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 11CAB
Compulsive Aussie Vee Dubber
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| posted on April 30th, 2010 at 06:30 AM |
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I have a similar problem with my baja pan. Its a super pan with a balljoint framehead. I got a lift kit buiilt on an early pan, and the bolt holes
dont line up.
65 Meyers Manx
68 Country Buggy (KO 367)
68 Country Buggy (KO 669)
68 Country Buggy (KO 789)
68 Country Buggy (KO 815)
68 Baja Bug
76 Baja Kombi Twincab
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Smiley
A.k.a.: Daniel Stephens
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| posted on April 30th, 2010 at 09:23 AM |
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| Quote: | Originally
posted by 11CAB I have a similar problem with my baja pan. Its a super pan with a balljoint framehead. I got a lift kit buiilt on an early pan,
and the bolt holes dont line up.
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What did you do to fix the problem?
Smiley 
If you said I was a Volkswagen man, you'd be right.
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Smiley
A.k.a.: Daniel Stephens
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| posted on April 30th, 2010 at 10:15 PM |
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Ok. So I got stuck in first thing in the morning to sort out all the body to pan issues.
I got dad to help me lift the body onto the pan before he left for work this morning. I jacked up the car and put in on some stands so it was easier
to work under. I put some bolts into the rear mounts to line things up where they should be. Then I crawled under and marked where area metal needed
to be ground and on which side of the hole etc. Then I jacked it up and put some long sockets under all four corners. Used the die grinder from
underneath to get all the holes lining up to where they should be. Most of them just needed a little tickle.
Once this was sorted I gave everything another clean down and ran a bead of sealer around the outside edge of the pan. On went the body to pan seal
and another bead around the top.
Then I dropped the car down into place. I put the four large bolts on the underside of the front in first cause i knew they would be a big hassle
later on.
It was a slow and painful process but I eventually got all the of the bolts in and everything done down snug.
And that is how you put a body on all by yourself.
So after I got back from getting my eye checked out this afternoon I got stuck into putting the mudguards on.
I only got three of them on before I decided to call it a night.
First put the drivers side front on. Looks great with the new black beading. I'm still tossing up where to put the front blinkers at this stage, on
the guards or on the front bar somewhere. You'll notice I had the holes filled just in case.
Rear guards went on next. Before I put them on I also bolts the rear cage supports on. once I had the rear guards on I bolted the supports in that I
made up. They do a fantastic job of stiffening up the rear guards.
I've said it once I've said it a dozen times. Definitely need to get the big wheels out and put them back on. Especially to fill out those massive
rear guards.
I don't think I could be happier with today's progress, things are finally starting to come together.
Plans for tomorrow include, front seats in, paint fuel tank ready to go in. finish the brakes off and bleed, last guard on, start putting the doors
together and get them on, start putting things into the dash, etc.
Plenty to do!!
Smiley 
If you said I was a Volkswagen man, you'd be right.
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11CAB
Compulsive Aussie Vee Dubber
If ya got it....Baja it
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| posted on May 1st, 2010 at 07:02 AM |
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| Quote: | Originally
posted by smileyman3000
| Quote: | Originally
posted by 11CAB I have a similar problem with my baja pan. Its a super pan with a balljoint framehead. I got a lift kit buiilt on an early pan,
and the bolt holes dont line up.
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What did you do to fix the problem?
Smiley
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Nothing yet...... I dont have the same enthusiasm as you..... 
65 Meyers Manx
68 Country Buggy (KO 367)
68 Country Buggy (KO 669)
68 Country Buggy (KO 789)
68 Country Buggy (KO 815)
68 Baja Bug
76 Baja Kombi Twincab
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 1st, 2010 at 04:52 PM |
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| Quote: | Originally
posted by 11CAB
| Quote: | Originally
posted by smileyman3000
| Quote: | Originally
posted by 11CAB I have a similar problem with my baja pan. Its a super pan with a balljoint framehead. I got a lift kit buiilt on an early pan,
and the bolt holes dont line up.
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What did you do to fix the problem?
Smiley
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Nothing yet...... I dont have the same enthusiasm as you.....
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Get into it!!!
First thing this morning the remaining guard was put on.
Then I spent ages screwing around putting the rear coils and second pair of shocks on. I needed about 3 hands and fingers like toothpicks to get the
nuts on the inside of the coils. Eventually they were mounted. Might need a wash though 
Then I spent the afternoon cleaning the inside and sealing my fuel tank up. I bought a POR15 fuel tank restoration kit. There's a few chemicals you
slosh inside the tank first to remove any varnish etc. Then one that removes any rust. After that you flush everything out with water and completely
dry the inside.
The instructions said that it was imperative that the inside was not wet in any way. So I went down to Big W and got a $15 hair dryer. Pushed it into
the filled tube with the other holes unplugged and left it run for about half an hour 
Then you just pour the paint inside and slosh it around an pour any excess out. Seemed to coat everything really well. A now have a fuel tank with a
silver lining 
Smiley
If you said I was a Volkswagen man, you'd be right.
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beetleboyjeff
A.k.a.: Jeff Walsh
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| posted on May 1st, 2010 at 05:27 PM |
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You should have got a cloud - EVERY cloud has a silver lining. lol
From your ole' mate Jeff
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 3rd, 2010 at 10:36 PM |
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I got a fair bit done over the last two days.
Not many pictures to show for it though.
I pulled all the drums off, replaced the rear axle seals, gave the insides of the drums a buff, cleaned and adjusted all the brakes. Dad gave me a
hand to bleed all the brakes. No leaks so far! (fingers crossed)
I bought some superbug handbrake cables last week. These are the longest for a type one. With a few mods to the springs they fit very well. Although
the adjuster nuts are screwed all the way down and I still think it might be a little loose. I might have to space it out with a nut or two until I
make the turning brakes up and fit them.
I fitted the handbrake cable. I decided to try the long one and was amazed that it fit....just. I'm going to see how it goes, may have to take an
inch off the end of it.
Yesterday afternoon/evening was spent getting the engine running. Hooked up the old battery but alas it was flat. Even though it had been charging for
a few days. I picked a new one up this morning. Put the engine back in again. Wired it up. Ran jumper leads from my Beetle. Hooked up some fuel. I put
a length of wire onto the spade terminal of the starter and left the other end bare so I could press it onto the main terminal of the alternator.
Turned it over, nothing.
Checked for spark. Was getting spark. Little weak but definitely there.
Checked for fuel. No fuel. Bloody wasp's nest in the metal line. Cleaned that out.
Turned it over. Still nothing.
Still not getting fuel to the carby.
I undid the top fuel hose right where it goes into the carby. Sucked to fuel up the lines to prime the pump.
Yucky horrible tasting stuff.
Turned it over again. A splutter but still nothing.
I put my hand over the top of the carby and turned it over. More splutters, it's trying to start but no getting fuel. The pump was doing its bit.
Went and 'borrowed' a fuel pump off my dad's old Baja, it's not registered anymore anyway.
Put the replacement pump on and tried it again.
Splutter.
Cough.
SHE LIVES!!!!!!!!
Gave it a few revs and she settled straight into a rough idle!!
Not bad considering it hasn't been so much as sneezed at for 6 months, two weeks and 6 days.
I shut her down and promptly went to bed.
The engine is going to have to come back out again. I need to put need exhaust studs and gaskets on both of the J-tubes, weld up some cracks in the
exhaust, fix the fanhousing coil mounts, give it a degrease. New plugs and leads to go on too.
I put the new battery in this morning. New leads and rubber grommets.
Strapped it all down good and proper. The strap loops that I put of the floor work perfectly. The battery is rock solid.
Fiddled around for a bit of the day doing odds and ends. Finds bolts and hunting for parts.
I put the new steering dampener and donut in place. Ready for the steering shaft/column to be fitted. I just need to paint them first.
I spent the rest of the afternoon picking out the best windows I have and giving them a good clean ready to go in tomorrow after work.
Then this evening I made a grand addition to the car.
SEATS!!!!!!!!!!
Look everyone!! Seats!!!1!!!
I know, they are a little grubby and need a good clean.
It feels good to finally be able to sit in it!
And i have to say that the seat height and placement is fantastic. I can't be absolutely certain until the steering wheel is in, but so far I like
it. I raised the seats just over an inch compared to my old Baja. When I sit in them my eyeline is absolutely smack bang in the middle of the
windscreen, top to bottom of course. I'm stoked. there's a good amount of room for the handbrake, the gear stick is easy to reach, the pedals feel
good. Just have to wait and see how much clearance I have with the doors on and get the steering wheel in.
Tomorrow afternoon I'm going to pick up my rims from the powdercoaters and get them over to have the tread put back on them. Also going to pick up
some alloy sheet, my exhaust bits and pieces and a few other bits and bobs.
Until then, thanks for reading.
Smiley
If you said I was a Volkswagen man, you'd be right.
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handycam
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| posted on May 4th, 2010 at 06:23 AM |
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looking grate "
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11CAB
Compulsive Aussie Vee Dubber
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| posted on May 4th, 2010 at 06:53 AM |
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Looking Good.
I cut my handbrake lever down when I moved the gearshift back on my manx. Wasnt too hard
Here's an early one sitting next to my cut down one
And the clearance to the gearshift
65 Meyers Manx
68 Country Buggy (KO 367)
68 Country Buggy (KO 669)
68 Country Buggy (KO 789)
68 Country Buggy (KO 815)
68 Baja Bug
76 Baja Kombi Twincab
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 4th, 2010 at 10:37 AM |
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That looks good.
Did you have to cut the spring down? Or just squash it more?
Smiley
If you said I was a Volkswagen man, you'd be right.
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Scarab
Wolfsburg Wizard
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| posted on May 4th, 2010 at 11:58 AM |
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Man, I think you really ought to give shortening that handbrake lever a go!
I had one like that in an old MK1 Cortina (sorry, blasphemy on a VW site I know )...but anyway. I put a GT remote shifter in it and the handbrake was as close as yours....
first time i used it, I smashed my knuckles  NOT COOL!! at
least the VW has a nice soft boot for your knuckles to hit against each time, mine had a big bulky steel surround!! OUCH!!
Everything is looking great though mate....keep it up!!
Paul
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11CAB
Compulsive Aussie Vee Dubber
If ya got it....Baja it
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| posted on May 4th, 2010 at 05:46 PM |
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| Quote: | Originally
posted by smileyman3000
That looks good. Did you have to cut the spring down? Or just squash it more? Smiley
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It was quite a while ago that I did that, but yeah I probably did cut the spring down a bit. I also cut and rewelded the rod inside the lever as well.
65 Meyers Manx
68 Country Buggy (KO 367)
68 Country Buggy (KO 669)
68 Country Buggy (KO 789)
68 Country Buggy (KO 815)
68 Baja Bug
76 Baja Kombi Twincab
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11CAB
Compulsive Aussie Vee Dubber
If ya got it....Baja it
Posts: 4674
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Registered: August 30th, 2002
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Location: Brisbane Northside
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| posted on May 4th, 2010 at 06:05 PM |
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I look forward to seeing this Blue Beast on our Mt Mee run at the end of the month
65 Meyers Manx
68 Country Buggy (KO 367)
68 Country Buggy (KO 669)
68 Country Buggy (KO 789)
68 Country Buggy (KO 815)
68 Baja Bug
76 Baja Kombi Twincab
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 4th, 2010 at 10:09 PM |
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| Quote: | Originally
posted by 11CAB
| Quote: | Originally
posted by smileyman3000
That looks good. Did you have to cut the spring down? Or just squash it more? Smiley
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It was quite a while ago that I did that, but yeah I probably did cut the spring down a bit. I also cut and rewelded the rod inside the lever as well.
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Yeah. I'll do something similar. I've already tapped the thread further down the rod so all I have to do is cut the end off.
I have to take the lever out to paint it so I'll sort it out then.
| Quote: | Originally
posted by 11CAB
I look forward to seeing this Blue Beast on our Mt Mee run at the end of the month
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That's if my new wiring harness shows up soon!!
I picked up my wheels from the powdercoaters this afternoon.
Pretty!
I took them straight over to have the wheels popped back onto them. Hopefully we be done by tomorrow.
And all the glass was put in. Actually starting to look a bit like a car now!
Smiley
If you said I was a Volkswagen man, you'd be right.
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Scarab
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| posted on May 4th, 2010 at 11:33 PM |
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those wheels look VERY nice mate!! certainly more appropriate than the stockies you've got on there now!!
Keep going mate....the end is near!
Paul
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bajachris88
A.k.a.: Chris Leete
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| posted on May 4th, 2010 at 11:54 PM |
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oh man...!
this thread is like a lady doing a show in a dirty bar....
as she continues on, things just get better and better. This baja is gonna be glamour. before u know it, u will be cruising in a 2010 model baja.
still heaps of motivation dude. payday is this fri... hoping to get interior finished. then exterior... 5 weeks left till holidays..
(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! |
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 5th, 2010 at 08:17 AM |
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| Quote: | Originally
posted by bajachris88 oh man...! this thread is like a lady doing a show in a dirty bar.... as she continues on, things just get better and
better.
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Don't you wish she would just get it all off?
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 6th, 2010 at 01:50 PM |
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I cut the handbrake down one inch.
Makes for a much better fit.
Gave it and the steering overtube and clean up and some paint.
Also gave the outside of the fuel tank a brush off and gave it some POR15 loving.
Carby has been pulled off the engine. A friend is going to rebuild it for me this afternoon while I'm at work.
Smiley
If you said I was a Volkswagen man, you'd be right.
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DubCrazy
A.k.a.: steff
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| posted on May 6th, 2010 at 09:05 PM |
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And there was you telling me you would be drivng it by tomorrow! i think you mite just have been slacking off young man!!!!!
i'll run away now before u throw something very heavy at me
steff.............
Life with out a v-dub is no life at all!!!!!
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 7th, 2010 at 01:06 AM |
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| Quote: | Originally
posted by DubCrazy
And there was you telling me you would be drivng it by tomorrow! i think you mite just have been slacking off young man!!!!!
i'll run away now before u throw something very heavy at me
steff.............
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Still waiting for my harness to show up. It better be here today!!!
BTW. I just got home from work and there was a lovely stack of wheels with tyres on them sitting in the carport
They'll be going on first thing when I get up in the morning.
Smiley
If you said I was a Volkswagen man, you'd be right.
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 7th, 2010 at 10:18 AM |
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Sweet sweet tyres!
These are before and after pictures. I put black tyre gel on them.
Rear wheels on. They fill out the guards perfectly! There's maybe an inch maximum of guard hanging out further than the tyre. And this will probably
decrease a little more once the rest of the stuff is on the car and the suspension sits down in place.
Front wheels on. These also fit very nicely. They do stick out front the guards a little touch, but it's only around 10mm max.
Well I'm off to paint the top of the fuel tank.
ENJOY!!!
Smiley
If you said I was a Volkswagen man, you'd be right.
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DubCrazy
A.k.a.: steff
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| posted on May 7th, 2010 at 08:57 PM |
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did the wiring loom turn up yet fella??
steff.........
Life with out a v-dub is no life at all!!!!!
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 7th, 2010 at 09:17 PM |
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| Quote: | Originally
posted by DubCrazy
did the wiring loom turn up yet fella??
steff.........
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They found it and sent it today.
So I won't see it till next week.
I'm going to get as much of everything else done on the car that I can. So then all I have to do is wire it up basically.
Smiley
If you said I was a Volkswagen man, you'd be right.
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DylanTheDubber
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| posted on May 7th, 2010 at 09:22 PM |
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Good on you mate , Alot of work looks like its gone into this bug and coulda been sent to scrap in tha first pllace but you saved it. = ]
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 8th, 2010 at 06:48 PM |
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| Quote: | Originally
posted by DylanTheDubber
Good on you mate , Alot of work looks like its gone into this bug and coulda been sent to scrap in tha first pllace but you saved it. = ]
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Thanks man.
I can't wait for the before and after pictures.
I got my new carby yesterday evening.
A good friend rebuilt me one cause it turns out the old one was a paperweight. Thanks again Andrew!
Although I never had any troubles with it, turns out the old one was a PICT 28, a 1200 carby. On my 1600 engine!! The new one is a PICT 31, 1600
single port carby. So the car will probably have a little more poke too!
Mounted on the engine. Hooked power and fuel to it and she fired right up! Only trouble I have now is that the fuel squirter linkage on the RHS of the
carb is fouling on the alternator housing. I've only got a few mm of travel in the throttle. So I'm going to have to grind the Alternator housing
away a little in the morning.
I did a rough wheel alignment on the front end and tightened all the tie rods up.
Then the steering wheel overtube was fitted with new rubbers, then the steering shaft, switchgear and steering wheel.
Fuel tank was then fitted and bolted down, lovely grey matches the wheels. I'm probably going to pull it back out again though because I want to fit
some rubber between it and the car.
Plans for tomorrow include making the mounting plates for the front bar and rear cage, rear lights on the guards, headlights in, a little more dash
stuff, grind alternator, rear seat in, and make a start on those doors!!
Smiley
If you said I was a Volkswagen man, you'd be right.
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OZ Towdster
A.k.a.: Andrew Westwood
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| posted on May 8th, 2010 at 08:08 PM |
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Arn't you suppose to be in Brisvegas sometime in the next couple of days ????????? IN THIS CAR
Don't let body work get in the way of real suspension travel
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11CAB
Compulsive Aussie Vee Dubber
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| posted on May 8th, 2010 at 09:26 PM |
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He needs to finish it before he leaves so he can bring it to Mt Mee.....
65 Meyers Manx
68 Country Buggy (KO 367)
68 Country Buggy (KO 669)
68 Country Buggy (KO 789)
68 Country Buggy (KO 815)
68 Baja Bug
76 Baja Kombi Twincab
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Smiley
A.k.a.: Daniel Stephens
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| posted on May 10th, 2010 at 10:25 PM |
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| Quote: | Originally
posted by OZ Towdster
Arn't you suppose to be in Brisvegas sometime in the next couple of days ????????? IN THIS CAR
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Not quite. My deadline was yesterday.
I'm coming down to Brisbane on the 23rd. My first day of TAFE is Monday the 24th.
And I'm definitely planning to be at Mt Mee. Even if I have to bum a lift cause my car's not ready.
I spent yesterday putting my doors on and starting to put them together.
Problem is they don't fit.
Passenger closes and fits ok, the gaps are a little out. And there's one spot where you can see daylight through when the door is closed.
But the drivers door won't close at all. The inside of the door hits the striker plate and I scratched the paintjob 
I think the problem is occurring because of the combination of mounts I used at the rear. It's causing the body to hunch forward and throw things
out. I'm going to try loosening all the body to pan mounts and swapping some rubbers around and see if this helps things.
On Sunday I also started my headlight adapters. I bought new headlights and buckets and the holes in the guards are a touch too big for them. So I
picked up some alloy plate to make some adapter rings.
This is the first one I made yesterday.
A lot of grinding and smoothing later, and it fits neatly onto the back on the bucket.
This is a picture of me holding it in place.
This is as far as i got yesterday. I was getting very frustrated and annoyed with everything because of the doors. So I decided to call it a day
before I made any mistakes.
This afternoon I finished both headlight adapter rings and got them all mounted on the car.
This is with all the holes drilled into it.
There are holes to mount the ring to the guard.
Holes to mount the bucket to the ring.
And holes for the adjuster screws to wind though when they go all the way in.
Bolted into place.
And with the bucket.
And lights!!!
Still no harness by the way.
They sent it express on Friday. So if it's not here tomorrow I'll be storming the gates of Australia Post with a flaming torch!!!
Smiley
If you said I was a Volkswagen man, you'd be right.
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Scarab
Wolfsburg Wizard
Posts: 646
Threads: 8
Registered: July 26th, 2009
Member Is Offline
Location: Brahma Lodge,South Australia
Theme: UltimaBB Pro Blue
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| posted on May 11th, 2010 at 05:19 PM |
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looks great mate!...shame about the doors though, but Im sure its not something that you can't solve!
keep plugging away...you are a real powerhouse mate, I dont know how you keep going at this pace.
at least you know you'll be out driving it before too long!
Paul
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OZ Towdster
A.k.a.: Andrew Westwood
Custom Title Time!
Keen to finish some projects
Posts: 1921
Threads: 132
Registered: December 7th, 2003
Member Is Offline
Location: Alexandra Hills Brisbane QLD
Theme: UltimaBB Pro Yellow
Mood: Having fun in our great land
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| posted on May 11th, 2010 at 05:37 PM |
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All i can say mate is don't go getting agro like i would and think it through and if that doesn't work then kick the tyre only !!
Don't let body work get in the way of real suspension travel
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