the kit was the profile of the mounting face where it is welded to the frame horn.
So I grabbed the grinder and file and shaped things a bit for a more snug fit. Should help to make the welds a bit neater at least!