Nicks Baja Build. - New engine!

Anthiron · 2011-09-19T12:25:54+00:00

The time has come to spend some time on my baja and build the car that I have wanted it to be since i bought it about 8 years ago. The origional plan was the repair the current body to a solid but not pretty state, throw some new paint on and keep on driving. Since removing the Baja kit tonight and doing some digging with a screw driver it has become apparent that it will be too big of a task to be worthwhile. There is a lot of rust in this body! New plan is to find a donor body and do whatever minor rust repairs are on that, switch my gear over and paint. My floorpan is solid luckily, Engine is great and gearbox was built a couple of years ago. Front end needs new link pin bushings but is already cut and turned so all in all the pan will get a nice freshen up with some gloss black, new bump stop rubbers, front end will get rebuilt. Already has new KYB gas shocks all round. I have invested in a little Mig welder and will be making some changes to the roof rack and bar work. Roofrack will house 2 7" Spotties, a shovel and the spare wheel. I will be shortening the rear cage as it is designed for a 4 into 1 exhaust and leaves a hideous departure angle. I will also be adding tabs for lights as i will not be running VW lights but round mounted lights much like you see on most American style Bajas. My experience with old VW tail lights and indicators has not been pleasant. My Saas seats will be recovered in black and red vinyl to match the Leather seats in my 944. I will also be painting the car in Guards red or as close as I can get. The Fenders and rear scoop will be black, as will the bar work. Wheels will stay Powdercoated white. The car when I bought it - Uploaded with ImageShack.us Looked kinda neat in these photos........untill you see the interior.... Uploaded with ImageShack.us [IMG]https://img31.imageshack.us/img31/1383/origionalinterior2.jpg[/IMG] Uploaded with ImageShack.us Uploaded with ImageShack.us This was the car a few years ago when i lived in Caloundra Uploaded with ImageShack.us Since then i fitted Wide guards and fitted a cut and turned beam and Custom Vee Dub had a gearbox buil;t for me and fitted Long axles. I put on some wide stockies on the rear with some Federal Mud Terrains and some Standard stockies on the front with All terrains. Also fitted some Saas Bucket seats and removed the horrible interior and made up some Checkerplate door cards. The car looked like this [IMG]https://img708.imageshack.us/img708/1293/currentvillage.jpg[/IMG] Uploaded with ImageShack.us Here it is parked in my garage Uploaded with ImageShack.us Uploaded with ImageShack.us And now after an hour or so removing most of the baja kit. Uploaded with ImageShack.us Rust Ville Uploaded with ImageShack.us Uploaded with ImageShack.us [IMG]https://img855.imageshack.us/img855/7476/222mv.jpg[/IMG] Uploaded with ImageShack.us [IMG]https://img854.imageshack.us/img854/9571/223wn.jpg[/IMG] Uploaded with ImageShack.us [IMG]https://img339.imageshack.us/img339/3718/224i.jpg[/IMG] Uploaded with ImageShack.us Turns out that drivers side front quarter was about 50% Bondo I will be chipping away at this for a while im sure. I would like to see it back on the road in 6 months......But I guess everyone says that ha ha Nicko

ancientbugger Custom Title Time!

1,986 posts · joined Mar 2004 · 10 Oct 2011, 9:45 pm

#866352

Not a hangover Nick!!! Sorry to hear that but yes Wednesday is good.

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 11 Oct 2011, 3:51 pm

#866450

Not a hangover, Just the flu. On top of that I had a Self insurance saftey audit today at work. Luckily we did fairly well on that.

To cheer me up though this was waiting for me at home, Thanks CBP 🙂

Uploaded with ImageShack.us

Does anyone know where I can buy Rust Bullet? Preferably online or over the phone for delivery

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 11 Oct 2011, 3:56 pm

#866452

PS Barry can you PM me your number. I have lost it

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

ancientbugger Custom Title Time!

1,986 posts · joined Mar 2004 · 11 Oct 2011, 7:25 pm

#866500

I think my PM is playing up, I've just tried twice and it's telling me I'm trying to save it (?) anyway my home number is 5449 1031 and my mobile is 0412 115193.Looking forward to seeing you Nick👍

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 11 Oct 2011, 7:42 pm

#866504

excellent Barry. Ill give you a call before I pop around. Need anything for Micks Baja? im trying to clear out my stash of parts now that I know what I am using and not using.

Well my neighbour came over this afternoon with a big box from CIP for me that had been misdelivered. So It was a good afternoon for packages!

Uploaded with ImageShack.us

Also have a few other bits and bobs for the project

[IMG]https://img16.imageshack.us/img16/3325/037kh.jpg[/IMG]

Uploaded with ImageShack.us

Uploaded with ImageShack.us

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 12 Oct 2011, 8:44 pm

#866700

Dropped the engine yesterday afternoon, and did a bit of a clearout of the garage. See my for sale thread here http://forums.aussieveedubbers.com/viewtopic.php?tid=93139

Went Down to my old mans place today and scouted out the front quarters on the new shell.

Uploaded with ImageShack.us

Uploaded with ImageShack.us

Uploaded with ImageShack.us

Got that far before my cheap but faithful angle grinder quit.

Drivers side was a little better

Uploaded with ImageShack.us

There was about a CM of Bog in some sections but at least the rust isnt as bad as it could have been.

Nice to drop in and see AncientBugger too. Micks baja is certainly impressive now.

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 14 Oct 2011, 2:05 pm

#866947

Picked up some Rust Bullet this morning

Uploaded with ImageShack.us

And then cut out the old battery tray

Uploaded with ImageShack.us

Lift kit also turned up today

Uploaded with ImageShack.us

Uploaded with ImageShack.us

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

ZoumbaZoumba Learner Dubber

5 posts · joined Oct 2011 · 14 Oct 2011, 5:07 pm

#866967

Really nice!

loco-baja Casual Dubber

27 posts · joined Sep 2011 · 15 Oct 2011, 2:06 pm

#867098

looking good

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 15 Oct 2011, 2:59 pm

#867107

Thanks guys.

Lift kit is going to need a fair bit of work.

Taiwan Empi made🙅

I will have to try to bolt it down to the pan bending/shaping as I go. then tack weld the peices together. Once it is joined where it will be when the body bolts on I can fill the hideous gaps and weld the seams etc.

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 16 Oct 2011, 3:12 pm

#867247

Got the lift kit bolted directly to the pan today. Had to widen 2 bolt holes in the rear piece. pulled about 2 inches of bend out of the side pieces.

Rear passenger side gap

Uploaded with ImageShack.us

Rear drivers side gap, This is probobly the worst

Uploaded with ImageShack.us

Passenger side front

Uploaded with ImageShack.us

Drivers side front. This join is the best

Uploaded with ImageShack.us

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 18 Oct 2011, 7:30 pm

#867591

Haven't made any huge breakthroughs the last few days.

Bought a little C02 Cylinder for the Mig.
Had a bit of a practise
Tacked the lift kit together and removed it from the floorpan
Scrapped the battery tray repair I had as I had not removed enough of the rusted metal and was blowing through. Have now cut a bigger section and am having success with plug welding the new peice down (I have overlapped it about 1cm on each side) I will then be welding mounts for the battery box to this new larger section.
Picked up a bit of scrap 1mm sheet from a metal place around the corner to use for finishing the lift kit.

Back to work tomorrow 🙁

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 19 Oct 2011, 3:47 pm

#867714

I Have booked in 2 weeks Holidays from work starting on the 21st of November.

Hoping to have the floorpan painted and lift kit finished and ready by then so I can spend 2 weeks on the body.

I Might be ambitious but I would like to see the bare body back on the pan by the time I go back to work on the 5th of December.

Aiming now to be finished by Dubs by the Pie 2012

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 21 Oct 2011, 1:49 pm

#867980

Well my welds are not the prettiest but they are solid.

Battery tray is in. Needs a bit more cleaning up but it feels good to have successfully welded something 🙂

Uploaded with ImageShack.us

Uploaded with ImageShack.us

I will use peices of angle iron to box in the battery box and weld a couple of loops for a strap to keep the battery snug.

Nicko

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 23 Oct 2011, 8:11 pm

#868330

Ordered a nice new dual tube front bumper today. It will see some modification but will be a much nicer starting point than what I currently have.

Also ordered some covers for my spotties and a k&n pre cleaner sock for my pod filter.

Scrubbed the frame horns. With some degreaser. You can actually make out the frame horns now.

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 24 Oct 2011, 6:58 pm

#868454

Progress....

A good mate dropped by and came for the drive down to dads.

Lewises low light bay window

Uploaded with ImageShack.us

Ripped the wiring out of the donor car
[IMG]https://img842.imageshack.us/img842/8657/007oib.jpg[/IMG]

Uploaded with ImageShack.us

Also removed Steering column, switches, front brake hose, all body bolts.

Body is now ready to come off the pan. which means the rolling pan is for sale if anyone is interested.

[IMG]https://img59.imageshack.us/img59/9835/009uf.jpg[/IMG]

Uploaded with ImageShack.us

Also grabbed this peice of angle iron while I was down there.

Uploaded with ImageShack.us

[IMG]https://img542.imageshack.us/img542/8297/014kl.jpg[/IMG]

Uploaded with ImageShack.us

Uploaded with ImageShack.us

Uploaded with ImageShack.us

Just need to find something to use as a good strap mount to weld front and rear of the box for a safety strap.

Still needs a good tidy up.

PS: I blantantly plagiarised this from Smiley. Hope you dont mind mate. It was just such a good idea.

Nicko

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 24 Oct 2011, 9:49 pm

#868485

Just ordered a 75Amp Alternator, Stand, Clamp, some under the pushrods tinware peices, blue leads, blue dissy cap, blue lead seperators, Degree Pulley, Tinware set screws and Alt pulley. From Classicveedub

Going with a Blue theme on the engine. Will be ordering some blue billet Pieces from airkewled in the USA when funds permit.

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 28 Oct 2011, 4:19 pm

#869143

Well a package from CVD came yesterday. It seems i have received a Chrome Alt instead of the Raw one I ordered. Also was charged for the crank pulley I ordered but It was not in the box....

Uploaded with ImageShack.us

Trying to get in contact with George to sort it out.

I started work on the lift kit

Cut the edges and bent down the rear pieces to meet the sides.

Uploaded with ImageShack.us

Then i trimmed the corners off and welded the whole thing together.

[IMG]https://img715.imageshack.us/img715/6305/004uxl.jpg[/IMG]

Uploaded with ImageShack.us

Please excuse my poor looking welds. 🤪

I got the rear pieces done and seam welded the joins where the side pieces bend before I ran out of CO2. So I shall continue tomorrow.

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 29 Oct 2011, 5:31 pm

#869276

Got a new CO2 Cylinder today and did some more welding on the lift kit. only have the topside of the front passenger join to do now. I Also spent about 2 hours grinding down the welds to smooth.

[IMG]https://img407.imageshack.us/img407/5079/001ncn.jpg[/IMG]

Uploaded with ImageShack.us

Also picked up a new Battery box strap and made up the mounts on the new battery tray.

Uploaded with ImageShack.us

Uploaded with ImageShack.us

The strap is rated for 300kgs so It should stay nice and snug.

Not too much longer and I will be able to paint the pan halves and tunnel.

Nicko

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 31 Oct 2011, 12:15 pm

#869630

lift kit is all welded and at the powder coaters.

Taking my seats down to Mick (1916baja) in brissy tomorrow for the upholstery.

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 3 Nov 2011, 10:10 pm

#870230

My welding is improving a bit

Uploaded with ImageShack.us

New bullbar

Uploaded with ImageShack.us

New light buckets for the nosecone

Uploaded with ImageShack.us

Bull isnt quite wide enough

Uploaded with ImageShack.us

Stripped the ancillaries off the engine

Uploaded with ImageShack.us

So much gunk on the engine!

Uploaded with ImageShack.us

Assorted Tinware, New 36hp shroud to go on.

Uploaded with ImageShack.us

Pre filter sock arrived today for the Pod

Uploaded with ImageShack.us

Thinking about cutting the mufflers off these and getting a 4 into 2 into 1 system made up.
[IMG]https://img842.imageshack.us/img842/1682/039xf.jpg[/IMG]

Uploaded with ImageShack.us

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 10 Nov 2011, 9:31 pm

#871491

Lift kit is back from the powder coaters

[IMG]https://img850.imageshack.us/img850/103/002pz.jpg[/IMG]

Uploaded with ImageShack.us

Uploaded with ImageShack.us

This also turned up express post from george (he forgot it in my last order) looks like he doesnt have any raw Alternators so I will have to settle for the chrome one.

Uploaded with ImageShack.us

I have started cleaning up the ttinware. Need to get a furniture trolley or something to move the engine outside to start cleaning it up. Also need to find a puller to remove the Crank pulley to fit the degree pulley.

Was hoping to have the pan halves painted by now but ended up having to make a couple of trips to brisbane on my days off chasing an injector for the 944 after number 3 started leaking. The guys at T + D say they have never seen one leak from the base before.

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 12 Nov 2011, 7:00 pm

#871796

New body off the pan today.

Uploaded with ImageShack.us

Ripped out the old head lining.

I will only be running a lining on the ceiling so the claws that hold the lining around the doors etc will be removed.

Uploaded with ImageShack.us

Uploaded with ImageShack.us

Pan before it was taken away by it's new owner.

Uploaded with ImageShack.us

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

AndrewB Seriously Crusin Dubber

141 posts · joined Jun 2011 · 12 Nov 2011, 9:57 pm

#871823

Have fun removing all the lining clips hehe, i just shaved all mine recently,
Bought two different spotweld drill bits... ended up removing all the clips with a cold chisel with a fairly extreme grind, got all the rows of clips off in one piece though lol
great fun! 😁

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 24 Nov 2011, 4:44 pm

#873992

Big shout out for Mick (1916Baja) for the great job he did on my seats.

[IMG]https://img15.imageshack.us/img15/340/002drtt.jpg[/IMG]

Uploaded with ImageShack.us

Went down to dads place today to do some stripping.

Got the front drivers side quarter done before the rain set in.

Uploaded with ImageShack.us

Thats Honey Brown the helper hound checking that the primer is dry.

Managed to get this tarp up in the Nick of time.

[IMG]https://img849.imageshack.us/img849/4838/015xs.jpg[/IMG]

Uploaded with ImageShack.us

I will be walling it in for use when welding at spraying.

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Smiley Veteran Volks Folk

2,125 posts · joined Oct 2008 · 24 Nov 2011, 10:17 pm

#874075

Those seats look amazing!!!

I assume that the car is going to be red in colour?

Smiley 🙂

If you said I was a Volkswagen man, you'd be right.

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 26 Nov 2011, 9:46 pm

#874392

Yeah I am stoked with how they turned out.

Car will be guards red with black fenders. Black bar work and white wheels.

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 28 Nov 2011, 6:47 pm

#874689

First coat of Rust Bullet on the pan halves.

Uploaded with ImageShack.us

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

Anthiron The Baja Rejuvenation Begins

4,936 posts · joined Oct 2003 · 29 Nov 2011, 7:01 pm

#874876

Started on the roofrack today.

the starting point.

Uploaded with ImageShack.us

The top hoop from an old bullbar to use as the light bar hoop.

[IMG]https://img819.imageshack.us/img819/9625/003jug.jpg[/IMG]

Uploaded with ImageShack.us

some peices of flat bar to use for the light mounts and the supports for the spare wheel. The half inch threaded bar is for the spare wheel mounts and the 5/8" threaded bar is for the shovel mounts on the side.

[IMG]https://img824.imageshack.us/img824/8899/005akd.jpg[/IMG]

Uploaded with ImageShack.us

Light bar tacked in place

Uploaded with ImageShack.us

Got the hoop tacked on one side before I ran out of gas,

Uploaded with ImageShack.us

62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom

nils Fahrvergnugen

971 posts · joined Jan 2008 · 29 Nov 2011, 7:29 pm

#874886

It's great to see this thing getting some love.
Saw it for many years cruise past my place in mooloolaba. Baja's may change appearance over the years but always live on.

In regards to the steering tube/body relocation for the lift kit. Leave it where it is and use 2 uni's down to the steering box, by moving the box position on the beam even a little your bump steer will be terrible. I made this mistake many years ago, and it took bajawes to set me straight on steering geometry.
Good luck with your build and look forward to the end result,

Quit calling rust patina