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 bugboymatt
A.k.a.: Matt
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| posted on October 24th, 2013 at 07:33 AM |
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Looking good mate.
Da Time For The Aircooled Revolution Is Upon US.
Brothers & Sisters Lets Hit The Streets, Roll As One. And Feel The Power Of The Aircooled Storm.
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vduboy
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| posted on October 24th, 2013 at 07:42 AM |
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| Quote: | Originally
posted by bugboymatt
Looking good mate.
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Thanks dude. I am a little excited...
It will all be OK in the end, if it's not OK it's not the end!
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bugboymatt
A.k.a.: Matt
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| posted on October 24th, 2013 at 12:22 PM |
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I bet your excited mate.
It's great watching your progress.
Da Time For The Aircooled Revolution Is Upon US.
Brothers & Sisters Lets Hit The Streets, Roll As One. And Feel The Power Of The Aircooled Storm.
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vduboy
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| posted on November 10th, 2013 at 04:07 PM |
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nate's Manxter Build
Well last weekend I got stuck in with the hole saw and put a few holes in the chassis stiffener...
Same on the other side, you can see the old vw hub cap full of my crush tubes. Cut them roughly then trimmed them to length on the lathe at work.
Welded the tubes in then ground them flat and hosed some paint on until I get my spray room back up.
Also started mocking up the air box set up I will be using, its from BMWs boxer twin motorbikes and even has the same dicky offset for the cylinders.
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on November 14th, 2013 at 06:57 PM |
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Had the engineer over again today to check out my work on the crush tubes and he also had a look at the rear disc kit I purchased seems happy with
that so now I have the go ahead to bolt it all together and get it down to him when its done so we it can get brake tested etc.
I also asked him about tyre and wheel combinations and got some ideas about what he can pass. He is happy with my plans for thing spindles too! hope
to have some piccys for you after the weekend. 
It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on November 17th, 2013 at 07:40 PM |
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Nate's Manxter Build
So woke up at sparrows fart to get stuck in and get a heap done, but was greeted with my road bike sitting in a puddle of fuel..  so after a couple of hours dicking around I finally got some buggy
stuff done. Got all the rear arms assembled with new bearing and my 930 cv kit, painted them the trailing arms the spring plates and the rear seat
bars. It felt so good to actually bolt something back onto the car.
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on November 17th, 2013 at 07:50 PM |
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Nate's Manxter Build
And some parts finally going back on! I set the spring plate angle at standard for now, it'll go up after it's all rego'd!
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It will all be OK in the end, if it's not OK it's not the end!
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nils
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| posted on November 18th, 2013 at 04:50 AM |
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At the risk of being a kill joy, I think you might be pulling those rear arms apart again to notch the springs plates to get the most from your 930
cv's.
great to see you progressing though
Quit calling rust patina
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vduboy
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| posted on November 18th, 2013 at 06:59 AM |
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Not a killjoy at all mate. That was the plan. I just want as little grief as possible when getting it rego'd. I appreciate all advice if I am about
to get something ass about! Cheers.
It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 1st, 2013 at 05:42 PM |
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nate's Manxter Build
Well I got heaps done this weekend.. Started off cleaning out the front calipers, one was seized solid and entirely blocked up inside, had to bolt on
a master cylinder and pump the pistons out one at a time while clamping the other one in. Painted them a nice red to give the chassis a little bit of
colour.
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 1st, 2013 at 05:46 PM |
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Nate's Manxter Build
Also pulled apart the front beam, under the inch thick layer or grease grime and crud it looked quite good, still had the original ball joints which
were absolutely buggered. pulled all the leaves out checked for broken ones re greased and put them back in.. eventually.. VW must have been feeling
very sadistic when they designed that leaf pack.
The tow point was all but sheared off so I helped it on its way to the bin.
Pressed in new ball joints all round fit new bearings to the re machined front discs, put some new shocks on threw some paint at the lot and now have
a complete front end.
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 1st, 2013 at 05:49 PM |
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Nate's Manxter Build
So with the beam complete, with the help of my brother got it back on its own wheels!
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 1st, 2013 at 05:50 PM |
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nate's Manxter Build
I also got my hands on a set of second hand 31's for the rear and couldn't resist throwing one under to see what it would look like. Pretty stoked
on how they fill the guards!
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 1st, 2013 at 05:51 PM |
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Nate's Manxter Build
I then took to the body with the sander to flatten out all the high spots on the underside of the body so the chassis stiffener would sit flat, I was
then reminded how much fiberglass itches. Oh well better get used to it I suppose!
So with little brother still around we were both dying to see the body on the pan..
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 1st, 2013 at 05:52 PM |
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The body/rear seat bracket needs some tweaking to get it back about ten mill so I can get the bolts to line up. But am super happy with its height and
look. 
It will all be OK in the end, if it's not OK it's not the end!
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rickp
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| posted on December 1st, 2013 at 06:42 PM |
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looking great! and get used to the fibre glass, because there is a lot of grinding cutting drilling....oh it never ends.. and it is itchy as hell.
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vduboy
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| posted on December 2nd, 2013 at 10:57 AM |
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| Quote: | Originally
posted by nils
At the risk of being a kill joy, I think you might be pulling those rear arms apart again to notch the springs plates to get the most from your 930
cv's.
great to see you progressing though
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I can't notch them at the moment as the trailing arms are just about touching the lower cage supports, so a bit of notching to the cage might be
necessary..
It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 7th, 2013 at 09:31 PM |
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Well had a crap day on the buggy today.. nothing I tried to put on fit, except for the genuine stuff... gearbox mounts don't fit, unsure if this is
because of poor quality mounts or the wrong ones.. might have to modify the original banana mount. Had to make some spacers for the handbrake cables
as they were out of adjustment out of the box so I pinched the collars of the original handbrake cables so now I have a handbrake! Fit up the rear
calipers after having to machine the brackets to get the discs in the centre, I also made some clamps for the barwork that clamps to the torsion
housing, these are usually welded to the housing but I had already painted the pan.
Fit up the new steering box as the old one was very crunchy.. 
Anybody know whether TRW steering boxes already have oil/grease in them??
Paul from Steelart also supplied me my hydraulic master cylinder and bracket for the clutch.. very nice work! I am going to attempt to move this right
forward into the frame head area with a longer pushrod for easier servicing as my pan doesn't have any access holes and my engineer would have
kittens if I cut a hole in the tunnel. Piccys to come.
It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 7th, 2013 at 10:08 PM |
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nate's Manxter Build
Rear calipers all bolted up, spacers for the handbrake cables and a handbrake that works!
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 15th, 2013 at 07:58 PM |
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Nate's Manxter Build
So had a whole weekend playing with the buggy, made the hard lines for the brakes, cut a bigger hole in the frame head to enable me to fit the clutch
master cylinder in the tunnel, also made a new panel to cover it up and got some quick release bolts (1/4 turn) to make it easy to check the fluid
level.
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 15th, 2013 at 08:01 PM |
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nate's Manxter Build
Also made a bracket up for the slave cylinder with a heim joint to stop it from binding as it goes through its range, Then I greased up my 930 cv's
and fit them up. What a crap job that is!
Then I dummied up the rear barwork to see if the exhaust I want to run will fit, looks like I have enough room!
I can now get the master in/out with the beam on without having to remove the pedal assembly and without a big hole in the tunnel to make my engineer
happy! Stoked!
I also welded a plate to the master cylinder's mounting bolts so I only need to do up one side.
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 15th, 2013 at 08:05 PM |
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Nate's Manxter Build
The clutch master sitting in the tunnel connected to the pedal, I mounted the tab in the middle to make it easy to get the mounting holes on a flat
bit of the frame head. But I then had to slot the hole slightly so I could get the pedal in the tunnel, minor over sight
I used the tool I made for straightening brake line to make RC rock crawler cages for funnily enough straightening brake lines..
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It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 15th, 2013 at 08:06 PM |
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nate's Manxter Build
Bracket for the slave cylinder, made out of 8mm alloy plate should be plenty strong enough
Cv's ready for installation, one of them looked like it had been chewed on the outside so had to clean it up first.
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It will all be OK in the end, if it's not OK it's not the end!
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nils
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| posted on December 16th, 2013 at 07:31 PM |
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Mmm......... 930 cv's
Quit calling rust patina
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vduboy
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| posted on December 17th, 2013 at 06:34 AM |
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| Quote: | Originally
posted by nils
Mmm......... 930 cv's
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Yeah they are pretty sweet, they are huge though took about a kilo of grease!
It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on December 28th, 2013 at 08:29 PM |
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Hi guys, I have clutch and brakes! Took the plunge and threw some brake fluid in it and bled up the clutch and brakes, came up really sweet, clutch is
very light and smooth. All my fittings are nice and dry, (once I done the last one up...  ) No pics as it all looks the same apart from some fluid in the reservoir!
Also finished of trimming the tinware and painting it all, unsure on whether the duct that routes the hot air off the cooler will clear the bar work
yet. Really like the look of the motor with the trimmed down tin. Now have a complete rolling chassis! Just waiting on some bar work to get tweaked
then on with it's body.
It will all be OK in the end, if it's not OK it's not the end!
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Aussie Dubbin
Fahrvergnugen
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| posted on December 29th, 2013 at 08:43 AM |
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Looking great fella keep at it
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No Dunes
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| posted on December 29th, 2013 at 08:55 PM |
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Hurry up so we can go for a cruise.
If you need a hand Im always happy to lend a hand
Shane 0410639269
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vduboy
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| posted on December 30th, 2013 at 07:50 PM |
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| Quote: | Originally
posted by No Dunes
Hurry up so we can go for a cruise.
If you need a hand Im always happy to lend a hand
Shane 0410639269
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Thanks dude, might take you up on that after I get the bar work sorted out. Cheers
It will all be OK in the end, if it's not OK it's not the end!
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vduboy
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| posted on January 5th, 2014 at 09:19 PM |
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Pretty much got the whole rolling chassis done now, I got stuck in and got the bar work sorted so the body would sit all the way back to get the bolts
in the right spots.
Had to clearance the body at the front for the steering box as the notch is in the wrong side of the body.
I'm not a fiberglass virgin anymore!
Bloody yanks driving on the wrong side of the road..
Also made some hard fuel lines for the carbs, gave them a clean and reset, they were quite clean inside for 40,000k's on them.
Now the body is in the right spot I get get some sika to stick down the floor seals and start bolting the body down.
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It will all be OK in the end, if it's not OK it's not the end!
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