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Author: Subject:  Alyce the Baja
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posted on December 6th, 2009 at 01:51 PM



Thats some nice work there mate! I'll bet you've got a good sense of accomplishment from doing it yourself too! Well done!!

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posted on December 6th, 2009 at 01:53 PM



I spent last weekend completely stripping the body of the car out. except for the doors and bonnet there's not a single crew or bit of nything left on the car. I removed all the glass, all of the wiring and speedo, the steering column, completely stripped everything out of the inside of the doors. dash grilles glovebox lid. It's cmpletely bare so I'll be able to start the minor rust repairs required and prep for paint.
When I was under the bonnet removing harness I noticed some tape on the flat area below where the glovebox is. I peeled this off to discover a lovely set of holes that would have been used as a speaker grille. So I went the the old Baja that I rolled and cut the same piece out as a replacement panel, thankfully it wasn't out of shape.

http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030007.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030008.jpg

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posted on December 6th, 2009 at 01:58 PM



Thanks Paul.
I'm itching to go offroading again because of the lovely hot weather we've been having so I've decided to stop being so slack and get this thing smoked(or at least try to)

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posted on December 6th, 2009 at 02:05 PM



Cool air con holes you could use there.
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posted on December 6th, 2009 at 02:06 PM



The biggest thing that has happened is I've decided what I'm doing with the floorpan. So the old one has gone into quiet storage for now leaning up against a tree, and I'm going to use a superbug pan that I've had sitting at home for a while.
Andrew(OZtowdster) and I were discussing my situation a few weeks back and he suggested the SB pan. I was going to have to replace the frame head on the other one anyway, so now I'm putting a new framehead on this one and I get IRS rear as a bonus.

http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030011.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030012.jpg


I'm probably going to just leave it a swinger for now and get it built, then worry about collecting parts and change it over down the track.
The only downside to what I'm now doing is that the Superbug pan also needs new floorhalves whereas the ones on the original pan are in top shape.
So I'm going to be ringing up various VW shops to get prices on a framehead with Napoleans hat section and two new floorhalves. Plus a few small repair panels I need for the body.

Let me know what you think.


Just went up and pulled the rear end off the pan of the Baja I crashed. Most of this will be getting straight swapped into the new car. Including all the suspension bit. It has standard torsion bars and twin shocks plus a coil on each side. So I have a bit of sandblasting and painting to do with the extra shock plates and other bits and pieces.
All that is left to come off the pan is the pedal assembly, all the brakes bits that are still on it, spring plates, gearstick, quickshift plate and shifter rod.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030013.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030014.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030015.jpg



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posted on December 7th, 2009 at 08:31 AM



roar! :tu: man this beast is gonna be like brand new from the shop. Keep up the good work man!

What colour schemes are on the card?
I just had a bit of fun with some etch primer 2 nights ago! Learnt that 2 hrs prior to sprayin the paint, spraying rust convertor and taking the respirator off before the light remaining mist settles is not a good idea! Man that stuff is deadly when airborn! well... didn't feel to good haha.

I seriously gotta get some pics up. My laziness is next to lamelyness :(




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posted on December 12th, 2009 at 01:13 PM



Quote:
Originally posted by bajachris88
What colour schemes are on the card?


Definately blue, will put pictures up after I get some good ones.


A small update, I got a bunch of the suspension components sandblasted yesterday morning before work. I hung them up this morning and gave them a brush with POR15, might be getting a second coat this afternoon if all goes to plan. Luckily the old roll cage out of my buggy makes a brilliant hanging rack.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030016.jpg


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posted on December 12th, 2009 at 05:25 PM



Have your new frame head sitting in the car ready to come back tomorrow + the other set of adjusters



Don't let body work get in the way of real suspension travel
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posted on December 14th, 2009 at 09:19 PM



I pulled the last few things off the body this afternoon, bonnet and both doors.
The bottom bolt for the passengers side door was fibreglassed over. I thought this was a little suss so I pulled the 'glass out, and hey persto, you need a new pillar.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030017.jpg


This got me a little worried cause there is a large fibreglass patch on the outside of the passenger's front quarter.
I decided to pull this off too.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030018.jpg



So I peeled off the big piece of fibreglass and lo and behold, new quarter panel is now in my letter to Santa. Also looks like the surrounding area is coated in about half an inch of bog.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030019.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030020.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030021.jpg


On the plus side Andrew picked me up a new framehead as stated above and I should be getting it some time this week. Awesome!! I know what I'm doing on the weekend.



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posted on December 19th, 2009 at 06:59 PM



Got some huge ammounts of work done on the car today.
I got the second coat of POR-15 on my suspension components this morning.
First lot of pictures is where I started cleaning up the framehorns. I welded up the heater cable tubes as these will no longer be getting used.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030022.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030023.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030024.jpg


Didn't get much further on the wire buffing because Andrew (Oztowdster) showed up and we got stuck into the real business of the day.



Andrew bought a new framehead up from Brisbane for me, thanks mate!!


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030027.jpg


We started by removing the floorhalves
These will be getting replaced with new checkerplate ones. Definitely have to get dad's ute registered now so I can pick some up.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030025.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030026.jpg



Floorhalves removed.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030028.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030029.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030030.jpg



Andrew did a little measuring and worked out where to make the cut and the chop was made.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030031.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030032.jpg


Inside of the tunnel looks quite good, except for the rat's nests.
The bottom plate the goes under the tunnel dips down at the front leading up to the framehead, this is starting to scale a little on the inside but other than that things look good.



This is the piece I was talking about above. It's not going to line up once the new framehead is on so I removed in now.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030034.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030033.jpg



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posted on December 19th, 2009 at 07:29 PM



The brake pedal is on the wrong side.......
Same as the framehead i picked up a little while ago.
Your project is coming along nicely




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posted on December 19th, 2009 at 07:49 PM



Quote:
Originally posted by 11CAB
The brake pedal is on the wrong side.......
Same as the framehead i picked up a little while ago.
Your project is coming along nicely


This is also the first thing that I noticed.
Just more holes to patch and drill I guess.
That Or let the passenger do the braking :lol:

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posted on December 20th, 2009 at 06:50 AM



haven't u finished this yet??? what the bloody hell have u been doin all this time? slack bastard!!!!!!

hey ur mate who brought the other Baja was chasing an engine the other week but i was crook and couldn't talk. did he manage to find one?

steff..........




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posted on December 20th, 2009 at 10:24 AM



He hasn't managed to find one yet. If you have any ones that you know are definately good he's keen for one.
Did Andrew get on to you?

I finally decided on a colour I want, cost permitting obviously.
Are you still keen to paint it? I was thinking about stripping it back to bare metal, would this suit you best to paint on?
I think the colour is Ford 'Sensation Blue', I'm going to go to the dealership on Monday afternoon and see if I can get a paint code for it.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/2132328247.jpg


I'm trying to get the car done ASAP cause I am trying to make this - http://www.manxclub.org/index.php?name=Forums&file=viewtopic&t=879 
I don't care what you have on you had better be there!!
So any way that you can help speed things along would be more than greater appreciated. I think I will need a lot of help/hints/tips when it comes to prepping the body for paint.

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posted on December 20th, 2009 at 10:55 AM



great looking colour Smiley.....looking forward to seeing the end result!

Scarab (aka: Paul)




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posted on December 20th, 2009 at 01:28 PM



I'll see what i can find in regards to engine

no Andrew didnt get hold of me, has he been trying? easiest to just give him my number

when ur getting to the paint stage of life give me a holla and i'll send u in the right direction and for a fella Baja u know i'll look after u price wise, bear in mind a solid is going to be cheaper than a mettalic(c.o.b) and will hide a few more sins:crazy:

Trip to 5 rocks and noone told me!!!! if i still have the green beast i'll be up for that one and that also explains why andrews been droping stuff off to u, i am SO out of the loop these days:lol:

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posted on December 20th, 2009 at 08:27 PM



Quote:
Originally posted by DubCrazy
I'll see what i can find in regards to engine

no Andrew didnt get hold of me, has he been trying? easiest to just give him my number

when ur getting to the paint stage of life give me a holla and i'll send u in the right direction and for a fella Baja u know i'll look after u price wise, bear in mind a solid is going to be cheaper than a mettalic(c.o.b) and will hide a few more sins:crazy:

Trip to 5 rocks and noone told me!!!! if i still have the green beast i'll be up for that one and that also explains why andrews been droping stuff off to u, i am SO out of the loop these days:lol:

steff.............................


It would be good to see you there, I'll probably be bumming a lift at this pace.

Can you do that same colour but not as a metallic?



Andrew came back around today, thanks a heap again mate!!

We got stuck into attaching the new framehead.
I got most of the join area cleaned up yesterday afternoon.
So we got it in on flat ground on fine adjustment jack stands so we could make sure it was completely level.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030036.jpg


After ages of lining up, measure thrice, everything was good so we tacked it in place. The diagonals are still out by a few mil but we will get this back by loosening the beam off and giving it a knock leftwards.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030035.jpg


After tack welding we double checked all measurements and ran some stitch welds inside and out.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030038.jpg


Then the power went out accross most of town.
And it started raining.
So I'm going to have to finish welding it tomorrow weather permitting.



While we were waiting for the power to come back on, and before it started raining, we grabbed Andrews battery 5" and drill and cut a donor piece out of the old pan that I crashed to cover the hole under the tunnel. This is the area where the superbugs slope down towards the front as I explained earlier.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030039.jpg



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posted on December 22nd, 2009 at 02:27 PM



wow....that must be some current draw on your welder to have blacked out half the town!! :lol:

great to see you are moving ahead mate.

all the best for Christmas

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posted on December 22nd, 2009 at 06:52 PM



Quote:
Originally posted by Scarab
wow....that must be some current draw on your welder to have blacked out half the town!! :lol:

great to see you are moving ahead mate.

all the best for Christmas

Scarab (aka: Paul)


It wasn't anywhere near the highest setting!! I could probably take out the state if I turned it right up!

You'll have to get stuck into that Type 3 of yours!!

I'm thinking about coming down to Adelaide mid way through next year so it would be good to catch up if you're not busy and in town. Might be able to give you a hand with the Notch if you're still pottering along with it.



Well, I might go do some more welding.
I'll bring you all some pictures later.
I also ordered my steel for the new floors today so I should be getting that tomorrow, expect some epic work over the weekend.

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posted on December 26th, 2009 at 03:10 PM



These are the pictures of what I got done on Wednesday night.

There were some fairly large gaps in the framehead right next to where the beam sits. After a little "ball-pein persuation" I filled these in the prevent water, mud, cat entry etc.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030040.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030041.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030042.jpg


I was fairly late so that's all I got done the other night.

Today a friend came round and we got stuck into finishing all the welds off on the framehead and seam welding the N-hat section.



The section where the accelerator arm goes had a large gap in it. So I got to try out my Christmas present, a hammer and dolly set. I hammered the section down until it was close enough to the tunnel so I could weld it up.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030043.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030044.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030045.jpg



Because the framehead is a LHD one I made up some templates to transfer the holes to the RHS. Then made up some plates to cover the old holes. Dad thought I was making Ford badges some reason.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030047.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030048.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030049.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030050.jpg



The superbug fuel line turned out to not be long enough to reach out the hole I drilled in the top of the tunnel. So I cut it off inside the tunnel near where the pedal assembly runs through. I then got some bundy tube and cut a piece the right length for the rest of the way.

http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030051.jpg


I wire wheeled all the framehead welds inside the tunnel and cleaned everything out and gave the inside a lick of POR-15.
Then connected up the separate fuel hard lines with a small piece of rubber fuel hose. I double clamped it just to be safe and make sure you put a rubber grommet on the hole where the hard line exits the tunnel.


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030052.jpg


http://i933.photobucket.com/albums/ad172/smileyman1968/Alyce%20the%20Baja/P1030053.jpg


While I was doing this my friend got happy with a wire wheel on a grinder and cleaned up the edges where the new floorpans are going to sit.



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posted on December 26th, 2009 at 05:46 PM



Don't stuff around with fuel lines. Replace the lot.



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posted on December 26th, 2009 at 06:03 PM



I'm loving what you've done so far but that join will give you trouble later. Interested where you sourced the framehead from, was it Mick Motors?



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posted on December 26th, 2009 at 06:20 PM



Quote:
Originally posted by mackaymanx
Don't stuff around with fuel lines. Replace the lot.


How hard is this to do?
Must you cut the tunnel open in a number of places in order to strap the fuel line down?

And I'm not exactly sure where the framehead came from, Andrew Westwood bought it up for me. I either came from CVD or Mick Motors.

I'm sure next time he reads this thread he'll post it up and let you know.

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posted on December 26th, 2009 at 06:35 PM



Here is a good place to start, shows where the fuel line is attached inside the tunnel.

http://www.vwdcqinc.org.au/vwdcqimages/insideabugimages/insidetunnel.html 

I haven't done one myself yet(I have to do my Manx sometime in the future), I sure someone will come up with some tips.




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posted on December 26th, 2009 at 07:21 PM



x2 its alot easier to replace the hardline while the bodys off
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posted on December 26th, 2009 at 07:35 PM



Thanks for the link Mackaymanx.

If anyone knows how to do this, has done this before or has any ideas on how to go about it best please post it up here and let me know ASAP, and I will get started on it first thing in the morning.

Thanks for you thoughts Joel and Mackaymanx.

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posted on December 26th, 2009 at 07:38 PM



there was a good thread on the samba with pics ill see if i can find
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posted on December 26th, 2009 at 07:43 PM



Thanks a heap Joel.
I was thinking seeing as i can flip the pan over incredibly easily it would probably be best to cut a section of the bottom plate and drill out the spot welds. Under the handbrake area where the center hold down is maybe a foot long piece. Then feed the new line in from the back and secure it in the middle (and redo the clutch one super strong while I'm going) then I already have access both ends to secure it. Then just weld the plate back on like I'm doing with the piece under the pedal assembly.

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posted on December 26th, 2009 at 07:50 PM



the stock line just has 3 metal tabs bent over to hold it like the brake line to rear along side the tunnel

the rear one is easy to get to from the shift coupler hole but most people have to cut an access window in for the one under the handbrake

the front one is under the pedal assembly

looked like a prick of a job so i just took the easy route and ran rubber lines front to back inside a protective conduit

engineer was happy enough with it so im sleeping eaasy :lol:
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posted on December 26th, 2009 at 07:51 PM



http://www.thesamba.com/vw/forum/viewtopic.php?t=240404&highlight=hardline 
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