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 555bug
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WRX Bug Boy
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| posted on June 2nd, 2008 at 10:38 PM |
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i have some picture somewhere of a car thats had about 20cm added through the middle. Massive job stay clear 
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westi
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what the
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| posted on June 2nd, 2008 at 11:43 PM |
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seeing what horrible people are up to with there evil ways.
maybe praying for us to be saved.
i got no idea.
down sharon.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on June 3rd, 2008 at 06:52 AM |
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| Quote: | Originally
posted by 555bug
a car thats had about 20cm added through the middle.
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That is what the genius' did at VW with the super bug...well, at the front.
| Quote: | Originally
posted by westi
That's mad Alan.
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on June 3rd, 2008 at 07:20 PM |
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Well with westi's words ringing in my ears... or perhaps that just the side effect of all the grinding ive been doing... I started to chop away at
parts of the body to make everything fit nice and snug.
Im pretty happy with how everything lined up too. It looks like only the left side of the floor pan up the front got a little heat distorted from the
welding. The gap torwards the front is only a few mm so it will probably tighten up once ther eis a rubber seal in there.
Ive also begun mocking up a new stronger section to join the left and right side of the body again over the gearbox nose cone. It will be entirely
metal for strength. The bolt in panels will alloy plate.
Pics...
A little raised gearbox clearencing.
Looks like I got the placement of the steering just right. Linking the steering with a pair of universals is going to be very easy from the looks of
it.
Thats all for now... should have another update tomorrow hopefully.
Cheers,
Ian
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JVLRacing
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| posted on June 3rd, 2008 at 07:30 PM |
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scary man you are!looks good Ian
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LIFE IN THE LOW LANE
A.k.a.: Brennden Alder
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| posted on June 3rd, 2008 at 09:09 PM |
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Loving it mate. Work of art!!
[size=4] ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE[/size]
Alder Outlaws VW Racing - check it out on fb!!
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Mick058
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| posted on June 3rd, 2008 at 09:17 PM |
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You and Westi are blowing me away. Looks the goods.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on June 4th, 2008 at 06:37 AM |
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Hi Ian, nice progress.
I had forgotten how big that tranny was, man it is a monster.
When you go for "a pair of universals",
you will need a small bearing at the lower end of the column tube.
| Quote: | Originally
posted by westi
That's mad Alan.
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ricola
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| posted on June 4th, 2008 at 08:44 PM |
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| Quote: | Originally
posted by dangerous
When you go for "a pair of universals",
you will need a small bearing at the lower end of the column tube.
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Or maybe use a column from a super?
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on June 4th, 2008 at 08:58 PM |
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Thats all easy stuff! I'll just buy a small bearing and machine up some sort of sleve to hold it snug at the end of the steering column. Whats
proving to be a pain in the ass though is getting a universal with the correct size spline for the 924 steering rack.
Well today i made a little more progress. I now have a frame work of sorts 3/4 welded into place for the firewall and reenforcing the body to make up
for all the metal I cut out of it yesterday. Ive used 20x20x3 angle and 13x3 flat bar to make up the framework. I'll be spot welding 1mm steel plate
to the framework to seal it all in.
I am considering running some steel wiring tubes to the engine bay as well. The plan is to make the car easy to work on, so easy accesibility to all
mechanical parts and wiring access is essental. Any improvement I can make will be a welcome one.
It took 3 hrs to remove the induction system from the previous engine setup to allow spark plug access. I want to be able to get access to any part on
the engine or anywhere else on the driveline in just a few minutes with this version of the car.
Last of all... no pics today. I'll be sure to take some tomorrow when the framework is finished.
Cheers,
Ian
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Dasdubber
A.k.a.: Alan Agyik
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| posted on June 4th, 2008 at 10:16 PM |
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| Quote: | Originally
posted by 2443TT
I'll be spot welding 1mm steel plate to the framework to seal it all in.
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hey Ian - looking good mate!
Although I'm sure it will be revealed in time, but how are you arranging your access "hatch" in the steel plate - DZUS fastened/screwed/bolted
etc?
Cheers
Al
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2443TT
A.k.a.: Ian
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| posted on June 5th, 2008 at 08:08 PM |
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Hi ya all,
Well today was a day of non stop interruptions from indecicive customers, so I didnt get a lot done. But I did come close to finishing my new
firewall. Its made out of 3mm flat bar and 3mm angle. The long horizontal brace has one angle bar welded at an angle inside another piece of angle
bar, to increase its rigidity and to provide the correct angles for the sections of the firewall that will bolt into place. Does that make sense?..
Everything from the horizontal bar forwards will have 1-1.5mm plate spot welded to it, and then be sealed from the back and re-painted.
I'll be using screws to hold the plate in place. You may be able to see the rear sections of the firewall supports are screwed in place (in the pics
above, not these two below). They have thread inserts crimped into them. All that remains is making up the pieces that link the steel section to the
alloy sections. The firewall will be one large piece with a fold across the middle.
So tomorrow is going to be finishing the firewall, and contemplating how to make a removable rear end.
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reub
Veteran Volks Folk
VWRX is gone...
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| posted on June 5th, 2008 at 08:25 PM |
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Cool dude
Reub
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VWCOOL
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| posted on June 6th, 2008 at 08:25 AM |
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G'day Marko!
Pay your debts, CxxT
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on June 6th, 2008 at 09:13 AM |
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Hi Marko,
Welcome to the forum, but by all means start your own threads. This thread is for the rebuild of my car..
Regards,
Ian
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2443TT
A.k.a.: Ian
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| posted on June 10th, 2008 at 07:19 PM |
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Hi all,
I didnt get much acomplished on the weekend, decided to take it easy for the most part instead, although I did cut the entire rear end off the car. 2
days of planning to do 5 minutes of cutting. Its all turned out very well and has allowed me to finalise the plan for my twin turbo manifold, and
intercooler placement.
Today I finished the firewall as well, except for the attachment of the sheet metal which will happen some time this week.
Next on the list is creating the new sealing air level to stop the cooling system recirculating hot air, and also to duct air from the intercoolers
into the engine bay. I am about to have to learn a little more about sheet metal work that I can remember from grade 10 metalwork. Should be an
interesting challange.
Last of all... here are the latest progress pics of my Rocky Jennings engine case. Trial assembly of the bottom end with an 88mm flanged crank and
custom bearings is done. Im told that all that remains is completion of the oil pickup... then one week later it will be in my workshop and engine
assembly can begin! Woo hoo! Not long till I need an engine to mock up the header on, so timing is perfect.
Cheers,
Ian
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MickH
A.k.a.: Michael Hutchinson
Bishop of Volkswagenism
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| posted on June 10th, 2008 at 08:04 PM |
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Yummm.....
tssnq.com.au
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on June 14th, 2008 at 07:11 PM |
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Hi all,
Today I finished the two rear body to chassis mounts off, and half completed the rear-apron re-attachment. Ive used some old urathane swaybar mounts,
some 3mm plate and a few bolts to attach the body to the rear suspension bracing.
The whole rear end of the car gets pretty flexable when you start cutting away at the rear wheel arches, so ive welded in some steel tube to the apron
and the wheel arch to make the whole lot rigid again. It also will server as the lower mount to supporting the rear apron. I will just be bolting it
on with some 10mm threaded rod that gets inserted through the length of the tube. I'll do the top part of the apron mount tomorrow.
I also ordered my aero guard kit from vintage vee dub this week. Thursday is the hopeful arrive date, so I might be trial fitting guards come the
weekend. They will need another 50-60mm added to them as well to clear the 8's and 10's.
I solved the steering link-up issue too. Tracked down a factory twin universal porsche 944 steering shaft, removed from a wreck in perfect condition.
You wouldnt believe what australian porsche dismantelers want to charge for even a flogged ot one. Found it in the us for $25.
Here's today's pics...
Cheers,
Ian
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555bug
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WRX Bug Boy
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| posted on June 14th, 2008 at 08:24 PM |
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nice work, i should try to get up north again just to see it
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2443TT
A.k.a.: Ian
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| posted on June 15th, 2008 at 06:58 PM |
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Hi all,
Finished the detachable rear apron mounts today. It was very time coming up with a method to positively locate the rear apron so it fit correctly
every time. In the end i came up with the idea of using hinges that would normally allow a door to be lifted off the other hinge so to speak. With the
hinge folded close on itself the holes line up and it allows a bolt to go through to lock it in place.
So thats the jist of it. The rear apron slides onto the two hinge dowels and then has two 6mm bolts go through the hinge holes to hold them together.
Then 10mm threadded rod is slid in the horizontal tubes and bolted at each end. Last of all there is another 6mm bolt with large washers each side
that bolts through the inner wheel well at the point of one of the large square edges. The result is a lot more rigid than i expected.
So with that done i put the rear wheels back on and spent the next 2 hrs cleaning up my workshop. Here's todays progress pics. Doesnt look further
along than yesterday, but at least it feels like im making some progress. It should be a car again sometime in the next 2-4 months all going
well...
That is all...
Ian
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Dasdubber
A.k.a.: Alan Agyik
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| posted on June 15th, 2008 at 07:19 PM |
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Great progress Ian - hats off to you!
What will the plans be for running boards between the extended aero guards?
Al
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on June 15th, 2008 at 07:21 PM |
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I havnt thought that far ahead yet... Though my old running boards are billet alloy I dont think they will look right considerign how much wider the
guards are going to have to be. I guess I'll be dealing with that matter soon enough when ive got some widened guards on the car inside the 2-3
weeks.
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063bug
A.k.a.: Alan
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| posted on June 17th, 2008 at 08:40 AM |
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Thats a good looking project.... very impressive. I am always amazed aty how small the boxer engine is in comparison with the car. I admit I haven't
read the whole thread and I was curious to know what size rims and rubber you ended up with as it looks like a really good proportion for the car....
Thanks and keep up the good work.
| Quote: | Originally
posted by 2443TT
Hi all,
I didnt get much acomplished on the weekend, decided to take it easy for the most part instead, although I did cut the entire rear end off the car. 2
days of planning to do 5 minutes of cutting. Its all turned out very well and has allowed me to finalise the plan for my twin turbo manifold, and
intercooler placement.
Today I finished the firewall as well, except for the attachment of the sheet metal which will happen some time this week.
Next on the list is creating the new sealing air level to stop the cooling system recirculating hot air, and also to duct air from the intercoolers
into the engine bay. I am about to have to learn a little more about sheet metal work that I can remember from grade 10 metalwork. Should be an
interesting challange.
Last of all... here are the latest progress pics of my Rocky Jennings engine case. Trial assembly of the bottom end with an 88mm flanged crank and
custom bearings is done. Im told that all that remains is completion of the oil pickup... then one week later it will be in my workshop and engine
assembly can begin! Woo hoo! Not long till I need an engine to mock up the header on, so timing is perfect.
Cheers,
Ian
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on June 21st, 2008 at 08:46 PM |
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Hi all,
Time for an update.
On the engine front i got an email from Rocky Jennings saying my engine case is ready to be shipped. With any luck it will be here in 2-3 weeks.
My guards arrived from Vintage Vee Dub last week. After trial fitting them ive started about cutting them up to, to widen them another 90mm to clear
the wheels.
So here they are, one 1/2 done and the other held together with cable ties for the moment. Ive used pieces of my old carbon fibre firewall cut into
rectangles and a whole lot of cable ties to hold the base shape before it all gets glassed into place. The carbon parts will then be ground out of the
inside of the guard from beind with a flapper disc on an angle grinder.
This is something i learned a few years ago when making my first porsche fan shround. Fiberglass resin does not stick to plastic packaging tape.
With the cable ties holding everything in place I then used tape to fill in the gaps and seal it all up.
And from the other side here it is with two layers of glass matting in it. Its not meant to be structual, its just to hold the shape. The structual
part will be built up from the other side and then the inside will be grinded back so it is all the same thickness. I dont want to make them too
heavy.
When the resin is hard i peel off the tape and then build up the other side. I hope to finish them off tomorrow. Thats is all for now.
Ian
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reub
Veteran Volks Folk
VWRX is gone...
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| posted on June 21st, 2008 at 08:55 PM |
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Gonna be a fat bug dude...
I like it - and so does Rach 
Reub
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mactaylor
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| posted on June 22nd, 2008 at 08:49 AM |
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you could have a picnic on those guards!!! good old cable ties gotta love them
EVERLAST CONCRETE TANKS
1800 552 123
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trickysimon
A.k.a.: Simon Azzopardi
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| posted on June 22nd, 2008 at 09:29 AM |
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Forget regular fat chicks. THIS is a fat chick.
Simon
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pete wood
A.k.a.: figure itout
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| posted on June 24th, 2008 at 03:21 PM |
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Ian, great work. your rear framing looks very similar to what I'm up to at the mo. I know what you mean about the lack of support to the rear when
you get rid of bodywork. I busted both gusset going from the torsion tube to the pan last year when I got mine slightly airbourne. The fix is a plate
and bar system that ties everything together, shock mounts, frame horns, cage, etc. All triangulated of course. I'm very jealous of your strut front
end. Wish I'd done that myself in the beginning...stinkin king and link pins! 
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Brad
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| posted on June 24th, 2008 at 04:29 PM |
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mmmm
| Quote: | Originally
posted by 2443TT
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mm very interesting, while I must say I take my hate off to you for doing this those guards just look wrong. Not that I can think of a better way to
do it, surely there must be a better option than screwing the proportions up so much
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on June 24th, 2008 at 07:55 PM |
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Hi everyone,
Pete i'd be interested in seeing what you did with your additional reenforcing, if you could take a pic or two and post it up i'd appreciate it.
Ive got to add a little more steel to the pan to provide some better roll cage supports before the body comes off, but the goal in my case is to cage
the chassis and keep it as rigid as possible. I dont want to go cracking the body when it starts to twist under the torque from the engine.
Brad, thanks for the honesty. I dont think there is any other way of doing what im doing though. Because the car is so much wider than normal there
is no way it can ever look normal.
But thats not the look im going for this time. Insane over the top is the goal here. The front is stitting 50mm too high at the moment too. The
front springs are 6kg/mm and they need to be 1.5-1.75kg/mm. Even filling the luggage compartment with spare steel wheels an crap i couldnt get it any
lower than about 2.5cm. The back has to go down about 2cm as well. The idea is to hide about 1-1.5cm of the tyre inside the guard. Ride height will
be about 120mm at steet height, and on its guts it will be about 80mm.
Here are the latest pics. Both front guards are widened now and still need propper re-enforcing but the basic shape is right and they measure the
same. I started the rears today as well. Slow progress as i also had visitors chatting to me all afternoon but I still got some work done.
Thats all for now.
Ian
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