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 crazyfiggi
A.k.a.: Alex
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 posted on February 11th, 2012 at 12:21 PM |
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My baja kombi build....Almost finished a new rear bumper bar.
Hey guys,
Thought i would post a topic about my baja kombi build.
Ive been a long time fan of baja kombis and have wanted to build my own for quite some time. Ive owned kombis in the past but have always had nice
ones which i wasnt game to cut up, but the van i have at the moment is rather rough and will be perfect to baja 
Its a 77 model that i bought dirt cheap from a mate. Ive been driving it for the past 3 years slowly fixing rust and other problems. Its done its fair
share of trips away camping and has been driven up some 4x4 only tracks that i never thought it would handle!
Ive been wanting to baja it since i first got it, so when Simon, guru here on the forum offered some baja kombi gear for sale i knew it was time.
I dont expect this to be a quick build, but am hoping to have it done for valla.
Plan is to fit the lift kit and wheels, along with a 1600 kombi box i have to get it on the road, then work on other things that arnt needed straight
away. Ive done a few custom tube bumpers, rock sliders etc for mates 4wds, so im sure i should be able to make up some for my van.
Being my first baja, im sure ill be asking plenty of questions here, so any answers would be appreciated.
Alex.
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tar76
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| posted on February 11th, 2012 at 12:38 PM |
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Looking foward to watch the progress. How much lift are you looking at giving it??
"Obey your Dreams"!
62 Std beetle.
65 11 wnd Split "The Cross".
6? coming very soon!!!!
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vwjon
Fahrvergnugen
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| posted on February 11th, 2012 at 01:41 PM |
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WOW, very impressive, can't wait to see more.
3 1959 cadillacs
1 musso
2 early notchbacks
2 split kombis
2 split panels
1 split ute
1 low light panel
1 ex-pmg bay
1 country buggy
1 beetle ute
1 14" syncro caravelle
1 16" syncro doka
1 golf cabrio
1 vw camper trailer
2 3meter bombs
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OZ Towdster
A.k.a.: Andrew Westwood
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Keen to finish some projects
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| posted on February 11th, 2012 at 03:56 PM |
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Hope your not going to fit the inverted tranny and reduction hubs as even John Alder will tell you it will drive like a pig .
As for the front end are you going to extend the chassis down or the beam up .
I would recomend the chassis down method myself as it is much stronger and can be made to look like part of the original chassis if done right .
If you do , do the beam up conversion i would highly advise fitting some brace bars from the bottom of the beam heading up foward to brace the beam
from trying to fold back under.
Other things to keep in mind are that you need to either lay back the master cylinder or make a dog leg rod between the brake pedal and the
mastercylinder, make a longer U rod for the sliding door or the back of the door will hit the flares , remove the front jacking points , cut the
bottom back corner of the front wheel arches back .
If the front crossmember of the cargo floor behind the front wheels is rusty behind the front wheels then do your self a favour and replace it now too
as with the removal of the jacking points this member will eventually sag . i replaced mine with a 50 x 50 x 3 mm shs , it is a bugger of a job as you
need to unpick the floor and any tubes to remove and refit the shs but well worth it when building a baja .
I have plenty of mods to my bus including a EG33 subie flat six , and climate control ac , all of which are unfinished at present but hopefully that
should be done by Valla .
To see the build on our bus log into Manx Club Australia and check it out in buggy and baja builds section under the heading " Our Baja Bus "
Don't let body work get in the way of real suspension travel
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11CAB
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If ya got it....Baja it
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| posted on February 11th, 2012 at 04:23 PM |
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To make the extension for the sliding door, an old kombi tierod is the perfect diameter tube. Andrew should be able to measure his, but I think its
either 75mm or 100mm you need to extend it.
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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OZ Towdster
A.k.a.: Andrew Westwood
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Keen to finish some projects
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| posted on February 11th, 2012 at 04:27 PM |
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100mm
Don't let body work get in the way of real suspension travel
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Smiley
A.k.a.: Daniel Stephens
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| posted on February 11th, 2012 at 06:17 PM |
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This is the post Andrew is talking about.
http://www.manxclub.org/phpbb3/viewtopic.php?f=2&t=1582
And here is some of the earlier work here on AVD
http://forums.aussieveedubbers.com/viewtopic.php?tid=66146
Enjoy!! Can't wait to see your progress, I've always wanted a Baja Bus. That might be my next project after my Buggy, Bug Bug and 1500 Beetle are
finished 
Smiley 
If you said I was a Volkswagen man, you'd be right.
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crazyfiggi
A.k.a.: Alex
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| posted on February 11th, 2012 at 07:51 PM |
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Wow, didnt expect so many comments so soon!
Nope, dont have the reduction hub/ irs set up.
For lifting the front i have plates that bolt to the beam and lower it away from the body 100mm. I have read here on the forum about boxing the
chassis in the front to lower it and how its stronger etc. Ill start with the plates i have, i can always mod the chassis later if i want. Im a ex
panel beater, but left the trade and have been a qualified boiler maker for the last 6 years, so the chassis mods shouldnt be to hard to do later if i
feel its needed.
Im thinking ill need to cut out the front jacking points and mod the cross member etc. The front wheels have 225/75/15 tyres now, but im thinking ill
get some 235s. A friend has some bf goodrich all terrains i can get at a very good price.
The kit i bought came with a dog leg brake rod so that shouldnt be a problem, and i can mod the sliding door rod my self. Makes it easier now knowing
it needs to be 100mm
Ive checked out the bus on the Manx Club Australia forum and must say its one of my favorite baja busses!
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11CAB
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| posted on February 11th, 2012 at 08:34 PM |
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Here's all the inspiration that you'll need
http://www.manxgallery.org/gallery/BajaKombis
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 February 11th, 2012 at 08:55 PM |
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| Quote: | Originally
posted by crazyfiggi
Ive checked out the bus on the Manx Club Australia forum and must say its one of my favorite baja busses!
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Mine too. It'd just be nice if he finished the damn thing so we can see it in action again!!!
Smiley
If you said I was a Volkswagen man, you'd be right.
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crazyfiggi
A.k.a.: Alex
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| posted on February 13th, 2012 at 06:21 PM |
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Whats the best tyre size for the front of a baja like this?
At the moment it has 225/75/15s but i want to change them. They seem like a hard size to get so im thinking ill get a 235/75/15. Cutting the van to
fit the bit larger tyre dosnt bother me.
The rears are 32s which are big enough for me
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11CAB
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| posted on February 13th, 2012 at 07:01 PM |
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I ran 215/75R15 on the front of mine, and 31x10.5 on the rear
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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vwsteve
A.k.a.: steve
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karmann crazy
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| posted on February 13th, 2012 at 07:14 PM |
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.
I made a semi baja kombi, i didnt weld on beam extensions but i spent a lot of time making my own beam adjusters and wound them as high as i could go,
dropped the bumpstops down more and rewelded them, lifted the back on the torsion bars, tapped the rear wheel arch lip flat and i run 215 and 235 bf
goodrich tyres on the merc rims without cutting the arches and tyres never scrape.
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1 1963 356b porsche coupe
2 1960 karmann ghia cab
1 1965 karmann ghia cab
1 1966 karmann cab
1 1961 split ute
1 1967 split p/van
1 1952 standard bug
1 1963 ragtop
1 1960 ragtop
2 1954 ovals
1 1956 oval baja project
1 1957 oval flying flea
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crazyfiggi
A.k.a.: Alex
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| posted on February 15th, 2012 at 06:25 PM |
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Thats a sweet looking bus Steve. I saw your build up thread about it and for a while was thinking about building my van in a similar style.
11CAB, now knowing your fronts are 215s im not so sure that i need to go with 235s. I wish i could get some decent tyres in the 225/75/15 size. I dont
really want to go much smaller than what i have.
Im still curious what tyre sizes some other bajas are using?
No much progress on my van. I did clean up a 1600 box i had in the shed and fitted a 091 bell housing with a 1800 input shaft.
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crazyfiggi
A.k.a.: Alex
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| posted on March 9th, 2012 at 07:01 PM |
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Now lifted
Still need to finish a few things off, tidy up the rear arches and fit the flairs, but its getting there!
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tar76
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| posted on March 9th, 2012 at 07:05 PM |
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Man that looks the goods!
"Obey your Dreams"!
62 Std beetle.
65 11 wnd Split "The Cross".
6? coming very soon!!!!
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crazyfiggi
A.k.a.: Alex
Wolfsburg Wizard
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| posted on March 9th, 2012 at 07:17 PM |
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Thanks mate!
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crazyfiggi
A.k.a.: Alex
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| posted on March 11th, 2012 at 05:25 PM |
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Man, i love how this thing is coming together.
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Smiley
A.k.a.: Daniel Stephens
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| posted on March 11th, 2012 at 05:36 PM |
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Dude!! I am loving the look of your bus!!!
It's coming together really nicely! Can't wait to see some pictures of it out offroading.
Smiley
If you said I was a Volkswagen man, you'd be right.
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pod
A.k.a.: paul mrvw061
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i`ve got to finish this thing one day
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| posted on March 11th, 2012 at 05:38 PM |
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now thats my style of kombi Keep up the good work Alex 
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grinderman
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| posted on March 11th, 2012 at 07:42 PM |
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Looking good, now go and and get that thing dirty (preferably bogged) with more photos
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11CAB
Compulsive Aussie Vee Dubber
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| posted on March 11th, 2012 at 07:42 PM |
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Looking good
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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crazyfiggi
A.k.a.: Alex
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| posted on March 13th, 2012 at 05:18 PM |
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Well i drove it today for the first time! It was only down to the end of my street and back, but i was surprised how good it felt to drive. I was
expecting a top heavy feeling, but after driving about 20 meters i forgot it was even lifted!
Only a few little problems, the rear shocks are to short and top out. Is there a certain model shock baja kombi guys use? Otherwise ill just go to the
local suspension place and see what they can get for me.
Also, i cant get the torsion bar caps back on. They sit to high. Here is a picture so you guys know what i mean.
Cant wait to get these things sorted out so i can get out and drive it.
Alex.
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11CAB
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| posted on March 13th, 2012 at 05:37 PM |
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I cant remember exactly what shocks i had on the rear, but I think they were from a Nissan Patrol
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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 matberry
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| posted on March 13th, 2012 at 09:02 PM |
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There's a one year only F100 shock that's a ripper, has longer than required long length so if you get 930 cv's you can get a fair biy more down
travel, '92 or '93 rings a bell.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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whathaveidone
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| posted on March 13th, 2012 at 09:09 PM |
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I dont know anything about kombis but have you tried swaping the cap with the other side???? maybe just upside down
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matberry
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| posted on March 13th, 2012 at 10:05 PM |
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The torsion cap issue.....you'll need to unbolt the diagonal arm from the spring plate, pop the spring plate off the stop, get some longer M10x1.5
bolts preferebly with thread all the way, get them started into the threads and after loading up the bolts a little to keep everything aligned, jack
up the spring plate to get it back onto the stop and tension the torsion cover bolts as you go to push the spring plate home. Swap over to correct
bolts one at a time once all together.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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daydreamer
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| posted on March 14th, 2012 at 08:37 AM |
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That is awesome i dig the Baja Buses. But how do they go with engineering and regos now with the new rules.
I dont think the authorities would buy the explaination. "no thats the standard hieght officer, the suspension has sagged on the other kombis".
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PHAT BUG
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| posted on March 14th, 2012 at 11:41 AM |
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That look fantastic!
Do you have any pics of the front end set up??
What did you do to raise the rear? Just raised it a spline?
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AA003
A.k.a.: Phill
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| posted on March 14th, 2012 at 01:58 PM |
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| Quote: | Originally
posted by crazyfiggi
Also, i cant get the torsion bar caps back on. They sit too high.
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Just try jacking it up and take the weight off the wheels. It may settle the rubbers enough to drop the covers.
I read it on samba, so it must be correct.
Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!
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