The Iguana Build - Subaru H6 and 6 Speed Buggy Build

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 31 Aug 2010, 9:43 pm

#799634

I wasn't going to do a build thread for my Buggy but since I have been getting such great support from several shops that do awesome work on VW's and others I thought it only fair to give them some credit.

Anyway after being away for a year or two it is finally time to finish off my Iguana Buggy. Not that it matters as so many things have changed anyway.

My Iguana is number 2 out of the mould and one of only 4 ever made.

The Build Specs:

Body - 4 Seater Custom Iguana
Chassis - Custom VW Tunnel witha heaps of mods
Suspension - A-Army front (A-Arm.com), CVD 3 x 2 rear, Fox 2.0 coil overs all round.
Engine - 2003 Subaru H6 3.0 EZ30D
Transmission - 2010 Outback Subaru 6 Speed with SubaruGears reverse cut Ring and Pinion
Tyres - 16x7 front with 235 x 75 x 16, 16x8 Rear with 285 x 75 x 16
Interior - Custom stuff everywhere, complete with climate control, Car PC, cable shifter, leather seats etc etc.

Build would not be possible without support from the following:

Custom Vee Dub - www.customveedub.com.au - Best Buggy Fabricators in Australia
A-Arm.com - Pete for the front end
SubaruGears.com - Without it I couldn't run the 6 speed.
Blitzkrieg Motorsports http://www.blitzkriegoffroad.com - Their work speaks for itself.
Baja Wes - Offroadvw.net - without Wes keeping my ideas in place I would go really stupid
My Mates - you can never have enough help.

Anyway enough blabin lets get fabbin.

Oh time line - Complete by the end of 2010 ......

As it sat just before I pushed it into the shed and sold off most of the bits... No real change till a few days ago.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 31 Aug 2010, 9:43 pm

#799635

Then after we got Rack and Pinion working on the beam front end I went away and had a great idea to change A-Arm .. time to start drawing again for Wes as now I wanted Power Rack and Pinion Steering on my A-Arm front.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 31 Aug 2010, 9:44 pm

#799639

Then I had a nice near new EJ25T with RJES Bell Housing and fully built 091 box to go in..

But went away again and started driving a H6 Subaru .... mm it was nice .,..

So out with the EJ25T and in with the H6 ...

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 31 Aug 2010, 9:45 pm

#799641

You can't have a H6 behind am old 091 Kombi Box, it just wouldn't be right .. so out with the 091 and in with the 6 Speed.

Now we are up to date, I just need to get the guys at Custom Vee Dub to stop working on everything else and get my Buggy Finished.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 31 Aug 2010, 9:45 pm

#799642

6 Speed sitting in chassis, it will go forward aroun 100mm from this picture.

The Iguana was built to take a Turbo EJ and WAIC so there is room for most things. Didn't think of a cable shifter though .. luckily it will just fit.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 31 Aug 2010, 9:46 pm

#799643

One of the issues I had with the A-Arm front end was with the original spindle design which used press fitted and welded VW style stub axles. These were never going to pass engineering so I had Pete make some changes and ship my uprights with a drilled PCD and no stubs or steering arms.

This allowed me to get some bolt on spindles and set the steering up to suit the power steering rack I wanted to use.

After looking around for a good quality spindle and hub provider I found http://www.blitzkriegoffroad.com/ - All I can say is WAY COOL ... Dennis and the Guys where great to deal with and their product is without a doubt the best I have ever seen. Fit, finish, Quality and great service.

Fitting pictures soon ....

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 · 31 Aug 2010, 10:23 pm

#799653

Looking good Brad - always loved the look of the Iguana body.....will be good for the changes to be finalised and see this beast finished eventually (I know whats it like, can't rush these things!)
Al

www.dasrestoparts.com.au

waveman1500 Also rides a Honda

1,346 posts · joined Dec 2009 · 31 Aug 2010, 10:47 pm

#799658

Dude, you certainly know how to unleash the cash! The spec list on this build is amazing. Is is going to be registered or do you just really like driving on sand? And I assume by the comment of air conditioning that you're going to put a roof on it? This is definitely a very interesting build.

1972 VW S-Bug - For Sale!
1968-onwards Beetle panels and glass for sale

matberry Moderator Go hard or go home

8,114 posts · joined Mar 2006 · 31 Aug 2010, 10:58 pm

#799659

👍👍👍

Have to watch this space I guess 😉

Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 31 Aug 2010, 11:23 pm

#799660

The Iguana will be fully registered as an ICV and approvals have been gained.

It will be fitted with an aluminium Roof built in the "Expedition Style" with intergrated Spare wheel and roof rack.

As for coin I would expect the entire thing ignoring R&D and $$$ lost on changing ideas to come in at around the $60k mark.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

555bug WRX Bug Boy

1,123 posts · joined Aug 2002 · 1 Sep 2010, 12:43 am

#799669

cool are you doing my box r&d 🙂 now i think i need some a-arm's

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 1 Sep 2010, 11:20 am

#799728

reub wrote:DUDE! Where have you been?? 🙂
Look forward to the finished product.

Saving $$$ to build this thing ... I look fwd to the finished product as well. 😂

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 1 Sep 2010, 11:20 am

#799729

555bug wrote:cool are you doing my box r&d 🙂 now i think i need some a-arm's

I think you need some too. I saw a nice set down at Custom Vee Dub the other day .. getting engineer approved and all.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 1 Sep 2010, 11:21 am

#799730

So now I had a 6 Speed I need to pull it down and get it to fit. As it was a brand new box there wasn't a lot of info out there so I decided to just pull it apart and see how it worked in there.

I thought a good place to start was by measuring it ... mmm she is a long one ..

Being the 6 Speed she also has these nice big wings on here which I am hopeing I can include in my barwork design to give extra stability and strength.

Along with the wings are the nice things such as hydraulic clutch and cable shift, should make for a nice shift setup if I can work out how to reverse it so I dont need cable which are 4m long.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Craig Torrens 6 times Australian, 7 times State Hillclimb Class Champion

8,040 posts · joined Jan 2003 · 1 Sep 2010, 11:47 am

#799734

Watch out everbody....Brad is bored again...........and this is going to be good !!!!

bajachris88 The international telephone dialing code for Antarctica is 6

6,661 posts · joined Apr 2005 · 1 Sep 2010, 11:48 am

#799735

Mmm.... i can feel some wheel stands coming on 😂

(ô_!_/ô) (ô_!_/ô)
69' baja: kombi box, thing spindles, irs, disc front, type 3 rear drums, 2 inch lift kit, 31x10 rears. 👍
New engine in process: 94mm p&bs, 74mm C/w chomol Crank, 35.5x39 SP heads, turbo. Wierd combo, hopeful torque monsta!

matberry Moderator Go hard or go home

8,114 posts · joined Mar 2006 · 1 Sep 2010, 12:21 pm

#799742

Cool, I say bring it on Brad...she's gonna be a beast.....I can feel beach drags are getting closer 😂😂

Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE

Sides Veteran Volks Folk

2,220 posts · joined May 2007 · 1 Sep 2010, 1:18 pm

#799753

Ooo ooo... Brad's giving the Iguana some lovin, with a H6 and all... excellent stuff !!!

👍👍

Much more my style than the 'Franken-brumby' idea dude... this is gonna be one very interesting thread I reckon...

😀😀😀

VWDCQ vice pres & web dude - vwdcqinc.org.au
Join a car club - get car peeps

My toys
'70 Hillclimb Bug 'Jezebel' w/- Haltech EFI - http://bit.ly/VwTNtQ
'60 KG Coupe - resto kinda started
01 New Beetle - gf's car, but I turn the spanners

baghall Ben Hal Outlaw Bushranger

1,021 posts · joined Jan 2010 · 1 Sep 2010, 2:11 pm

#799756

Sooss glad you decided to do a build thread. Looking forward to following the progress.👍👍👍

68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 1 Sep 2010, 4:14 pm

#799775

In order to get the gearbox to be shorter I need to remove the nose cone and centre diff from the case.

With the nose cone unbolted you can see the rear drive gear that would have driven the rear drive shaft in AWD Config.

No need for that anymore or the rear drive shaft

Looking into the box there is heaps of stuff I dont't need ..

Out it goes ... no need for a centre diff .. thinks of all the weight I am saving...

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 1 Sep 2010, 4:15 pm

#799776

mm now I wonder how much of this I need ... all of it I guess since I want to shift gears when I drive.

The 6 speed like most Subaru's I have looked at have a nice tabbed rear mount which I will try and re-use. I like them as they have tabs that stop the box from falling out should the rubber break.

If you look real close you will even see stick on weights which I am guessing has more to do with vibractions than weight

Brad
Why copy when you can own an original ?
Meyers Manx Australia

baghall Ben Hal Outlaw Bushranger

1,021 posts · joined Jan 2010 · 2 Sep 2010, 7:45 pm

#800004

Have not seen one of these bodies before but I love it. Awsome lines and definitley will want to see this when it's finished. I love a good buggy.

68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 2 Sep 2010, 9:35 pm

#800045

Ok well I rushed home from work today as I had a need to make some chips and new that this would result in my stubs going onto my uprights for the first time, I was very excited about that.

When Pete at A-Arm.com made the kit for me he left the stub axles off and drilled PCD for me to bolt something to. When I eventually settled on the BMS stubs and hubs they arrived with a 5mm shoulder on the back. This meant that I would have to machine a round pocket on the uprights to take this. It also meant I would have to face it once done to make sure they sat perfectly flat.
So after having a chat to Dave at Custom Vee Dub it was decided I would need to do it in the Mill as it would be too hard to get it to fit in the lathe due to the off centre nature of the upright.

So into the mill it went for a pocket and a new face.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 2 Sep 2010, 9:36 pm

#800046

I have also been thinking about the best approach to modify the 6 Speed to fit in the VW. After many hours of thinking and head scratching I have pretty much decide I will need to modify my torsion housing as unlike the 5 Speed the 6 Speed will have to stay 130 mm longer .

To make sure this was the case I dropped by SubiEvolution (http://www.subievolution.com.au/) and the Russell gave me an AWD 5 Speed to pull down to put alongside the 6 speed to check out the differences. As you will see it is very much the same but at the same time quite different.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

ttriebler Officially Full-On Dubber

321 posts · joined Jan 2008 · 3 Sep 2010, 2:24 am

#800111

Now THAT's a first gear! Nice and wide....I can see some launches happening with that.

Reversed gears for Subaru transmissions.
Fit a Subaru 5 speed to your rear engined car
www.subarugears.com

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 4 Sep 2010, 9:25 pm

#800442

Well not much progress to show. Spent most of the day coming up with crazy ideas and trying to sort out the best dash setup. Anyway after more than a few hours of distraction from Ben I have settled on using the Outback Dash complete with Sat nave and Climate Control. I wasn't going to bother with the climate control but since Wes had it I didn't really have much option.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Sides Veteran Volks Folk

2,220 posts · joined May 2007 · 5 Sep 2010, 7:51 am

#800475

Heh heh - love it dude... you've "settled" on having the full Outback dash in there... makes me wonder what the number 1 choice was !!!

Climate control is mandatory in a soft top IMHO, and Sat nav... well it might help what with some of the places this thing will probably go...

😂

VWDCQ vice pres & web dude - vwdcqinc.org.au
Join a car club - get car peeps

My toys
'70 Hillclimb Bug 'Jezebel' w/- Haltech EFI - http://bit.ly/VwTNtQ
'60 KG Coupe - resto kinda started
01 New Beetle - gf's car, but I turn the spanners

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 5 Sep 2010, 5:59 pm

#800568

Sides wrote:Heh heh - love it dude... you've "settled" on having the full Outback dash in there... makes me wonder what the number 1 choice was !!!

Climate control is mandatory in a soft top IMHO, and Sat nav... well it might help what with some of the places this thing will probably go...

😂

Yeah cheers Dave, it is pretty tough when you have to choose between custom outright, custom with Outback or Outback Custom 😂

The end result is working out as thought which is a good thing

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 9 Sep 2010, 9:30 pm

#801339

Ok so I have been away for a few days but the build continues. Due to time line intents I have a few things on the go at once.

So anyway I decided to fit the 6 speed and make sure all the linkages were going to work. After looking at it for a while I decided that I wanted to use the front transmission mount and keep the front bearing carrier. This meant I had to modify the florr pan a little to fit it all in.

First part done, still need to box it out and add some supports, but it fits.

Brad
Why copy when you can own an original ?
Meyers Manx Australia

Brad Wolfsburg Elder

3,764 posts · joined Aug 2002 · 9 Sep 2010, 9:31 pm

#801340

I also ran out of storage space to put all the bits as I strip them down. Not wanting to loose anything I smacked out a couple or parts trays to keep tabs on things, you have to love ally and Kemppi Tigs.

On the electrical front my H6 schematics should arrive next week and then I can skin the loom. I have also decided to run a couple of Motec PDM's instead on Fuses and Relays ... I must say after years of wiring buggies I am in love with the Motec PDM ... it is AWESOME...

Brad
Why copy when you can own an original ?
Meyers Manx Australia