Thought I might post some photos showing what is happening to my daily baja
Heres whats been done so far:
* stripped out floor including sound proofing (flooded interior of car by over 1 foot dep) and resound proofed
* removed rear screen and fitted rear bar work. (rear screen fitted via preheat mounts and tinwear, not very good)
baghall ·
* new rear speaker box
* rewired stereo with new dvd, amp, 6x9s and still 2 tweeters and 4"s to go in front
baghall ·
* polished aluminium checkerplate dash panels
* aluminium checkerplate door cards need to be finished with polish and still to decide what I will use for map pockets and door handles.
* also replaced old torn racing seats with old torn Daihatsu Charade G11 seats 😂, to be recoverd in blue and white ( the colour scheme for interior when I get round tuit)
baghall ·
* also have begun reshaping rear guards (not normal baja guards (still looking for cheetah baja guards, may even make my own)
* stiil lots of work to do and ideas to realise.
Hope you guys enjoy seeing it happen. Not easy trying to work and improve on a daily driver.
cam070 ·
Nice work, keep the progress pics coming.
RZEDGE ·
that's awesome! Love it!
Rural Baja ·
Gotta love a Baja 😁
baghall ·
Rural Baja wrote:Gotta love a Baja 😁
Saw photo in your profile of rear of baja. Got any more? Would love to see some.
baghall ·
Well my plans for these hollidays change just a little. Was hoping to begin work on front bar and tail lights. But car had other ideas and decided I needed to work on another engine. Car thought that there wasn't enough oil on the road and dumped the lot in space of 10 meters on the freeway🥲. Anyway now preping second motor for putting into car so I can rebuild current motor.
beetleboyjeff ·
Man, I gotta get a chance to call in and have a look.
baghall ·
Well Geoff once I get it reliable I hope to be heading up your way to catch up with a mate and possibly see dylan the dubber for same parts. Not sure when this will happen though.
Barnabie ·
Its looking better by the day - the rear bar you fitted is a major improvement. Hope your motor dramas get sorted without too much grief!😉
donn ·
Lookn good.........PM sent
donn ·
Realy need to talk to baghall (Ben?) if someone knows him could you ask him to check his PM. 👍❗
baghall ·
Well motor was preped and installed but is not starting. Turning over but I think I need to check valve clearances just doesn't sound right. Also need to check for spark as used old dizzy but may need my new one fitted.
baghall ·
Pm Donn
jjwebb123 ·
wow looks sweet good job
baghall ·
Finally got engine running on thursday. So on friday took it for a test drive to check engine etc.
Problem is found some puddles and couldn't help getting the car washed.
It's what a baja is for!
baghall ·
Well rego time is upon me.
Not gonna be an easy one.
Work done:
Rust repair of 'A' & 'B' pillar - 'B' pillar is actually completely separated at base. Both are now repaired but unbeleivably a previous owner had cut out the rust in the 'B' pillar and just put a single layer of fiberglass in to replace the steel. What sort of an idiot does that, particualrly in a structural area?
Replaced number plate light.
Replaced VW bolts with M14 studs in rear barke drums. A previous owner had changed rear drums to an earlier type. Another stupid move.
Brakes been repaired by CBB. They were very poor, looked like they hadn't been serviced in years.
CBB also found:
Needs new steering box & 2 upper ball joints.
Thanks to Mike and the guys at CBB for being a great help.
By the way have finally named the car. I call it Al. Just seems to suit it.
Joel ·
You can caaaaaaaaall meeeeeeee Aaaaaaaaaal.
Damn that makes me feel old that that song was the first thing that popped into my head straight away 🤪
baghall ·
Joel wrote:You can caaaaaaaaall meeeeeeee Aaaaaaaaaal.
Damn that makes me feel old that that song was the first thing that popped into my head straight away 🤪
Sorry Joel but cannot recall the song who was it by?
donn ·
Oh yeah, thems was the days, think I'll go back and maybe I can call him Paul and maybe meet his mate Art. 🤓
Just went back and am listen again, reading the words makes me wonder what the hell they were on. 😂
baghall ·
AAhh now I remember. They were sooo cool in their day, also agree Donn. Reading the words brings back memories of what drugs do to the mind.
baghall ·
Well Al has finally past rego and feels like new!
baghall ·
Have now taken the car off the road for a time so I can lift the front and rebuild the gearbox.
baghall ·
Well just spent 2 days working with a fibreglasser working on laying up a mould for him and making some carbon fibre racing dashes and wings. Love the stuff and now am thinking that when I make my new rear guards I will use some carbon fibre for them. Just bloody expensive! $6000 dollars a roll for the fibre.
baghall ·
Not been too many updates except for when hit in rear. Finally got sick of dealing with the other persons insurance and told them to p*&^%^f. Al's back on road and have now got some motivation to do some other work on it that I had planned on but never got to. Guess some good has come out the accident.
Anyway, pulled off front bar today bcause of a broken mount. Bar was really over engineered; - 3mm wall thickness on 50mm OD pipe with 10mm by 40mm flat bar welded to front of floor pan and hooked over bottom beam.
baghall ·
It took a little persuation to get the mounts off the car. Had to cut the welds ( they looked ugly but I guess if there is enought weld metal then they will hold) with the grinder and use a largish hammer for encouragement. Done though.
baghall ·
Don't mind the look of Al without the bar. Pity bout the fiberglass though!
baghall ·
Well more work done today. Cut up front bar to reshape it and couldn't believe how heavy it is. You can see why in the photos. Double layer of tubing at top of the bar.
1st photo shows the twin tubes that were approx 400mm long and how much weight the front bar lost. At least 6-7 kg and maybe more.
2nd and 3rd photos show the newly designed bar preped and ready to weld up.
baghall ·
These 2 photos show the bar welded up with the welds ground smooth. Also show position bar will be in when mounted to the car so I can mock up and measure where I will be attaching the horizontal bar.
Bar sits higher as I plan to mount it level with the bottom torsion bar.
If anyone is looking at these photos, I would be keen to here some ideas on how I could attach the bar.
My thoughts are to weld some flat bar onto the bottom tube and to the mounting bracket, then weld a short piece of tubing onto the flat bar that I can slide the bullbar onto nad bolt through. Also will have some tubing attaching to the shock towers.
What do people think?
baghall ·
This is what I mean by the a bracket on the bottom tube.
pod ·
when i made one for the baja i was building i used the bottom beam mounting bolts to mount the bar
baghall ·
Hey Pod, do you have any photos of the brackets you made up. I like the idea just seems too easy!
Smiley ·
Have a look at the bottom on page 14 of my build and on page 15, shows the mounts I made up for mine.
The only thing I would have done differently (and will be fixing in the future) is run tubes from the the back of the mount to the floorpan under the A-pillar area. This helps support the front beam.
Smiley 😎
PS - Baja is looking great! Good to see you're motivated even after the setbacks with the crash.
baghall ·
Continued to modify old bar by cutting up a 2nd bar and rewelding both together.
Several holes needed filling as well.
baghall ·
And here's the bar all together. Have started fabricating brackets but due to time constraints will end up taking a bit more time to make. Will upload photos when done!
Bar is a bit heavier than I would like but beggars can't be choosers, and it would be ample strong enough to mount a 4x4 winch.
pod ·
no pics of brackets ,but i know i used 100 x 10 black steel,i had a pipe welded at the back of the legs with the brackets welded to this
baghall ·
The only thing I would have done differently (and will be fixing in the future) is run tubes from the the back of the mount to the floorpan under the A-pillar area. This helps support the front beam.
Glad you like the baja. A previous owner did manage to have the brackets going back to the 'A' pillar but they used 10x40mm flat bar. Bloody heavy and way over engineered. I may do this but will use different brackets to save on weight,
baghall ·
1st photo shows the bracket for mounting the front bar.
next 2 photos show the bar on Al.
baghall ·
following photos show the condition of the brakes and what they looked like after cleaning up and preparing gearbox to install to replace the old box with only 3 gears. Lost 4th gear.
baghall ·
gearbox cleaned up. Sorry no picks of before I cleaned it, but was quite oily and dirty.
Was terribly unsuccessful today with assembling the brakes, due to brake specialist not getting the shoes religned in time. Wasn't completely happy as was planning to go off roading for easter but now car is off the road till after easter when I can get the shoes. Oh well, hopefully I can get some other stuff done to the car.
11CAB ·
Hope you didn't get any water into the transmission through the broken axle boots.....
baghall ·
11cab
Yeah I assume I did but was very carefull, but will be changing out oil anyway. Oil that leaked was crystal clear though.
baghall ·
Had intended installing new master cylinder monday but rain put a stop to all work. Garage is too small for me to store gear and work on car in there. Oh well, realised I have next weekend to complete gearbox and master cylinder, if I don't get time on after work.
baghall ·
Well new gearbox installed, engine being difficult to get in as is 1 handbrake cable and still waiting for brake pads to be done with new linings.
Was slack with the MC and have not installed it yet.
Smiley ·
baghall wrote:Well new gearbox installed, engine being difficult to get in as is 1 handbrake cable and still waiting for brake pads to be done with new linings.
Was slack with the MC and have not installed it yet.
Keep at at mate! Not much left to go and you'll be looking for some nice mudholes to try her new gearbox out in!!
Smiley 😎
baghall ·
Yeah thanks Smiley. Will get there soon Just trying to fit engine to the bell housing but turns out gearbox was a 6V flywheel. So gotta clearance for the 12V flywheel. Almost fitting about 5mm to go. Getting impatient though.
Bloody frustrated with the brake specialist.
baghall ·
👍 Brake shoes are here. FINALLY. but can't fit as I forgot to get some other parts due to damage from trying to get seized shoes to release from drum. Buggar. Hopefully I can get them tomorrow.
Engine is in but unable to star. Flat battery! Guess I should have put it onto the charger. Oh well!
baghall ·
It's ALIVE! Yeah.
Got brakes together and have also got it started finally. However the alternator pulley was running a concentric circle SO not good. Bought a new ingot pulley to replace the original pulley. Original was badley chewed out and had twisted on the shaft. Not sure why this happened but new pulley does look good.👍
baghall ·
Look what arrived yesterday, side draft dellorto. Wish I was ready to put it onto Al but not yet, few more things to do and buy first.
kaiisons ·
hey man saw you driving on the great western highway towards penrith on tuesday arvo. looking and sounding good mate! wouldn't have seen me I wasn't in my Kombi
baghall ·
Buggar attahment too large now I gotta type it all again.
Gidday kaiisons, yeah I live in Kingswood. Will keep an eye out for the kombi.
Well got off my arse this week and worked on Al.
Bought a set of sunraysias from a suzuki vitara with 139.7 PCD. Wire wheeled them clean and repainted them. Used silver hammertone paint and think they will look good. Will be fitting some 2nd hand 205/70 all terains for now. Also got my new front rotors drilled to suit. Painted these also but in red. Just gotta wait till next saturday when I can fit them.
'scuse the ugly mug but thought I would post a photo of my war wound from the wire wheel. Thank God for safety equipment. Got hit several times in the face by wires. Felt like someone was throwing rocks at me.
kaiisons ·
That was me at Mike's too!
baghall ·
kaiisons wrote:That was me at Mike's too!
Met a few people there recently. Were you the guy I was talking to under the orange kombi?
kaiisons ·
Yeh, thats me, the young bloke haha. My kombi is like in my avatar.
baghall ·
kaiisons wrote:Yeh, thats me, the young bloke haha. My kombi is like in my avatar.
Was good to meet you today. Hope the engine runs well for you now!
baghall ·
Spent the day giving Al some TLC.
Replaced master cylinder with a new German made one. Replaced front brake lines with a new braided pair. Replaced front brake rotors with a new pair, painted red cause as we all know it means better performance. Also cleaned up brake calipers and painted them. Red of course!
Photos are of rims before cleaning and painting and calipers before and after.
baghall ·
TheTLC continues. More photos of the love.
I think the wheels look good against the red.
Just gotta bleed the brakes in the morning to complete the work.
baghall ·
Seems I have an added bonus with the wheels. I knew I would get some lift at the front due to the rolling diameter being almost 2" taller, but what I didn't expect is I have improved the ride comfort. I'm assuming its because of the higher tyre profile. Brakes have awesome feel now due to braided line. Now to get the rear end upgraded.
I'm sick of being a swinger!😊
baghall ·
Interesting trips up & down the mountains. The baja is obviously magnetic. Some are attracted to it and some are repelled. 😏
Trip 1 - bunch of blondes eyeing off the car (could have been me though😂 ), a guy yelling out to me how cool it is at the lights, and a 2 girls madly waving at me and smiling (again it could have been me😎).
Trip 2 - followed by a van with driver and passenger Iphones out videoing me as a drive between blaxland and springwood. Bit off putting to be honest!🤪
chuttla ·
wow,top work! those wheels look so much better! the discs come up good to. if you dont mind me asking, whats it worth to get them redrilled these days? are you going to get the rear redrilled with matching wheels as well?
baghall ·
Yeah the rears will be done as well but I may need to get a different set with more offset as these rims don't clear the front calipers without a spacer. The drums and drilling cost just over $400. Sorry but can't remember exact amount.
OberonViking ·
baghall wrote:Interesting trips up & down the mountains. The baja is obviously magnetic. Some are attracted to it and some are repelled. 😏
Trip 1 - bunch of blondes eyeing off the car (could have been me though😂 ), a guy yelling out to me how cool it is at the lights, and a 2 girls madly waving at me and smiling (again it could have been me😎).
Trip 2 - followed by a van with driver and passenger Iphones out videoing me as a drive between blaxland and springwood. Bit off putting to be honest!🤪
Funny you should say that. I have a mate who drives a White Caravelle. He knows I like the bajas... He sent me these in an email last night. I guess he was impressed.
matberry ·
Hey Bag's, when is that IRS (double jointed rear suspension) coming, that positive camber will hurt you or someone else if your not carefull!!!!
baghall ·
OberonViking I was wondering if I would see these on the forum. Didn't expect to see them on my topic though. I think you are being kind as I don't think it's that impressive yet, though it does sound it with the twin cannons.
baghall ·
matberry wrote:Hey Bag's, when is that IRS (double jointed rear suspension) coming, that positive camber will hurt you or someone else if your not carefull!!!!
Awh cut me some slack Mat, I will be picking up the box begining of July but still gotta get suspension components, and I am collecting for another aspect of the car as well (supercharger).
It doesn't look that bad in real life. Mike at CBB keeps me pretty honest with it. I have tried to get most of the lift with the 31s on the rear.
OberonViking ·
baghall wrote:OberonViking I was wondering if I would see these on the forum. Didn't expect to see them on my topic though. I think you are being kind as I don't think it's that impressive yet, though it does sound it with the twin cannons.
Perhaps they are impressed that a baja that looks a lot like mine was registered and running. I too have twin cannons, and it needs the paint patched in places.
matberry ·
All good mate. Nice to hear you care that much for your car that you have Mike keeping you on the straight and narrow.
You wont know it once you convert to the later design rear end 😂 not to mention blown !!
baghall ·
matberry wrote:All good mate. Nice to hear you care that much for your car that you have Mike keeping you on the straight and narrow.
You wont know it once you convert to the later design rear end 😂 not to mention blown !!
I think that if I want his help and advice I gotta do as he says also he has to pass it for rego.
And I am just peed off that I keep having to spend my money needless expenses like food, roof over fam, etc. It stops me getting my parts sooner.
Smiley ·
matberry wrote:You wont know it once you convert to the later design rear end 😂 not to mention blown !!
I'm hanging out for progress on this 😀😀😀😀😀😀😀😀😀
Smiley 😎
baghall ·
Smiley wrote:
matberry wrote:You wont know it once you convert to the later design rear end 😂 not to mention blown !!
I'm hanging out for progress on this 😀😀😀😀😀😀😀😀😀
Smiley 😎
Not as much as me Smiley. Not as much as me❗❗❗
baghall ·
Well let the fun begin. Finally got an item I have been trying to get for a while which has forced a decision. Just waiting on delivery.😁😁😁
matberry ·
Spill the beans dude !!!!!
baghall ·
Yeah when I get the item I will post photos!
baghall ·
Look what has finally been delivered😍😍😍
Now I just have to find the time to build the motor for them.
BTW I blame Smiley for the 🤪 of installing twins onto Al, but should look great as well as go ok!
matberry ·
👍👍👍
Smiley ·
I take full responsibility 😀😀😀😀😀😀😀
Smiley 😎
baghall ·
I might have to get you to come down and help me build the engine then.😂
It has motivated me a bit now!
Smiley wrote:I take full responsibility 😀😀😀😀😀😀😀
Smiley 😎
baghall ·
Well Al has again done it's own thing. Driving down to Berry to meet up with other VW owners and Al decided to scrap it's diff. 😬Ended up spending a couple of hours on the side of the road waiting for NRMA.
Looks like it will be off road till I get new gearbox built and fitted.
matberry ·
Bummer mate. Just chuck in a second hand one as you will need a type 2 double jointed box when you get all that new power/torque.
baghall ·
This is the second hand one I just put in! The trip to Berry was to pick up a gearbox for rebuilding. I think I need to just sit this one out till I have the new box built and installed. Bloody pain though as I was supposed to be picking up another project car next week.
matberry wrote:Bummer mate. Just chuck in a second hand one as you will need a type 2 double jointed box when you get all that new power/torque.
baghall ·
Well have now moved house so I have more room for the VW's. Just gotta sort out the garage so I can begin work on lifting the body off the pan and getting it converted ti IRS.
Anthiron ·
Very Impressive Baghall!
I Have some rear baja guards that are yours for the price of freight if you like. Only problem is they aren't the wide kind.....if youre handy with glass you might be able to widen them?
baghall ·
Thanks Nicko but I actually heve a couple of spare guards for the car but are also not wide enough. I hope to be making a wide set sometime but they maybe made from carbon instead of fibreglass. Just depends on the cost of materials.
Smiley ·
How is your Baja going mate?
Get those blowers fitted yet??
Smiley 🙂
baghall ·
Hey Smiley. Nah been very slack of late but did pick up the rebuild irs box the other day so now I got no excuse and need to get off my a__. Have started but don't want to over exert myself so I only pull off the rear spoiler.
Smiley ·
What type of IRS Box is it?
Kombi or Beetle/type 3?
I just put a 5-rib Kombi box in mine before Christmas and have to say it's easily paid for itself 😀
Smiley 🙂
baghall ·
Hey Smiley, i5t is a custom made irs beetle box with super diff and welded gears. Should be strong enough to take more power than I plan and the punishment it will get. Ironically it was just shy of twice what i paid for the car itself.
Smiley ·
Super duper new gearbox and you haven't posted pictures yet!!?? Shame on you 🙅
Did you choose a custom set of ratios to suit your tyre size a bit better.
I had a Type 3 IRS box in mine for a while before swapping up to the Kombi box. The Type 3 box has the lowest ratios of a standard IRS box without going to a Kombi. And I still found that they were too high for my liking, even with a biggish engine to pull them.
Are you running a 31" rear tyre? I can't remember.
Smiley 🙂
baghall ·
Mike & I agreed to keep the ratios standard for highway and normal road running. I think it was from a type 3 but am not sure. Am current;y running 30s (thought they were 31s but was mistaken, oops), but plan on running 31s or 32s on rear (possibly 33s) and 2inch smaller on front. If I am allowed.
Here it is Smiley, oh and I got some extra support for it as well. Was gonna make one but not worth it with the price!
Smiley ·
Sweet!!!
It really looks the goods. Have you got it fitted yet or is that as far as you've gotten so far?
You might find those ratios are a bit high for crawling some of the bigger hills etc. It will make for a great highway cruiser and fast dirt/sand car though.
I'm looking forward to seeing more updates, so keep at it!!
Smiley 🙂
baghall ·
Not fitted yet Smiley I'm a bit (read lot) slower than you. It will happen though.
baghall ·
Finally been doing some work on Al.
Thought the wiring was a little messy so I tidyed it up.
baghall ·
Also found some rust. Red arrow is pointing to a gap between wheel guard and firewall. Gap is approximately 1cm wide by about 200mm long.
baghall ·
Other photos of weight loss for Al.
2nd photo shows another spilt in body and 3 rd photo shoe why the car was unreliable and needed a bit of work. This was someones idea of electrical work.
baghall ·
Well played a little more with the Al. Found more rust and a really easy fix for it.
Just cut out a piece of metal to cover the rust scre it over the rust section and plaster it with a bitumen based water proofing ......... and hope no one notices!
Also cut in a scoop for making into a vent for demisting, heater idea etc.
baghall ·
Also a better image of the split between the firewalland rear guard.
Should I pull this off and how can I do it without wrecking it?
Any sugestions on how to remove modern soundproofing?
baghall ·
Hope to take body off this weekend and then i can start cleaning up floor pan.
baghall ·
Well weekend plans came to fruition and finally got the body off the pan.
Second photo shows son trying to imitate the flintstones.
Smiley ·
Great work!
Looks like she's coming along nicely.
Will you be fitting a bodylift while you have it off??
Smiley 🙂
baghall ·
Smiley wrote:Great work!
Looks like she's coming along nicely.
Will you be fitting a bodylift while you have it off??
Smiley 🙂
you gotta admit it was about time I got off my a..., also i miss driving the car. A 2 inch lift is written on the board but gotta sort out the rust and new gearbox first.
But first a trip to meet some more VW people this weekend at Valla.
Smiley ·
baghall wrote:you gotta admit it was about time I got off my a..., also i miss driving the car. A 2 inch lift is written on the board but gotta sort out the rust and new gearbox first.
But first a trip to meet some more VW people this weekend at Valla.
I'm going to be there in Alyce the Baja.
So don't be a stranger and make sure you come and say hello!
It will be great to put some faces to online usernames lol
Smiley 🙂
baghall ·
Just look for an older, chubbier version of the photo of my son and you got me, but will definitely trying to meet up with people and I just can't help it I stop and look at any VW, particularly bajas.
baghall ·
Spent some more time removing the soundproofing. Finally got it all off but have now been able to see better some of the issues with the body. It helped to take a wire wheel to some suspect areas.
baghall ·
some more photos
baghall ·
A photo of what was behind the DIY rust repair and the other side of the firewall which has also separted from the side of the car
baghall ·
Well starting Long ervice leave this weekend for rest of school term. Hope to get some work done on Al.
Smiley ·
baghall wrote:Well starting Long ervice leave this weekend for rest of school term. Hope to get some work done on Al.
Where are all the updates??!! 😀
Smiley 🙂
baghall ·
Coming Smiley (Patience), just got new welder and sand blaster but have injured leg so been a little slow working on it. Anyone able to help cut and weld in the mods for the IRS setupjust unsure of placement. Also anyone got the bars I need for getting them positioned properly. I need to borrow a pair. Thanks.
baghall ·
Here you go Smiley my new welder. Just waiting on the sparky to connect up the 15amp socket.
baghall ·
Cut out some rust yesterday in between visits to the doctor and physio. I guess this is an example of what happens when rust isn't dealt with properly
Smiley ·
I have been there!
It's no fun but once it's all done you no it's going to last a while longer.
Smiley 🙂
baghall ·
Smiley wrote:I have been there!
It's no fun but once it's all done you no it's going to last a while longer. 🥲😠
Smiley 🙂
Yeah you're right there. Problem is I am still waiting on the bloody sparky to wire up a 15amp socket so I can weld.😠😬
baghall ·
Well electrician finally showed yesterday and wired p the power for the welder. So I have been welding up the first major rust holes and the front shock towers. Will were seam welded. Will load photos tomorrow. It feels good to be getting some work done on it.
baghall ·
3 photos showing stages of rust repair
Heater channel
Don't know what you call it but the channel heater channel is in tacked up and then fully welded with new tube for heater duct.
baghall ·
started welding in new panel for guard and found I hate rust even more, cause I found more. Cut it out and welded in another patch. Now it just needs cleaning up.
And a photo from inside. I know the welds are not the best looking but it will hold.
baghall ·
Got some more work done yesterday
Repaired some rust inside the rear guards
baghall ·
Also rewelded the firewall and inner guards seams cause they were separating and some with large gaps.
baghall ·
Cut out some more rust and began repairing it today.
ALso a photo of my new welder on a trolley I made cause I got sick of carrying it around (gets heavy after a while).
Oh and I hate it when you cut out rust and find a larger problem underneath.
baghall ·
and the beginingsof a repair.
Smiley ·
Wow dude!
No wonder you were having issues with the body cracking in that area. I'd say that the rust has weakened the body a little.
Smiley 🙂
baghall ·
Yeah I am a little scared of when I start cutting up further on the pillar.
baghall ·
Finished the repair today.
First photo shows me using a vice clamp to press the folded edge for the gutter. Came out ok but need a bit of dressing up before painting.
baghall ·
Tentativley attacked some more rust today. Here is the saga in photos.
Photo 1 shows just how much filler was usedlast time it was repaired, even used fibreglass as filler with surface rust underneath.
Photo 2 and heres the rust.
Photo 3 rear wheel arch passenger side.
baghall ·
Photo 1 shows previous repair
Photo 2 even past repairs are rusting away
Photo 3 started gutting it all out
baghall ·
Photo 1 cutting out rust continues.
Photo 2 and began repairing the rust again
My welding is getting better too.
baghall ·
Well more rust repaired today, and I realised thatI only have 3 areas of rust left. Bottom of A pillar, down passenger side of rear window and next to the heater inlets at rear. 'A' pillar will definitely be the worst to repair. Finally feel like I am getting somewhere. Tomorrow I'm having a day off from repairing rust and going to begin work on preparing rear guards to make moulds off them.
Also realised electricity bill will be huge for this quarter with all the welding etc.
baghall ·
Been working on Al again but have now burnt out a 5" and 4" grinder and a 18V drill. Bloody getting expensive this exercise.
baghall ·
Well found a bit more rust at the begining of the week, but had enough of cutting and welding atm so decided to do some work on the rear guards, spoiler & bonnet.
This set shows progress on the guards.
Photo 1 - gringing glass to prepare for glassing up holes. Need to grind so new glass can key to old material.
Photo 2 - 3 layers of glass were used so I could build a larger flange. Most of the holes are broken or cracked. Going to try to use a slightly larger flange for mounting in the hope of stopping this happening.
Photo 3 - first layer of putty for shaping. In total I used 3 layers of putty finishing up with stop putty for the small pin holes etc.
These are going to be used as a plug to build some moulds. This way I can make as many as I brake 😂
baghall ·
While putty was drying I began working on positioning the whale tail Igot at Valla onto the rear spoiler. This is shown in photo 1. Stuck this down temporarily using heavy duty putty.
Photo 2 is the second attempt at getting the whale tail fixed. First attempt was skewed approx 9 mm and looked crap.
Photo 3 shows the enlarged hole in the front bonnet for my fresh air duct.
baghall ·
Photo 1 - shows the fresh air scoop for the cabin.
Photo 2- shows the rear whale tail now fixed down in the correct position
Photo 3 - Shows the guards ready for painting, however, they need the slots cut in for the planned recessed LED tail lights.
Anthiron ·
Nice work on those rear guards! Coming together
Smiley ·
👍👍👍👍👍👍👍👍👍
Looking great!! Now can you make me some that are 3 inches wider? In carbon? Pretty please 🤓
Smiley 🙂
baghall ·
Thanks Anthiron, Smiley they aren't finished yet still gotta cut out for the custom lights and these are only the plugs. Planning to make moulds from them in case I break them.👍 Did cut oul holes for lights but still got to make plugs and lay up than more putty and sanding. have to get these done so I can make the guards as the resin I will be using has a shelf and will need to be thrown out soon. Problem is I gotta go back to work on monday.Work really does interfere with what you are doing sometimes.
baghall ·
More work on guards yesterday
Photo 1 - mock up ready to mark out for lights
Photo 2 - lights cut out (there goes all the hard work)
Smiley ·
I still need them widened too, about 3 inches should do it. Thanks! 😀
Smiley 🙂
baghall ·
Smiley wrote:I still need them widened too, about 3 inches should do it. Thanks! 😀
Smiley 🙂
😂😂😂😂😂😂
baghall ·
Not a lot done during last week (back at work buggar it). However started glassing up for recessed lights this weekend.
Photo 1 - shows pugs glued in.
Photo 2 - shows start of glassing in plugs hopefully finish glassing them in on monday arvo.
baghall ·
Well went round to collect and finish the glassing of the guards from a mates place and his wife had finished glassing the light sockets (& nicely done). So I ust had to take them home and begin filling and sanding to final shape.
Photo 1 - completion of glassing
Photo 2 - Dog wanted a photo 😂
Photo 3 - Putty started but shows the holes for the lights
Smiley ·
Looking great! Keep it up.
Smiley 🙂
baghall ·
Thanks Smiley but won't be some updates for a couple of weeks. Gonna take a little while to get shape completed & I got my folks 50th anniversary this weekend. Mum wants me to bake the cake. SCAREY that one!
Bone ·
If you can maintain a baja, you can make a cake ! Keep those photos coming of the rear guards coming as I'm keen to possibly copy your idea. (New rear guards) Nice work mate.
baghall ·
Thanks Bones, don't mind you copying them but you gotta wait till I have been driving mine first!😂
baghall ·
Well it's now good friday so hopefully get some more work done on Al. Nothing done since last post as had a shit end to 2012 and shit start to 2013. Mum diagnosed with cancer early November and passed away Australia day. Spent all of school break helping family nurse her, was difficult but well worth it.
Anyway plan on working on light holes in guards over weekend as well as doing more work on the body have several rust areas to be done still, and will work on them to have a break from working on the guards. I clearly have no patience for the filling and shaping in order to get 4 holes looking the same! Have also bee working on the rear spoiler and will get that close to glassing up just need to sand the filler and shape it a little better.
Craig Torrens ·
Sorry to hear about your mum.
baghall ·
Thanks Craig.
Been doing bits on car after work but not got a lot done, too damn tired. Looking forward to weekend to get some work done and begin holidays in a week so hope to get some work done then.
BTW don't know if I mentioned it but I dislike shaping, ready to make mould in fibreglass.
baghall ·
Finally getting some work done Al again. Completed pulling down the floor pan and started work on it.
Pictures show preparation of rear forks for clearancing for CV joints of new gearbox.
1) Cleaning up for cutting and welding
2) Holes cut out
3) Holes ground to suit pipe sections for welding in. (bottom right dog wanted to get in the photo)
baghall ·
this set of photos show
1) Pipe section welded in. Had to do this twice as MiG was not welding them properly and had to grind them back and reweld using stick welder. This caused me to blow in some holes fortunately I have had lots of practice at this.😂
2) Painted for temporary protection
3) Oh, and this fits with room for CVs.
OberonViking ·
Good to see some progress (I should really get on with mine).
nils ·
Great to see you back at it mate
baghall ·
Yep trying to get it done before valla. Really want to drive it up next year.
baghall ·
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).
baghall ·
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
baghall ·
4. Cut to length
5. Shapping ends
6. Enlarging holes with second hole
baghall ·
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. 👍👍
baghall ·
10. Looks OK and can now use the shorter torsion bars.
11.Still looks OK
12. Thought I saw some rust
baghall ·
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.
Smiley ·
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 🙂
baghall ·
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.
baghall ·
Not very clear but here are 2 photos of the seam welded shock towers with welds ground smooth.
vduboy ·
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?
baghall ·
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.
baghall ·
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.
baghall ·
4-5/ show the welds all around
6/ shows both side rails in place temporarily
baghall ·
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.
vduboy ·
Awesome work mate! Are you welding in crush tubes or captive nuts to hold it all together?
baghall ·
Gonna use crush tubes and was recommended this by the mechanic.
vduboy ·
That sounds like the best option, probably a lot more dicking around but at least it'll be strong!
baghall ·
vduboy wrote:That sounds like the best option, probably a lot more dicking around but at least it'll be strong!
👍
baghall ·
Photos
1. Rear tacked up
2-3 templates for bending flatbar to shape for front of tunnel section.
baghall ·
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.)
baghall ·
1-2. shows bars fitting over templates neat
baghall ·
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.
Bone ·
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 ·
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.
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.
baghall ·
1. not as neat but it works
2. tacked in
3. all tacked together now just got to fill in the straps
baghall ·
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.
baghall ·
Finally finished welding up the lift kit, but still need to clean up the welds and complete the crush tubes.
baghall ·
Finally got lift kit finished.
Seems to fit body OK.
baghall ·
First coat of paint on lift kit. Going to finish inside and outside using Stone chip paint.
Photo 2
But can anyone tell me whether I should worry about strength for off road with this cracked. Also wondering how I could weld it if necessary.
vduboy ·
Brilliant work mate! looks like it fits really well. Glad to see some more progress! 👍
baghall ·
vduboy wrote:Brilliant work mate! looks like it fits really well. Glad to see some more progress! 👍
Thanks mate.
Not sure what happened to the photo of the painted kit but oh well too bad!
Handy ·
Good job, keep going, I really like your Baja
vduboy ·
baghall wrote:First coat of paint on lift kit. Going to finish inside and outside using Stone chip paint.
Photo 2
But can anyone tell me whether I should worry about strength for off road with this cracked. Also wondering how I could weld it if necessary.
I believe you have to pre heat the metal before you weld it as it is cast, makes it a lot easier to get decent penetration.
baghall ·
Thanks handy!
Handy wrote:Good job, keep going, I really like your Baja
baghall ·
Finally got off my rear and did some more work on Al;
Welded pivot boxes in,
Ground down old welds from front bar supports and
Filled some small holes in drivers side floor.
baghall ·
Also started to wire wheel floorpan. What a awful job that is.
Need advice on methods for cleaning up in tight corners and what I should use to paint the floorpan. Need to know what would be the toughest paint to use.
baghall ·
Well finally finished the modifications on the floorpan including welding on adjustors for the front beam. Just got to clean it all up and paint it. Photos will come later as they didn't load properly and were lost.
By the way wire brushes are bloody painful. Had heaps of wires hitting me but when I finished for the day I noticed and irritation in my stomach. Finally found a small piece of metal stuck to my stomach. When I pulled it away an inch of wire from the brush came out of my stomach.😁😂😁
vduboy ·
baghall wrote:Well finally finished the modifications on the floorpan including welding on adjustors for the front beam. Just got to clean it all up and paint it. Photos will come later as they didn't load properly and were lost.
By the way wire brushes are bloody painful. Had heaps of wires hitting me but when I finished for the day I noticed and irritation in my stomach. Finally found a small piece of metal stuck to my stomach. When I pulled it away an inch of wire from the brush came out of my stomach.😁😂😁
Haha been there, I pulled a bit of wire out of my forehead once.. Get some pics up mate! I need more inspiration!
baghall ·
More photos
1. floor pan being cleaned with wire wheel
2. kiss from grinder caused me to knock off a little early today
3. adjusters welded on front beam
baghall ·
another photo to give an idea of how much the grinder loved me today!
nils ·
Hi mate,
You can weld that section of the torsion housing back together. VW castings weld reasonably well, preheating with the oxy will help too. Generally bracing the torsion tube back to the pan will help strengthen that area. Have you got a copy of the Jeff Hibbard book? Most of the answers you seek are in that book.
Watch those wire wells mate, you know they make those in impregnated poly now days. 😀
have fun
baghall ·
nils wrote:Hi mate,
You can weld that section of the torsion housing back together. VW castings weld reasonably well, preheating with the oxy will help too. Generally bracing the torsion tube back to the pan will help strengthen that area. Have you got a copy of the Jeff Hibbard book? Most of the answers you seek are in that book.
Watch those wire wells mate, you know they make those in impregnated poly now days. 😀
have fun
Yeh thanks Nils. I do have a copy of the book just can't find it at the moment.
With the pan upside down I noticed that they had actually been cut by someone. I assume it was by the person who patched in he new battery section of the floor pan.