nils Fahrvergnugen
971 posts · joined Jan 2008 ·
Great to see you back at it mate
Quit calling rust patina
Photos of my rusty baja and the work update Jan 15 2014
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Yep trying to get it done before valla. Really want to drive it up next year.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
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baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Well got some more work done today. Finished seam welding front shock towers and preped for welding on adjusters (just gotta find the bloody things now).
Also started working on shortening the springplates from swinger to IRS so that I can run with the shorter torsion bars. Will put up photos when the kids return my phone cable, buggers).
Also started working on shortening the springplates from swinger to IRS so that I can run with the shorter torsion bars. Will put up photos when the kids return my phone cable, buggers).
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Didn't find adjustors so I ended up modifying old spring plates.
1. Using template for marking out holes
2. pilot holes drilled
3. holes drilled to size
1. Using template for marking out holes
2. pilot holes drilled
3. holes drilled to size
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
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58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
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baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
4. Cut to length
5. Shapping ends
6. Enlarging holes with second hole
5. Shapping ends
6. Enlarging holes with second hole
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baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
7. Continue enlarging holes
8. Finishing with a file
9. Test fit to see all lines up and whether enough movement available for wheel alignments.
👍👍
8. Finishing with a file
9. Test fit to see all lines up and whether enough movement available for wheel alignments.
👍👍
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85 T3 Kombi - still growing
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58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
10. Looks OK and can now use the shorter torsion bars.
11.Still looks OK
12. Thought I saw some rust
11.Still looks OK
12. Thought I saw some rust
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
13. So I cut off these (Never used them anyway, car was too high to use jack safely)
14. Cut out the patch and found that they weren't rust holes but where the jacking point had bracken away underneath.
15. welded patch in and cleaned up.
14. Cut out the patch and found that they weren't rust holes but where the jacking point had bracken away underneath.
15. welded patch in and cleaned up.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
Smiley Veteran Volks Folk
2,125 posts · joined Oct 2008 ·
Hey man. Make sure you trim your swinger spring plates down so they are the same width as the IRS ones should be. I think they are 12mm or so wider than the IRS ones so you have to trim 6mm off each side. Measure and check for sure cause I'm pulling these numbers out of memory and they are probably wrong.
If you don't do this you are limiting your down travel cause when it hits the bottom stop will be sooner than it normally does with the IRS plates.
Smiley 🙂
If you don't do this you are limiting your down travel cause when it hits the bottom stop will be sooner than it normally does with the IRS plates.
Smiley 🙂
If you said I was a Volkswagen man, you'd be right.
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Yeah thanks Smiley I noticed that but wasn't going to worry about it as I am planning on notching the plates a little anyway and thought that the extra width wouldn't hurt too much.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Not very clear but here are 2 photos of the seam welded shock towers with welds ground smooth.
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58 Baja ute - and the pain spreads!
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58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
vduboy Insano Dub Head
702 posts · joined Oct 2012 ·
Hi mate liking your work so far! I also have my beam out and was wondering if it was worthwhile welding the seams up as well? I dont plan on jumping the car but fire trails, bush tracks will be the norm.. what do you think?
It will all be OK in the end, if it's not OK it's not the end!
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Thanks vduboy.
Just helps strengthen them. The Baja and off road bible ( Baja Bugs and Buggies : for Off-Road Fun and Racing) talks about it if I remember correctly. Ran as a baja offroad a lot without them welded and no problems, but I decided to do it because I have the car off the road and well why not. Can't hurt.
Just helps strengthen them. The Baja and off road bible ( Baja Bugs and Buggies : for Off-Road Fun and Racing) talks about it if I remember correctly. Ran as a baja offroad a lot without them welded and no problems, but I decided to do it because I have the car off the road and well why not. Can't hurt.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Started work on fabricating a 2" body lift on the weekend. Decided not to buy a ready made kit cause I have already spent way too much on parts for this bug and still have more to get.
Anyway, this shows how I bend curves without a tube bender,with a bit of welding.
1/ cutting and bending curve for side rail
2/ tack welded before welding completely. Can see that gas was not flowing properly. Indicator is the porosity of the welds.
3/ Welded up. Notice much smother welds when gas is working properly.
Anyway, this shows how I bend curves without a tube bender,with a bit of welding.
1/ cutting and bending curve for side rail
2/ tack welded before welding completely. Can see that gas was not flowing properly. Indicator is the porosity of the welds.
3/ Welded up. Notice much smother welds when gas is working properly.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
4-5/ show the welds all around
6/ shows both side rails in place temporarily
6/ shows both side rails in place temporarily
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
7/ Curve over rear inspection hole tacked up. This was done by cutting 20 holes spaced approx 15-20mm (can't remember exactly) apart but found curve was not enough so did another 20 cuts in between the others. All cuts done with 1mm cutting wheel. Curve was not quite enough but I felt that once welded it would tighten to what was needed, due to distortion.
8/ All welded and cleaned and it can be seen, if one looks hard enough, that the curve is almost exact.
Now need to work on the harder sections, but need to get more gas. Those small bottles of gas last no time at all. Think I will need to hire a bottle. Had to finish some of the welding with gasless wire. Hate using gasless.
8/ All welded and cleaned and it can be seen, if one looks hard enough, that the curve is almost exact.
Now need to work on the harder sections, but need to get more gas. Those small bottles of gas last no time at all. Think I will need to hire a bottle. Had to finish some of the welding with gasless wire. Hate using gasless.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
vduboy Insano Dub Head
702 posts · joined Oct 2012 ·
Awesome work mate! Are you welding in crush tubes or captive nuts to hold it all together?
It will all be OK in the end, if it's not OK it's not the end!
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Gonna use crush tubes and was recommended this by the mechanic.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
vduboy Insano Dub Head
702 posts · joined Oct 2012 ·
That sounds like the best option, probably a lot more dicking around but at least it'll be strong!
It will all be OK in the end, if it's not OK it's not the end!
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
👍vduboy wrote:That sounds like the best option, probably a lot more dicking around but at least it'll be strong!
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Photos
1. Rear tacked up
2-3 templates for bending flatbar to shape for front of tunnel section.
1. Rear tacked up
2-3 templates for bending flatbar to shape for front of tunnel section.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
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58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
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baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
1. Marking midpoint of flatbar for even beding to fit over front of tunnel
2. bending flatbar to fit curves using rollers
3. both bars bent (note the difference between inside of curve to outside.)
2. bending flatbar to fit curves using rollers
3. both bars bent (note the difference between inside of curve to outside.)
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
1-2. shows bars fitting over templates neat
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
1-2 show a neat fit for the bars
3 shows I stuffed up and cut the top bar too short (measure twice cut once) so had to fab up another.
3 shows I stuffed up and cut the top bar too short (measure twice cut once) so had to fab up another.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
Bone Officially Full-On Dubber
299 posts · joined Aug 2009 ·
Looking good. As you probably already know is that the tunnel section lift changes size (not just 2' all the way down sides) so the strap/infill section welded in is a good way to go.
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Yeeah wasn't sure how to do this but was told by Mike (CBB) to do it this way. A bit of mucking around but worked well.Bone wrote:Looking good. As you probably already know is that the tunnel section lift changes size (not just 2' all the way down sides) so the strap/infill section welded in is a good way to go.
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
1. not as neat but it works
2. tacked in
3. all tacked together now just got to fill in the straps
2. tacked in
3. all tacked together now just got to fill in the straps
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
1. ran out of gas so had to weld in the the sides with gasless wire. I hate using it. Also got really bad welders flu, still getting over it.
2. Front needs to be made up in pieces.
2. Front needs to be made up in pieces.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Finally finished welding up the lift kit, but still need to clean up the welds and complete the crush tubes.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
baghall Ben Hal Outlaw Bushranger
1,021 posts · joined Jan 2010 ·
Finally got lift kit finished.
Seems to fit body OK.
Seems to fit body OK.
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68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car