The Cal-look Lounge

Today I picked up an original Manx II shell in exchange for a set of rims I had laying around. The shell is in good shape but has been sitting outside for several years. The car will be a late '60s early '70s look.

--louis

COOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOL ;D

I am glad you think so as I am sure I will have some questions for you later.  ;)

--louis

Ask away dude - I'm always happy to help with a retro styled manx - My tip is Keep It Simple, But that should be quite easy with the way your doin it  ;) :)

Right now I am looking at wheels and tires. I want to use stock style steel rims painted white but not sure of a good street tire combo. Any suggestions? My other thing is do I go Holley bugspray or stock carb on the single port? The engine will be stock 85.5x69 except for some cleaned up heads and a w100 cam and an extractor or glass pack style exhaust. (I don't want it overly loud)

--louis

Finally got the shell home today. Its pretty dirty but not in bad shape. You can see the modified rear fenders. Progress will probably be slow on this project since the '66 takes priority. I plan to work on this one when I have down time on the '66. First thing I want to do, other than soak it in some bleach, is to get the chassis done. (That is the '66 pan it is sitting on in the pics.)

(http://images.thesamba.com/vw/gallery/pix/572305.jpg)


(http://images.thesamba.com/vw/gallery/pix/572304.jpg)


(http://images.thesamba.com/vw/gallery/pix/572303.jpg)


(http://images.thesamba.com/vw/gallery/pix/572302.jpg)


(http://images.thesamba.com/vw/gallery/pix/572301.jpg)


(http://images.thesamba.com/vw/gallery/pix/572300.jpg)


(http://images.thesamba.com/vw/gallery/pix/572299.jpg)


--louis

What Wheels did you Trade for it?    and What wheels are going on the 66 now?

I traded the repo gasburners for it. I picked up a set of Porsche pattern Erco's for the '66 that I am going to use.

--louis

Cool  were the Erco's Daniel Hoods wheels off the chop top? did you get them from Luke?

Aye, it was that set. I am waiting on the big brown van to drop them off any day now.

--louis

Finally got around to doing something on the Manx. I need to get it to roller status because having 2 projects in a 2 car garage is making it a bit tight. So I decided to start on the chassis work. First thing up is replacing the frame head. My good friend Bobby and I spent the afternoon cutting the very rusty frame head off my '67 chassis and mocking up the new one. It is turning out to be not as difficult as I thought. Just a lot of measuring, measuring and then measuring again before cutting anything. I will weld it on when I get back from vacation.


(http://images.thesamba.com/vw/gallery/pix/594382.jpg)


(http://images.thesamba.com/vw/gallery/pix/594383.jpg)


(http://images.thesamba.com/vw/gallery/pix/594381.jpg)


(http://images.thesamba.com/vw/gallery/pix/594384.jpg)


(http://images.thesamba.com/vw/gallery/pix/594385.jpg)


(http://images.thesamba.com/vw/gallery/pix/594386.jpg)


--louis

Good to see some progress dude  :)

Looks like your working hard :o Stay Hydrated  ;)

(http://images.thesamba.com/vw/gallery/pix/594382.jpg)

lol, its mostly the humidity. With 90% humidity you can break a sweat standing still and it doesn't evaporate. But you do have to keep drinking fluids. (And beer doesnt count.)

--louis

It's gonna be an hard and very long work!! GOOD LUCK!!!
which wheels you want use for the manx?

Louis Your Shortening the Wrong End  LMAO  ;D ;D ;D

I have some stock solid 15x4s that I plan to have widened. I am still debating tire size but I think it will be 165R15s front and 235/60-15s rear.

--louis

Sounds about right dude - mybe 225's though  ;)

shoud be a great project!! let's know your progress!!

Rims came tonight. I also got the frame head and Nepolean's hat welded on. We started cutting the frame to shorten it 14 1/4'" but had to call it a night.

My rear rims from Rally America. 15x6.5. They will get painted or powder coated white. I am thinking of running them sans hub caps w/ black painted drums.

(http://images.thesamba.com/vw/gallery/pix/607452.jpg)


(http://images.thesamba.com/vw/gallery/pix/607451.jpg)


(http://images.thesamba.com/vw/gallery/pix/607452.jpg)


Couple of shots of the buggy after it had been washed by my friend Bobby.

(http://images.thesamba.com/vw/gallery/pix/607447.jpg)


(http://images.thesamba.com/vw/gallery/pix/607446.jpg)


Cut off those ugly rear flares. Going to be fun trying to reform this area.

(http://images.thesamba.com/vw/gallery/pix/607448.jpg)


And finally the progress on the pan. We should be shortening it this weekend.

(http://images.thesamba.com/vw/gallery/pix/607445.jpg)


(http://images.thesamba.com/vw/gallery/pix/607449.jpg)


(http://images.thesamba.com/vw/gallery/pix/607453.jpg)


(http://images.thesamba.com/vw/gallery/pix/607454.jpg)


--louis

Good progress dude - this is gonna be a COOL Looking manx ;D

Cool project and I like those rims.This is gonne be a fun car.  ;)

Got the frame shortened this today. Took a lot of trimming and measuring but it came out nice IMHO. On to the pics:

My cutting the bottom the other night:

(http://images.thesamba.com/vw/gallery/pix/608426.jpg)


(http://images.thesamba.com/vw/gallery/pix/608427.jpg)


Cut lines marked. The one drawback I found to using this method is I will need to reweld the clutch tube bracket. Not a big deal:

(http://images.thesamba.com/vw/gallery/pix/608428.jpg)


(http://images.thesamba.com/vw/gallery/pix/608429.jpg)



I left a 5" or 6" lip on the bottom that I really think helped to line every thing up.

(http://images.thesamba.com/vw/gallery/pix/608430.jpg)


Last mockup with the body. I did this several times but I am paranoid so there you go.

(http://images.thesamba.com/vw/gallery/pix/608431.jpg)


I added these "V" cuts on each side to help everything line up.

(http://images.thesamba.com/vw/gallery/pix/608432.jpg)



Get it up on jack stands and make it all level.

(http://images.thesamba.com/vw/gallery/pix/608433.jpg)



How do you like that fit?  :)

(http://images.thesamba.com/vw/gallery/pix/608434.jpg)


Cleaning up the welds. And yes I need to clean up the garage but I would rather spend my time working on the car.

(http://images.thesamba.com/vw/gallery/pix/608435.jpg)


(http://images.thesamba.com/vw/gallery/pix/608436.jpg)


(http://images.thesamba.com/vw/gallery/pix/608437.jpg)


One area I am not happy about. But its the body that is warped not the pan. First time I placed the body on the pan after replacing the pan head I nearly had a heart attacking thinking I had welded it on crooked. Then I realized the fiberglass is warped. Not sure how to fix it yet.

(http://images.thesamba.com/vw/gallery/pix/608438.jpg)


Woo Hoo! IT FITS! I almost have a real buggy instead of just a fiberglass shell.

(http://images.thesamba.com/vw/gallery/pix/608439.jpg)


--louis

double post.

Triple post.  ::)

Hi Louis Question when you cut the Pan did you just cut the tack welds on all the inner tubes and shove them threw to the back then trim them off?  of did you splice them somehow?

I cut where they were tacked in the back and shoved them through. Then cut them off and rewelded them to the bracket. There is a good description here

http://www.meyersmanx.com/garage/garage_shorten_p1.htm

on how to do it.

--louis

Thanks ;D ;D ;D

Looking good Louis! E-mail Rob at East Coast Manx, he might be able to mould up the rear arch sections you need and post them to you. He's a good guy and it may well be the sort of thing he'd do to fix an original Manx. :)

Yep drop rob an email - I am sure he will be able to help  :)

Cool, thanks to the tip guys. When I get ready to start on the *itch* *itch* fiberglass repairs *itch* *itch* I will get in touch with him. Probably be in the spring. Right now the focus is on the pan and engine.

Thanks,

--louis

Send me a photoshopped pic of the areas you need replacing and I will let Rob know - he VERY accomodating - Shipping might be a bitch though :-\

I will get some up close ones tonight.

Thanks,

--louis

Tonight's work:

(http://images.thesamba.com/vw/gallery/pix/609703.jpg)

Mocked up for a quick sanity check. Pan halves are from Wolfsburg West. Still some trimming to do but I should be able to weld it in this weekend.

--louis

Hey Louis beter call the Cops Someone stole your Seat rails? ;)

Stole nothing, I cut those suckers out with the sawzall.  ;D

--louis

Rob is on here too - he's ROBTHEMANX, his build thread is about his NED Bug replica.

Cool, I will PM him and see what he thinks.

--louis

 Careful louis, Your on your way to the worlds nicest manx !! Very nice repair and shorting the pan work that you have completed. Off the subject, But how square was the body from the builder. Kinda nice to see how stuff was built many moons ago. Could any thing been improved?

Agreed cool work on the pan - thats pretty much what we've done (me&Rob) but we also cut and lifted that dropped section so we have an almost flat flooor :)

Worth it if you eevr wanna take it for a spot of off roading and trust me YOU WILL  ;)

Thanks Danny, its not up to your quality of work yet but I am getting better. Really wishing I had a TIG right now so I could do the roll bar myself. My little 110 MIG won't handle it. As for the body, its a little off but I am not sure if it was a manufacturing thing or just age and abuse. This body was built after Bruce Meyers left the company and I have heard quality dropped some after that. The front bulkhead is bowed out and the rear of the body seems to be about 1" - 2" narrower than the pan will end up being. I will have to figure out some way to fix it. Its a question of cutting the pans some or cutting the body some.


Honestly, if I had not already had the pan halves from WW I would probably have fabed up a flat floor with square tubing and 18 gauge steel sheet. Or just purchased one of the Berrian tube frames with fiberglass floors.

--louis

Nice work Louis, very tidy!

Dunebuggy Dave Barret builds these in town.  If and when I do a buggy, it will have one of these with a tunnel welded or bolted to the spine for registration purposes.

http://www.thesamba.com/vw/classifieds/detail.php?id=291681

lol, you and Bryan67 must think alike. He just PMed me the same info. Those are nice too and I know he makes a cross country trip once a year. I just like trying to do things myself. To me, building them is as much fun as driving them. I must me touched in the head.

--louis

Hey Louis Did You Forget About your 66?  What Happened to Sweep the Floor Manx???  LOL your getting like me once you get out in the garage you look around, its real easy to find something to Do I have Three cars Going at once and Cant get Any of them Done LOL

I think I blew through that $1000 budget in about three days.  :D

I am trying really hard to keep this project from getting out of hand but you know how it goes, especially when you tend to have high standards. The '66 is on hold for a bit while I get the Manx up and running. I want something I can drive and realistically the '66 is a five (or more) year project. By having a running car I will be less likely to cut corners with the '66 just to get it done. At least that's what I keep telling myself. I hope to have the Manx done by end of summer, then I will get back to the '66.

--louis

A Manx...... A 66 project...... you sound WAYYYYYYYYY to much like me dude  :D :D :D :D :D :D :D :D

At least I know how to blame now.  ;)

--louis

Nice!  This is gonna be a great ride for you!   ;D

  Use baby powder to clog your pore's in your skin before doing glass work! No more itch!!

I have never heard that one before. I will give it a try when I start the body work.

Just as an update, I decided to take Lee's advice and cut out the lowered section of the floor pans. I will fill the hole with some 18 gauge sheet metal once I get my hands on a bead roller.

--louis

Good idea dude - its not mine idea though, I have Rob at eastcoastbuggies for mine  :)

Thanks for the tip...

Couple of update shots. Got the windshield and mirrors mounted last night. I used a Berrien kit to mount the windshield and it worked great. I also mounted the steering column support but didn't get any pics. The mirrors are repos I think from a 1970s Honda motorcycle. They fit the period theme perfect. You can also see the standard VW steering wheel I picked up as well. I like it because it doesn't have the horn ring.  This weekend I am going to pick up my new hard top.

Its almost starting to look like a real buggy.  :D  In the foreground is the rebuilt tranny from Locash Racing waiting to be installed.

(http://images.thesamba.com/vw/gallery/pix/620907.jpg)


(http://images.thesamba.com/vw/gallery/pix/620908.jpg)


(http://images.thesamba.com/vw/gallery/pix/620909.jpg)


(http://images.thesamba.com/vw/gallery/pix/620910.jpg)


--louis

Diggin the mirrors dude  :)

I would love to do a project like that!   ;)

After an 11 hour drive I picked up my new hard top yesterday. Here is a pic of it set in place. I am really digging the orange and black combo.

(http://images.thesamba.com/vw/gallery/pix/621615.jpg)

Now I need to decide what color to paint my steel rims. White, black or silver. Currently leaning towards silver as see in this pic:

(http://images.thesamba.com/vw/gallery/pix/621617.jpg)

I really like this blue buggy.

--louis

I won!! I drove 26 hours in a weekend to go at the European bug In to have my hardtop!!  8)  8)

Cool seeing new update about your Manx, where did you found the hardtop?

I found a guy here in Florida who had planned to build a vintage style Manx and then changed his mind. He was selling off all the parts he had collected.

--louis

Looking really good Louis, I'm more than a bit jealous! :D

Here is attempt 1 at painting one of my widened rims. I used a metallic silver and a clear satin on this. The bottom pic shows a wheel I painted to show before applying the satin. When I first sprayed the rim with the metallic silver I though "Oh 'ell, what have I done" but the satin clear really helped tone it down. I think it will go well with the GM Hugger Orange paint I am considering.

(http://images.thesamba.com/vw/gallery/pix/622255.jpg)

(http://images.thesamba.com/vw/gallery/pix/622256.jpg)

(http://farm3.static.flickr.com/2713/4134045129_4908d7eff1_o.jpg)

I got a slight run I need to fix but over all not too bad.

--louis

What a difference,but it turned out nice with the satin.
Wheels will clearly look VERY cool under that orange body.
Way to go Louis.  ;)

the satin is amazing!!

really nice. i love it! your buggy getting really cool!

Thats much better after the clear. I think it would look good with hubcaps too.

Great thing is I can always add the clips if I want to run caps and trim rings. And now that you got me thinking about it, that would be a nice look.

--louis

Just hubcaps though. No beauty rings. Like Ol Red has on it.

The big brown van dropped off my Dietz headlights from Speedway and stone guards from Moss Motors tonight. I like these better than the cheap Empi chrome jobies.

(http://images.thesamba.com/vw/gallery/pix/622523.jpg)


(http://images.thesamba.com/vw/gallery/pix/622524.jpg)

While the wife is out shopping on Black Friday I hope to get some more work done on the pan.

--louis

Louis why didn't you blast the Front wheels you can see all the chips and scratches under the Paint?

I just painted it to show the difference in color. I will take both front wheels to the sand blasters before I do them.

--louis

Fronts look like Mexi Chrome LMAO

Very cool dude BUT one thing I have noticed - The screen needs to be more "vertical" it just looks alittle too angled back to me - Just my 2 cents bro  ;)

Love the headlights by the way  ;D

The windscreen? I followed the manx instructions and set it to align with the dash to hood joint. That's the way the original was. It may just be the picture.

--louis

I like it laid back a little. Perhaps Manx one and Manx 2's have slightly different bonnet mouldings?

Yep thats what I did the first time and it kinda works with a shorter screen BUT with taller screens I just think they need to be slightly more upright  :-\

What I did when I fitted the new taller screen is : Fit the screen using only the TOP bolts in the hole you already have then with these loose pivot the screen forward until the join of the bonnet/dash is just hidden behind the front edge of the screen then mark it and drill the new hole (I hope that made scence :-\)

maybe worth mocking up and seeing what you think - you might like it dude  ;) :)

Okay I will check it out. It might make the top lip fit better as well. Speaking of, how did you mount the front of you top?

--louis

Yeah it will help with the fit of the hard top too - Mine is just hooked over the lip on the screen and my friend had some aluminuim blocks cast that bolt through the hard top and clamp it to the small inside edge of the screen - I will take some pic's and see if he has any in stock  ;)

Cool I would appreciate that.

--louis

these are the front top mounting hardware that Rob makes. really nice and clean. these are polished.

That is really sweet looking. Clean way to mount the top. Be nice to make something like that that would mount to the rollbar as well.

--louis

Rob simply used a couple of old leather straps - he made four slots in the hood near the roll bar and then fed the straps through and strapped it down nice and tight :)

P.S Thanks for the pic's Davide - it is a VERY cool bit of kit :)

 ;)

 ;)

thats ONE of my favourites right there  ;) :)

Cool article. Thanks for posting it Fabs.

--louis

I was thinking something like this guy fabbed up.


(http://www.manxgallery.org/gallery/albums/Building-my-orange-Manx/HARDTOP_UPPER_MOUNTS_2.sized.jpg)

(http://www.manxgallery.org/gallery/albums/Building-my-orange-Manx/HARDTOP_SIDE_MOUNT_2.sized.jpg)

(http://www.manxgallery.org/gallery/albums/Building-my-orange-Manx/ALUMINUM_HARDTOP_MOUNTS_SIDE.sized.jpg)

Not sure how I would make them though. Could make something like chopper showed for the front to match.

--louis

Are those going to be the mounts for the roof? If so very sano idea.

Yeah they are to attach to the roll bar. I am still not sure how to make them though. Think you could fab up something like that?

Thanks,

--louis

I like the nylon inserts to stop the ali blocks from scratching the rollbar. Very neat.

Louis do you have a water jet cutter local ?

Its doubtful, remember I live in Resume Speed Florida not So cal.

--louis

Hell louis I'm in BFnevada and we have one. Try finding one and send a pattern to them, Alot ez'r than bandsawing and hole sawing the things out. and its pretty cheep.

Okay, I will look for one. Thanks for the idea.

--louis

the blue monocoque article manx is simply wonderful. but i firmly think that after all that job, on such an important car, the owner should have choosen a best vintage tire solutions, with thinner rims at the front.
 

Agreed , so many vintage tyres being remade now , why use modern . And Coopers too !

Rob

OR you could just spend 5 years searching like i did  :o ::) :)

Finally got some time lately to do more work on the Manx pan. I welded in the flat inserts last week. I still need to dress the welds but I am happy with the results. I also modified the seat mounts. I am using the Speedway mounts but I was unhappy with the angle that the seats were at. So I whipped up some brackets which will give the seats a 20 deg tilt and welded them to the mounts. This should make them more comfortable and give me a little more head room as well.

(http://images.thesamba.com/vw/gallery/pix/628776.jpg)


(http://images.thesamba.com/vw/gallery/pix/628777.jpg)


(http://images.thesamba.com/vw/gallery/pix/628778.jpg)


(http://images.thesamba.com/vw/gallery/pix/628779.jpg)


(http://images.thesamba.com/vw/gallery/pix/628780.jpg)


Next I need to mount the seats and seat belts. I plan to weld some 1/8 inch flat stock to reinforce the seat mounts. Other than some body supports that should be the last of the welding. I hope to have the body to the sand blasters in the next couple of weeks.

--louis

Nice work dude.   ;)

Finally some progress now that the weather has warmed up. I am about half way through with the fiberglass repairs here. I ran out of resin so I have to wait till next weekend to go any farther. I am using the West Marine products and I am happy with them so far. It takes a lot of the guess work out. I have a couple of small repairs to make and then its time to mount it to the pan. I am waiting on England to thaw out enough for Rob to lay up my fender sections. Hopefully they will get here by March.


Seems like every buggy I see has this area butchered:

(http://images.thesamba.com/vw/gallery/pix/638073.jpg)


(http://images.thesamba.com/vw/gallery/pix/638074.jpg)


One of the PO's more questionable repairs.

(http://images.thesamba.com/vw/gallery/pix/638075.jpg)


(http://images.thesamba.com/vw/gallery/pix/638076.jpg)


(http://images.thesamba.com/vw/gallery/pix/638077.jpg)


(http://images.thesamba.com/vw/gallery/pix/638078.jpg)


Laying up the 'glass:

(http://images.thesamba.com/vw/gallery/pix/638079.jpg)


(http://images.thesamba.com/vw/gallery/pix/638080.jpg)


(http://images.thesamba.com/vw/gallery/pix/638081.jpg)


(http://images.thesamba.com/vw/gallery/pix/638082.jpg)


(http://images.thesamba.com/vw/gallery/pix/638083.jpg)


(http://images.thesamba.com/vw/gallery/pix/638085.jpg)


(http://images.thesamba.com/vw/gallery/pix/638084.jpg)


(http://images.thesamba.com/vw/gallery/pix/638086.jpg)


(http://images.thesamba.com/vw/gallery/pix/638087.jpg)


(http://images.thesamba.com/vw/gallery/pix/638088.jpg)


(http://images.thesamba.com/vw/gallery/pix/638089.jpg)


Lots of sanding and more epoxy filler:

(http://images.thesamba.com/vw/gallery/pix/638068.jpg)


(http://images.thesamba.com/vw/gallery/pix/638069.jpg)


(http://images.thesamba.com/vw/gallery/pix/638070.jpg)


(http://images.thesamba.com/vw/gallery/pix/638071.jpg)


(http://images.thesamba.com/vw/gallery/pix/638072.jpg)


Once the repairs are done I will lay a coating of Featherfill on and block sand everything.

That tip from Danny Gabbard to use baby powder to close up your pors to keep the itching down when doing fiberglass works really well.

If anyone is interested in the West Marine system, here are two short vids on how it works:

http://www.youtube.com/watch?v=6N7YMr6E564

http://www.youtube.com/watch?v=ZrxhGYXEjkA

I will warn you though, its not cheap.


--louis

Nice work dude  ;D

Really good work!! Are yo going to rebuild the rear fender too?

Yes I plan to repair the fenders. RobtheManx is going to make me some replacement fender sections when it warms up. Then I will just have to graft them on to the body.

Thanks,

--louis

Coming alog good Luis!   I want one of those........be a kick in the pants.   ;)

Still working on fiberglass repairs but I think I am nearing the end. Got word last week that my new rear fender sections are on their way from England. (Thanks Rob!) Here are some pics of some recent progress:

(http://images.thesamba.com/vw/gallery/pix/652306.jpg)


(http://images.thesamba.com/vw/gallery/pix/652304.jpg)


(http://images.thesamba.com/vw/gallery/pix/652305.jpg)


(http://images.thesamba.com/vw/gallery/pix/652314.jpg)


(http://images.thesamba.com/vw/gallery/pix/652303.jpg)


(http://images.thesamba.com/vw/gallery/pix/652311.jpg)


(http://images.thesamba.com/vw/gallery/pix/652308.jpg)


(http://images.thesamba.com/vw/gallery/pix/652309.jpg)


(http://images.thesamba.com/vw/gallery/pix/652310.jpg)


(http://images.thesamba.com/vw/gallery/pix/652313.jpg)


(http://images.thesamba.com/vw/gallery/pix/652312.jpg)



Back end is finally done. Before and after shots:

(http://images.thesamba.com/vw/gallery/pix/638073.jpg)


(http://images.thesamba.com/vw/gallery/pix/652315.jpg)



Here I glassed in some fender washers, 4 per side, to the headlight mounts for better support:

(http://images.thesamba.com/vw/gallery/pix/652316.jpg)


I still have the hood and fenders to do plus getting it mounted to the pan, then its just some cosmetic stuff and it will be ready for primer.

--louis

Louis, do your self a favor and regel coat the outside of body and seal up all repairs, So they do not soak up and you see sand scratchs in the new paint 6 months later.

Hi Danny

Thanks for the input, I will look into that. So far all the repairs have been done in epoxy resin and I was planning to put a coat of Feather Fill primer on next. I have heard good things about using Feather Fill on fiberglass.

--louis

Looking good! I hate working with fiberglass but I'm determined to give it a try one day. Running stock 67 turn signals front and rear?

Hey Zach,

Your work on the blue car is making me want to get this done and get back to my '66 project. Fiberglass is easy to work with but man it itches. As for the turn signals, peanuts in front and '67 rears with LEDs.

--louis

That's good to hear! It's giving me the itch to get started back on my '67 as well. 11 years of ownership has given me lots of (bad) ideas ;)

Started working on the Hood mods/repairs today. I had purchased a gas cap that was original equipment on AC Cobras for use on the Manx. I have to say I was a bit surprised at how large it was when it arrived. It didn't look that big on the website. Determined to use it though I decided to sink the gas cap into the hood to help lower the profile.


Areas I need to repair. The buggy had been wrecked some time in the past and some repairs were made. I originally planed to just grind out the old bondo and use some epoxy filler to clean up the repairs. But as I got further into them it was obvious that most of the repairs were substandard and would have to bee redone.

(http://images.thesamba.com/vw/gallery/pix/654422.jpg)


(http://images.thesamba.com/vw/gallery/pix/654423.jpg)


(http://images.thesamba.com/vw/gallery/pix/654419.jpg)


Some cracks in the dash:

(http://images.thesamba.com/vw/gallery/pix/654410.jpg)


(http://images.thesamba.com/vw/gallery/pix/654411.jpg)


I cut out the original gauge area and plan to replace it with an engine turned stainless panel:

(http://images.thesamba.com/vw/gallery/pix/654412.jpg)


My gas cap, mold and a big hole in the hood.

(http://images.thesamba.com/vw/gallery/pix/654395.jpg)


(http://images.thesamba.com/vw/gallery/pix/654413.jpg)


(http://images.thesamba.com/vw/gallery/pix/654414.jpg)


(http://images.thesamba.com/vw/gallery/pix/654416.jpg)


First test fit showed that the hole needed a little clearance around the cap latch. Great thing about fiberglass, if at first you don't succeed, grind it out and glass it back up.

(http://images.thesamba.com/vw/gallery/pix/654420.jpg)


(http://images.thesamba.com/vw/gallery/pix/654429.jpg)


I still need to glass in the little area I cut out of the latch but over all I think it looks pretty good. A little epoxy filler to clean it all up and I am done.

(http://images.thesamba.com/vw/gallery/pix/654427.jpg)


(http://images.thesamba.com/vw/gallery/pix/654428.jpg)


Time for a Guinness.

--louis

Very cool mod!

Painted my wheels last weekend. They came out pretty well with the single stage paint, no runs, but I do have some orange peel. Not sure if I will try to color sand them yet or just live with it.  :-\

(http://images.thesamba.com/vw/gallery/pix/664067.jpg)

(http://images.thesamba.com/vw/gallery/pix/664066.jpg)

(http://images.thesamba.com/vw/gallery/pix/664068.jpg)

--louis

PS: After I painted them my friend Bobby pointed out that the set I had widened did not have any valve stem holes.  :-[

I'd say live with the orange peel, it's a Manx! But the valve stem hole, now that's a problem :-\

After a little reading on the interweb I found out I could just drill a 5/8" hole. I started last night slowly working my way up but then realized my 5/8" bit is for a 1/2" drill and I only have a 3/8". Sounds like a trip to HF is in order.  ;D

--louis

Don't fill bad louis, I was watching OC Choppers , One of the two times I could take those Idiots. They built a bike, painted the tank and were assembleing and realized they forgot to weld a fuel bung in tank.

I used to watch that show to see the fab work but I cant stand it now.

--louis

I would think about running the stem on the inside. It would look clean, little harder to fill though.

But the fronts still have it on the outside. Might as well make it match.

Did not see that, I agree.

I will say that getting the wheels done has been an eye opener. I figured it would be cheaper to go with steel rims than a set of mags. (My first choice was Crager SS rims) But after buying the rims, having 2 widened, having them sandblasted and then painting them with real paint it has been almost the same price. And that is if I don't count my own time. I probably have $700 in the rims now and I am not totally happy with them. Mind you I could have saved a bunch by going stock width, hand stripping and painting them with rattle cans.

--louis

My friend Bobby came over today and after 4 hours of cussing we got the body mounted to the pan and the seats bolted in for the first time. The body has always been a little narrow, this was evident from the fact that the stock seat supports had cut into the mounting lip in the past. We tried a couple of things to get it to fit, including using a bottle jack and slowly stretching it for the past week. No matter what we did the body was about 1 1\2" narrower than the back of the pan. So it was decided to cut the shell on each side at the rear corners and spread the body out some. You can see the cuts in the pics and this allowed us to get a perfect fit of the pan and body. I will use some fiberglass cloth and fill in the gap hopefully next weekend. Once the body was spread out the seats fit much better so we drilled the holes. I still need to weld in some 1/8" stock to reinforce the mounts. I also want to weld in some 1"x1" tubing around the perimeter of the pan when the body bolts go to strengthen it. That will be the last of the welding on the pan. (crosses fingers)

(http://images.thesamba.com/vw/gallery/pix/666655.jpg)


(http://images.thesamba.com/vw/gallery/pix/666656.jpg)


(http://images.thesamba.com/vw/gallery/pix/666657.jpg)


(http://images.thesamba.com/vw/gallery/pix/666658.jpg)


(http://images.thesamba.com/vw/gallery/pix/666659.jpg)


After we bolted the seats in we just had to climb in and sit in it.  :lol:  It felt really good to have the body finally bolted to the pan.

--louis

Looking good Luis!  I'm waiting for some brake lines to get plumbed.   ;D

good job there louis. keep it up . BTW cool neiborhood you live in with all the trees 8). GITER DONE there sir . UD .

I took the day off today so I could graft in the new rear fender sections.  My friend Bobby came over to provide an extra set of hands and also took the pics.


First two shots are from last weekend when I glassed up the cuts I made in the shell to fit it to the pan:

(http://images.thesamba.com/vw/gallery/pix/673550.jpg)


(http://images.thesamba.com/vw/gallery/pix/673551.jpg)


First we drilled a few holes and used sheet metal screws to hold the  new fender sections together with the shell:

(http://images.thesamba.com/vw/gallery/pix/673552.jpg)


(http://images.thesamba.com/vw/gallery/pix/673553.jpg)


Then we flipped the shell over and I used a jigsaw to cut both the shell and fender sections so they would match:

(http://images.thesamba.com/vw/gallery/pix/673560.jpg)


(http://images.thesamba.com/vw/gallery/pix/673561.jpg)


Fitting up the new sections to check for fit:

(http://images.thesamba.com/vw/gallery/pix/673562.jpg)


Then we used some scrap 18 ga sheet metal and sheet metal screws to hold everything together:

(http://images.thesamba.com/vw/gallery/pix/673556.jpg)


(http://images.thesamba.com/vw/gallery/pix/673557.jpg)


(http://images.thesamba.com/vw/gallery/pix/673563.jpg)


Shot of me glassing in the new sections.

(http://images.thesamba.com/vw/gallery/pix/673558.jpg)


The bracing removed:

(http://images.thesamba.com/vw/gallery/pix/673555.jpg)


(http://images.thesamba.com/vw/gallery/pix/673554.jpg)


(http://images.thesamba.com/vw/gallery/pix/673555.jpg)


Next weekend I will layer in some mat on the bottom and top then coat the top with some epoxy based filler.

Thanks,

--louis

Hi Louis

Looking good , glad to see they were a good fit .

Just a tip , on my Manx's I glass in a length of 40mm flexible rubber hose each side from front to back , from inside the ridge on the rear arch , down the side , ending at the front bunkhead panel. Hold the tube in place with a hot melt glue gun, then glass over the top . This puts a ton of strength into the body to help prevent cracking , and is also great for wiring , just remember to feed a bit of string through the hose before you fit it , for pulling wiring through .

I get the hose from a Koi carp/ garden pond shop .

Rob

That is a great idea Rob. I know the original Manxs had something like that but I guess they quit doing that when Bruce left the company and quality took a back seat. Thanks again for making up those fender sections. Getting those on is a major step forward in resurrecting this old girl.

Thanks,

--louis

I managed to slip out into the garage tonight and start working on the pan braces. Hopefully these will stiffen the pan and body some. I have put the body in summer storage, meaning in the back yard under a tarp, until I can get the pan rolling. Then I will get back to the fiberglass work in the fall when it cools back off.


I started off with some 1" x 1" steel tubing:

(http://images.thesamba.com/vw/gallery/pix/676798.jpg)


Bent it to fit the body with the redneck tube bender (sawzall).

(http://images.thesamba.com/vw/gallery/pix/676799.jpg)


(http://images.thesamba.com/vw/gallery/pix/676800.jpg)


Tubing was not quite long enough so I have to add an extension:

(http://images.thesamba.com/vw/gallery/pix/676801.jpg)


A piece of 1/8" plate will anchor it at each end:


(http://images.thesamba.com/vw/gallery/pix/676802.jpg)



I also plan to use some 1/8" flat stock where the seats bolt in and weld it all up together. 

--louis

Great minds think alike dude - I did the EXACT same thing on the SR I just built - I will post some pic's soon  ;) :)

Please do. I would like to see what you did.

--louis

Like I said dude Pretty much EXACTLY the same thing apart from the plate at the front, I "puddle welded" the box section to the pan from the TOP and welded up ALL the "slices" I had made, Then drilled through all the original pan holes, and before painting I ran a bead of seam sealant down each side of the box to fill the gap - The pan was SOOOOOOOOOO much stiffer when it was all finished  :)

Oh I will be picking up a certain little package for you this weekend by the way  ;) ;D

Cool, on both parts. Good idea with the seam sealer too. I hope to have the pan to the blasters by the end of the month. BTW, is the SR yours? I know where one is I have had my eye on for a few years. Same guy I got the Manx from has one. But that is a few projects down the road.

--louis

Na I built the SR for a friend for Volksworld shoew this year - Should be being featured VERY soon  :)

There has been a change of wheel plans. I got annoyed with the steel wheels and sold them over the weekend. I also ordered a set of these:

(http://ecx.images-amazon.com/images/I/51j4aNzqcWL._SL500_AA300_.jpg)

American Racing Torque Thrust D's (2 14x6s & 2 15x8.5s) and I am looking at 205/70R14s (same height as 165/15s but wider) & 235/70R15s BFGs w/ raised white letters front and back.

I am also reconsidering color choices with the new rims. (Plus the wife hates the orange color) I am thinking one of the following:

Close to guardsman blue:

(http://www.eastwood.com/media/catalog/product/cache/1/image/250x160/9df78eab33525d08d6e5fb8d27136e95/p39071.jpg)


Gee, where have I seen this color before:

(http://www.eastwood.com/media/catalog/product/cache/1/image/250x160/9df78eab33525d08d6e5fb8d27136e95/p32661.jpg)


Purple, maybe with flames?

(http://www.eastwood.com/media/catalog/product/cache/1/image/250x160/9df78eab33525d08d6e5fb8d27136e95/p38403.jpg)

My wife is pulling for the purple but I am not sure that I am manly enough to pull it off. I would list it as third. I do think it needs to be a bright color with the dark rims. I think the bright blue with a white top and the raised white letter tires would look pretty good. Any input? If you have another suggestion, post it. I am not really good with colors. Oh and no reds.

Thanks,

--louis

Kawasaki green

I hope you're not planning on disc brakes with those 14's...

And I'm partial to metalflake orange myself!

Nice wheels ! I like the blue and the green. ;)

Nope, it will be drums w/ adapters all the way around. A metal flake paint job would be my first choice but I doubt its in the budget. And then there is the issue of actually finding someone who could do a good metal flake paint job.

--louis

You've done a great job by yourself so far, I think you should set up a makeshift spray booth and give it a try.

I have been thinking about it. I may try to get some quarts of paint and play around a little.

Thanks,

--louis

I say lemon yellow, like on a Suzuki dirt bike

Ohhhhh you're right, yellow would look great, too.

My best friend's bug is yellow and it would be a little weird to have matching cars. What about this green in a heavy metal flake?

(http://www.eastwood.com/media/catalog/product/cache/1/image/250x160/9df78eab33525d08d6e5fb8d27136e95/p38399.jpg)

I am thinking kind of Gasser colors.

--louis

Looks like a booger

Not that I intend to impose my opinion on you, but:

Buggies that are done in "modern" colors and styles usually turn me off.  So I think if the color choice stays close to looking like an "old Manx" color, you can't really go wrong.

The bright blue with white top would be great.  That purple shown looks too modern to me.

The purple is actually '70 Cuda Plum Crazy. (Monitor may make it look different.) I am thinking a blue along these lines w/ big bass boat flakes:

(http://lh3.ggpht.com/wheelerdealerblog/RywQJFHG3aI/AAAAAAAABUA/8wp9AzEdjB8/DSCF6427.JPG)

I have been reading up on spraying flake and it looks doable. I may try to get some small quantities and practice on some spare fenders.

--louis

Good choice on the wheels but not too sure about the 14`s. A friend of mine re gel coated his buggie with BIG flake blue and it looks awesome.

Manx's originally were offered from Bruce Meyers w/ 14x7 & 15x7/8 rims depending on what tires were going to be used so I decided to KISS and do the same. Plus it lets me run a 70 series tire for a taller sidewall without going really wide/tall in front. I was trying to keep it around 26" in front and 27' to 28" in the rear. The combo should give a nice rubber rake to the buggy. (At least I hope.) And before anyone starts, no I am not running bias-ply tires.

Thanks,

--louis

My old paint instuctor use to put a ball bearing in his spray gun cup to keep the large flake stured up, Never tryed it so I do not know. In the new Hot Rod mag there is a artical on heavy metal flake paint jobs.

but only if you use a siphon gun, gravity fed gun it will just make a good stopper

That's funny, I was actually thinking "maybe Plum Crazy would be nice" when considering the purple.  My grandfather had a 71 Super Bee in Plum Crazy with white top & interior, so I am familiar.   ;)

Here is the new version.

(http://4.bp.blogspot.com/_GIlsuSZq_VM/SuHRUVLfsxI/AAAAAAAAYzQ/1bimXvc8c6o/s1600/2010%2BDodge%2BChallenger%2BPlum%2BCrazy%2B1.jpg)

--louis

Couple of Metal Flake Candy colors:


(http://www.tcpglobal.com/kustomshop/images/UKB8303.jpg)


(http://www.tcpglobal.com/kustomshop/images/UKB8308.jpg)


(http://www.tcpglobal.com/kustomshop/images/UKB8315.jpg)


(http://www.tcpglobal.com/kustomshop/images/UKB8311.jpg)

These are concentrates so you can vary the darkness.

--louis

I'll think the yellow metalflake will look insane on your Manx  :o

gr
Wout

Louis, mine is candy apricot flake.

I love green flake too. 14 rim in front looks very good!!! I like a lot old Ansen wheel too for a pure 70's buggy.

I love metalflake buggys! Especially this Manx:

[attachment=1]

That looks like a root beer color metal flake. Veddy Cool!

I showed the wife this orange Manx and may have convinced here that orange is a good color. (She doesn't like orange because it is a rival football team's color. Go fig.  ::)  )

--louis

LOL GO with RED!!! LOL

Nice project thread you have.
I had same problem as you to pic up the right color for my Beach buggy. I had it painted flake green..

(http://i10.photobucket.com/albums/a104/fgronlun/semester2008/Picture045.jpg)
(http://i10.photobucket.com/albums/a104/fgronlun/semester2008/Picture036.jpg)

r. Fredrik

Sweet looking buggy!

--louis

Need more inspiration to convince your wife for a orange buggy?!  ;)
This is what reminds me on orange ones!  ;D

[attachment=1]

You don't have a hair on your ass if you don't clone this car louis :o :o

Your right, I have seen the light. I want my buggy to look just like that. Bet those wheels are great in the sand.  ;D

--louis

dude can you PM me your address please  ;) ;D

Not red! (I want a red one...) :D

It has been a while since I have been able to make any progress on the Manx. Today I welded on the battery box using some home made brackets.

(http://images.thesamba.com/vw/gallery/pix/685853.jpg)


(http://images.thesamba.com/vw/gallery/pix/685854.jpg)


(http://images.thesamba.com/vw/gallery/pix/685855.jpg)


Thanks,

--louis

Want ?

I can't do red, wife has some superstition thing about red cars being bad luck. (Dont ask, I haven't figured it out after 14 years of marriage either.) I saw one of the new challenger's in a killer orange yesterday. I think I have found the color I want, at least this week  ::)

(http://www.shutterpoint.com/photos/T/698213-Bright-Orange-Challenger_view.jpg)


Oh, and if anyone is considering resurrecting an old buggy. save yourself the hassle and buy a new shell from Rob. I will have more in mine by the time it is painted than he charges for a new one. And from the fender sections he sent me I can tell his work is top notch.

Thanks,

--louis

Wow...that´s a good choice!  :o

Do you want to add some hotrodblack for details of the buggy, too?! Looks good...in my opinion!

I'm completly agree.. after rebuilding mine I think buying a new painted shell is the best way to save yourselfe and save money too!!!!

when you work out the costs a new shell just makes sence - I mean approx 1300 GBP for a NEW gel coat metalflake body with near a KILO of flake in each one, you don't get much better than that (sorry just doin my salesman bit for Rob  ;))

The Pan is Done! At least the welding anyway. I need to drill a couple of holes and then its time to send it to the sandblasters.


(http://images.thesamba.com/vw/gallery/pix/689876.jpg)


(http://images.thesamba.com/vw/gallery/pix/689871.jpg)



The next couple of shots show the finished bracing for the pan, seats & seat belts welded in:


(http://images.thesamba.com/vw/gallery/pix/689874.jpg)


(http://images.thesamba.com/vw/gallery/pix/689879.jpg)


(http://images.thesamba.com/vw/gallery/pix/689872.jpg)


(http://images.thesamba.com/vw/gallery/pix/689873.jpg)



A couple of shots of the battery box mounted without the body in the way:


(http://images.thesamba.com/vw/gallery/pix/689875.jpg)


(http://images.thesamba.com/vw/gallery/pix/689878.jpg)



My new rims also showed up this week. (14x6s front and 15x8.5s rear) My Mastercraft AT tires (195/75R14s & 235/70R15s) show up next week and I hope to get them mounted soon. I want to thank everyone who gave input either on the forum or through PMs on the rims and tires.


(http://images.thesamba.com/vw/gallery/pix/689869.jpg)


(http://images.thesamba.com/vw/gallery/pix/689870.jpg)


Thanks,

--louis

Lookin great, Louis! That pan looks sturdy, and the wheels are a very nice choice.

Keep it up!

Hey Zach, you get my PM on the rear seat area?

--louis

Ok, I want a red one, all complete and running on BRMs with an IDA stroker motor in the back! ;)


Louis, the wheel choice is superb, a friend of mine had an orange SWB GP buggy with the same wheels and it looked great! ;D

Ohhh those wheels are gonna look good!

Louis, Didnt you have a bug at one time, Looking good and great choice on wheels

You might want to consider having the lips on those Americans polished. I had the ones on my old Nova done and it made a huge difference.

I still have the '66 bug, its patiently waiting on this three month quickie to get done.  ::)



I have been thinking about it too. I will probably wait on it though as I really want to get this project done by the end of the year and if I keep adding things, it will never get done. It has already grown from what was supposed to be a 3 month throw her together and drive it to a year and a half complete rebuild. (And that is if I push hard to get it done by the end of the year.) Best laid plans of mice and men.

--louis

Like These? ;D or full polish

Like This.
(http://i85.photobucket.com/albums/k74/Bryan67photos/Nova005.jpg)

Nice wagon.

--louis

Thanks. It was fun while I had it but just couldn`t live without a VW I guess.

For kicks and giggles I decided to mock up the buggy with the new rims & tires to see what it would look like. I was a little concerned that the front tires were too wide for the look I want but I am happy with them now that I see them up against the buggy. I may go a little lower than this in the end but not too much. I still have not been able to get the rear tires to seat correctly so I may end up taking them to the tire shop.

(http://images.thesamba.com/vw/gallery/pix/697145.jpg)

--louis

nice

Looks good but maybe the front tires are a little tall.

That stance looks badass! I like the thread on the back tires as well 8)

LOVE IT!

That looks great ! You should go with a red/orange metalflake like the body color is now.

Looking good dude (ps I recieved your package back the other day "undelivered"  >:( I will resend it on tuesday!)

Been working on the fenders over the past few days. Got one sanded down and the other ready to be sanded. I still need to do a little shaping and some more filler before they are done.


Passenger side ready for filler and final shaping:

(http://images.thesamba.com/vw/gallery/pix/698677.jpg)


(http://images.thesamba.com/vw/gallery/pix/698678.jpg)


Grinding down the driver's side before laying 'glass.

(http://images.thesamba.com/vw/gallery/pix/698679.jpg)


(http://images.thesamba.com/vw/gallery/pix/698680.jpg)


Waiting on it to dry:

(http://images.thesamba.com/vw/gallery/pix/698681.jpg)


(http://images.thesamba.com/vw/gallery/pix/698682.jpg)


It has been raining non-stop here for several days and the temp is up in the '90s. I have been trying to work on it early in the morning before it gets too hot. I am so ready for fall.

Thanks,

--louis

PS: No worries Lee. I am sure it will get here sooner or later.  :-*

I have been down for the past week with a major sinus infection. That and the fact that we have had 100+ temp and 98% humidity for the past couple of weeks means I didn't get anything done last week. But if I go too long without working on the Manx I feel like a bad parent so I sucked it up today and spent a couple hours sanding on it. Got the driver's side fender roughed in and most of the Passenger's side fender filled and sanded.

(http://images.thesamba.com/vw/gallery/pix/701778.jpg)


(http://images.thesamba.com/vw/gallery/pix/701779.jpg)



I also started dealing with this issue. As you can see the lip does not line up correctly with the top hat. I drilled a hole in the front and put in an eye bolt backed with a fender washer. Then hooked up the come-along and started stretching it. I used the halogen lamps in the bottom of the picture to add a little heat as well. It seems to be working but it's not where I want it just yet.

(http://images.thesamba.com/vw/gallery/pix/608438.jpg)


(http://images.thesamba.com/vw/gallery/pix/701780.jpg)


Time for a beer.

--louis

Finished up block sanding the rear fenders where the new sections were grafted in. I also finished up another small repair and mounted the rear tail lights and license plate light. I hope to get those off to the chromers soon. I still need to finish up the repairs where I widened the rear of the body and glass in the wire tubes since mine are missing and clean up the mounting flange but that is it for the shell. Still lots to do to the hood though so the itching is not over yet.


Fenders Done! The profile may not be exactly the same from side to side but as Bill Hines once said "You can only see one side of the car at a time." Or something to that effect.

(http://images.thesamba.com/vw/gallery/pix/703462.jpg)


(http://images.thesamba.com/vw/gallery/pix/703466.jpg)


(http://images.thesamba.com/vw/gallery/pix/703469.jpg)


(http://images.thesamba.com/vw/gallery/pix/703465.jpg)


Tail lights mounted. I am still not sure if I will run the solid red lenses of the Euro style. I do plan to convert them to LEDs though. I was thinking of adding a backup light w/ a red housing as a third brake light right above the license light but I may not.

(http://images.thesamba.com/vw/gallery/pix/703463.jpg)


(http://images.thesamba.com/vw/gallery/pix/703464.jpg)


Inner rear fender area. This section has a big hole where the original mounts were ripped out. I have some sturdier mounts in mind to help support this area. A friend of mine is going to make up a rear seat back and bottom which I will Velcro in place. That way they can be removed and a box can be installed for storage on longer trips. If I get adventuresome, or lose my mind, I may try to make the rear box out of fiberglass.

(http://images.thesamba.com/vw/gallery/pix/703467.jpg)


Boy I can't wait to see this all in one color. It almost looks like a real Manx body. I found a painter up in Tenn that will be doing the metal flake paint. Bass boat flakes, here I come.

(http://images.thesamba.com/vw/gallery/pix/703470.jpg)


Thanks,

--louis

Oh yeah, forgot to post a pic of the front bulk head area I pulled back into shape

(http://images.thesamba.com/vw/gallery/pix/703468.jpg)

--louis

"If cars were meant to be symmetrical, they'd say "FORD" on one side, and "DROF" on the other ;)

Looking good, Louis!

hand made staff never looks simmetrical!!!  ;)

my car isn't simmetrical!!!! but it looks good the same!  ;D ;D

really good job.

Picked up my pan and suspension parts from the sandblasters today. The pan will get a coating of rust bullet and then bed liner. The suspension parts will probably just get a coat of rattle can black.

(http://images.thesamba.com/vw/gallery/pix/707242.jpg)


(http://images.thesamba.com/vw/gallery/pix/707243.jpg)


--louis

I was home the last two days with a sinus infection, the second one this month. So I took the opportunity to paint the suspension parts and reinforced the tunnel access hole with 1/8" x 1" flat stock.  Hopefully this weekend I can get the first coat of rust bullet on the pan. Oh, and the temp outside today is 112+ deg F.

(http://images.thesamba.com/vw/gallery/pix/709553.jpg)


(http://images.thesamba.com/vw/gallery/pix/709554.jpg)


In other news I am looking at FI for the engine instead of the 40 IDFs I had planned. (Mild 1835) If anyone has any input on running a buggy with FI I would like to hear it. I am thinking a Megasquirt brain box and one of the Mexico FI setups as see here:

http://www.thesamba.com/vw/classifieds/detail.php?id=519841

It looks like a nice clean simple setup, but in the end, price may be the deciding factor. I could sell the freshly rebuilt Italian IDFs to recoup some of the cost.  Still, I need to get this buggy finished some time this century. I am already getting grief from certain parties at the length of time this 3 month build is taking.  :D

It also looks like I will need to come up with another BJ beam as the one I sent to the sandblasters came back with several holes in it. Two steps forward, etc, etc.

Thanks,

--louis

Hey Louis I got a Beam for you ;D ;D
http://www.thesamba.com/vw/classifieds/detail.php?id=992523

Nice project to follow, but what I don t understand is why aren t you/people using Bus ('66) taillights and place them horizontaly,
saw that once and looked the part on buggies.
Sorry for this comment. :-[ :)

Kind regards edgar

Nice beam Shubee but I don't think I want to drive to Tejhas to pick it up.  ;)

--louis

Hi Edgar,

I dont think I have ever seen bus tail lights on a buggy before. It probably would look good though. Thanks for the comment.

--louis

I can ship it to you LOL  Lights look good on the Buggy but I think you are starting to part out the 66?? Why not use the beam in the 66 since you are going for the 6 inch narrowed  look in the front and 2 clicks in the rear  Dont Ya just love that Look??? LMFAO!!! ;D ;D

I just borrowed the tail lights, they are not that hard to come by. I probably will use the '66 beam since I have a lowered 2" replacement already.

--louis

Jeff Denham contacted me yesterday to let me know my heads are ready. This is the second set of heads done for me by Jeff and as always the work looks top notch. They are a small oval port with 40 x 35 valves. Engine will be an 1835 w/ a Webcam 163. Should be a nice little cruiser motor. Here are a couple of photos:

(http://images.thesamba.com/vw/gallery/pix/710076.jpg)


(http://images.thesamba.com/vw/gallery/pix/710075.jpg)


Thanks,

--louis

Remembering back in the day most of the Manx bodied cars I saw had '65-'66 Mustang tail lights.  The fit well and looked good.  You probably won't want to do that, but there sure were a lot with those on them.  Hey I have a set of the smaller taillights from an oval.  They look good, but need upgrading to be seen.

I never cared for the mustang tail lights on a buggy. I thought about the Oval style lights but I am already worried about getting rear ended. I think I am going to try and rig up a third brake light some how. I plan to convert the ones I have to LEDs as well which should be fun when I do the wiring. Speaking of Donny, you want to fly out and stay a week in Florida and wire this thing?  ;D

Thanks,

--louis

Louis, you got the look right. All you need to do now is chrome the T lights and Lic. light.

I agree, it looks right. And the license plate light housing can just be polished, if you decide to go that route ;)

Put a coat of Rust Bullet silver on the top of the pan. I decided to go ahead and get a coat on due to the high humidity, as the pan was already developing a nice coating of surface rust. Unfortunately, I miscalculated how much I needed and only had enough for one side. Next time I will know to order at least a quart.


(http://images.thesamba.com/vw/gallery/pix/710764.jpg)


(http://images.thesamba.com/vw/gallery/pix/710765.jpg)


I am almost tempted to leave it silver but I plan to put a coating of the black top coat they make after I have welded on the skid plate.

Thanks,

--louis

Will THe Skid Plate Fit With The 4 Quart Sump you will be Using?? LOL ;D

Hmmm... it does look good in silver...

That sounds like fun, however with money going the way it is around here I better stay put.  You might want to check out this site: http://www.rebel-wire.com/vwkits.shtml.  They have a 12 circuit kit for a bug for $185.  They come highly recommended by the H.A.M.B. which is a pretty cool place to check out Hot Rod stuff...

Actually, that is the same kit I was looking at already. Looks like a nice setup for a good price. And I agree, the HAMB is a great site.

--louis

I am probably going to rewire my '66 with that kit.  On another note, my friend Dave Rosensteil today agreed to remove the dents from my front fender.  You keep asking if I had it fixed.  It wont be for a few weeks, but he will do it.  I could not ask for a better person to do my body work. 

Cool!

--louis

Put a coat of Rust Bullet on the bottom of the pan and painted the pan head and rear forks with Black Shell. The silver area will get coated in bed liner.


I wanted to treat the inside of the tunnel for rust and came up with this solution. A bottle of Mar Hyde and a $10 garden sprayer. I sprayed it in the tunnel and then rotated the pan around a few times to get everything coated. Seems to have worked pretty well:

(http://images.thesamba.com/vw/gallery/pix/713495.jpg)


First coat of Black Shell:

(http://images.thesamba.com/vw/gallery/pix/713496.jpg)


(http://images.thesamba.com/vw/gallery/pix/713497.jpg)



My "new" beam for the buggy. It came off my barn find '66 from Arizona so it's rust free. The original ball joints are even in factory new specs for wear. Stripped it down and started wire brushing it off:

(http://images.thesamba.com/vw/gallery/pix/713498.jpg)



--louis

Hey Louis You are making a mess of that Garage Floor LMAO!!! ;D ;D

Yeah I have already promised the wife I would paint the garage floor once I am done with the messy stuff.  ;)

--louis

I seam sealed the pan yesterday and put a coat of Duplicolor bed liner on the bottom tonight.


(http://images.thesamba.com/vw/gallery/pix/715580.jpg)



(http://images.thesamba.com/vw/gallery/pix/715581.jpg)



This update brought to you by George Killian's finest Irish Red.  :lol:


--louis

Finished painting the pan tonight. For some reason I ended up with a lot of texture in the Rust Bullet Black Shell. I am not sure if it is from the high humidity or if it was just some old product. If I were doing a show car I would probably spray it, but for a buggy that will get driven a lot, I am okay with it.

I used a regular brush to apply both the rust bullet and the Dupli Color Undercoating since I did not want a lot of texture in the top. I am still deciding on if I want to go without any floor covering or if I will use a black rubber mat on the floor.

I am also debating if I want to make a 1" to 1.5" lift for the body. More for some added head room when the top is on than anything. I am 6'4" and windshield is just at the top of my head.

Now it is time to start prepping and bolting up the suspension.


(http://images.thesamba.com/vw/gallery/pix/716851.jpg)



(http://images.thesamba.com/vw/gallery/pix/716852.jpg)

--louis

What seats are you going to use? Maybe you should use some lower ones.

I have a set of EMPI suspension seats and they are on the floor already. (And leaned back some from stock.) I don't think it would be too hard to fab up something like this:

(http://images.thesamba.com/vw/gallery/pix/650651.jpg)

That is a 3" lift which is more than I want. I would stick with a 1" or 1.5" x 1.5" tubing. It will also give me a good solid mounting point for the cage.

--louis

Hi Louis,
I'm building an old school Baja Bug but I've a problem....maybe you can help me.
The rear deck lid (like Manx one) doesn't match the body so I need to straighten it.
I tried to warm up and straighten the piece with a jack positioned in the center, but this did not work. When I removed the jack the piace is returned in bad shape.
How can I do?

(http://img695.imageshack.us/img695/9421/124cf24fb075dbbff2483d5.jpg)

Thanks

Mauro

Hi Mauro,

I used a combination of heat and stretching to get it back into shape. I had to keep pressure on it for several days. It also required that I stretch it farther than the original shape as it would spring back. Hope that helps.

--louis

aaah ok......for several days!
I had warm up only one time. I will try again

Thanks
Mauro

Been working on the lift for the buggy but not many pics. Here is the 1.5" x 1.5" lift tack welded for mock up. The sheet metal sections in the picture will form the section over the napoleons hat.

(http://images.thesamba.com/vw/gallery/pix/721716.jpg)


Since deciding on the lift I am thinking about running side pods to camouflage the lift. I was also thinking I might be able to hide some storage compartments in the side pods as well. Any one ever do that? I know Meyers offered some pods with built in storage.

--louis

Louis, personally I wouldn't use the sidepods - I think it tries to modernise the design of the classic buggy just too much. I'd make some nerf bars that stick out from the lift kit and use them to fit jerry cans and a couple of tool chests to if you really want the extra storage.

I go back and forth. I like the way it looks on this buggy:

(http://i190.photobucket.com/albums/z271/Siggymanx33/outerbanks2007046.jpg)


But as you say, not very traditional looking.

--louis

Spent 5 hours fabing up the front crossmember today out 14 gauge sheet metal and I am beat. Got everything tacked together and the body mocked up for a trial fit. Looks like everything is where it is supposed to be so that was a relief. Now I need to finish welding and grinding everything.


(http://images.thesamba.com/vw/gallery/pix/723203.jpg)


(http://images.thesamba.com/vw/gallery/pix/723204.jpg)


I think the 1.5" lift will be just right for what I want. Oh, and I think I have talked myself out of the side pods again. But I am considering the side nerf bars built so I could put a gas can and some tools in it.

--louis

Louis, I have always liked the side pods and regardless of what folks say they were doing them back in the late '60s so that should be traditional enough.  I think they give it a finished look.  If you plan to do a lot of off road stuff then perhaps the side nerfs would be better.  If you are just running on the beach then it wouldn't matter.  I just remember Steve McQueen in the Thomas Crown Affair blasting on the beach in his Manx....

Hi Don, hows it going? I think the most off road driving this buggy will see is some trail riding when I go camping. I am still kicking the idea around for the side pods but who knows. Right now I am trying to get it up and rolling by Oct 23 when it is supposed to go get a full cage installed. A lot of work ahead to get there.

Thanks,

--louis

For what its worth I'll offer my 2 cents worth, I agree with Donny. I recall the 60's/70s well, when two distinctive types of Manx's were popular.
The offroad look with Jackman's/Norseman's and KC Hi liters or the street look, slightly lowered, side pods,60 series tires and hard/soft tops.

The choices are yours of course, but if it were mine I'd lay in woven roving over cardboard tubes and foam filled plastic bags in the side pods.
Cheap insurance in a dangerous world....IMHO  ;)

Sorry, but I`m going with the unpopular vote. I say no side pods and the bottom half black.

Started modifying the front beam today following the advice from Jeff Hibbard's book for off road buggies.  I had another beam sandblasted but it turned out to have a good bit of rust in the towers so I chunked it and went with this one instead. This one is rust free and I stripped it by hand with a wire brush.


(http://images.thesamba.com/vw/gallery/pix/725312.jpg)


Close up of one of the shock tower braces made from 1.5x1.5 tubing:

(http://images.thesamba.com/vw/gallery/pix/725316.jpg)


I used a torch to burn out any grease from the tower seams then cleaned them up with a grinder to make the seams were even. After that I fully welded the them:

(http://images.thesamba.com/vw/gallery/pix/725314.jpg)


Adjuster mocked up in position to give 3" lift from stock:

(http://images.thesamba.com/vw/gallery/pix/725315.jpg)


My plan is to finish up the adjusters next weekend. I am having new Febi ball joints pressed into the trailing arms and then I will install a hook and pin stop. Some Fox class 11 shocks are also in the plans but I will have to wait on those for now. 

Thanks,

--louis

I managed to slip out into the garage tonight and get the adjusters welded into the beam. After comparing the angles for the torsion leaves it looks like I ended up 2 degrees raised from stock. The stock angle for the grub screws were 50 top and 55 bottom. After welding mine were 52 top and 57 bottom. Hopefully that will not be an issue.

(http://images.thesamba.com/vw/gallery/pix/725725.jpg)

Thanks,

--louis

Went home early today with the goal of getting the trans buttoned up and installed. This is the trans that the locash guys put together for me and it has been sitting under my work table for the last year waiting on me to install the torsion tubes.

Here is a shot of all the rear suspension parts. Trans is stock geared with a 4.12 R&P, threaded super diff and welded 3rd & 4th gears. I added braces to the stock side covers and a longer clutch arm. Also shown are the adjustable spring plates, stock torsion bars, stock rubber torsion bushings, the requisite chrome torsion tube caps, rear wide 5 to Chevy adapters, bus snubbers, spring plate retainers and new factory torsion tubes with 1 piece boots. 

(http://images.thesamba.com/vw/gallery/pix/729737.jpg)


This shot shows the difference in the two clutch arms. Should make that Kennedy stage 1 fell like a stocker.

(http://images.thesamba.com/vw/gallery/pix/729738.jpg)


Here is the tranny dropped into place. It was at this point I realized the Bugpack side cover braces did not clear the frame horn flange so I will have to do some clearancing. While I am at it I think I will weld up the seam on the frame horn. I am still debating that last one.

(http://images.thesamba.com/vw/gallery/pix/729739.jpg)


I sure hope the damn thing doesn't leak. I hate working on transmissions. I will do almost anything on a car but there are two things I will gladly pay someone else to do, wiring and transmission work.

--louis

Hahaha! I feel the exact same way! :D Looking good dude :)

Wow, its been almost 2 months since I have posted any real progress. Stuff has been getting done but none of it very picture worthy. Today though I feel I made some real progress. Got the rear suspension wrapped up and the rear tires mounted. As soon as the front disc kit shows up from So Cal Imports I will be able to get it rolling.


I hate mounting the rear trailing arms. I can never find a bolt the right length so I end up doing stuff like this:

(http://images.thesamba.com/vw/gallery/pix/760358.jpg)



Discs on one side, drums on the other?

(http://images.thesamba.com/vw/gallery/pix/760359.jpg)



This is better. I still need to run the brake cables/lines. A set of Fox shocks are on the wish list but for now the oil shocks will have to do:

(http://images.thesamba.com/vw/gallery/pix/760361.jpg)



Side shot. The cheap chrome torsion covers have already started to rust. Plus they seem thinner than the factory ones.


(http://images.thesamba.com/vw/gallery/pix/760360.jpg)



Last shot is of the trans mid mount and rear cage support Danny Gabbard made for me. I had a pic of the rear tires mounted up but it didn't come out and I am too tired to go take another so you will just have to wait.

(http://images.thesamba.com/vw/gallery/pix/760362.jpg)


Thanks,

--louis

I have not updated in a while, mostly because I am not sure if this is really of interest to you guys. I have sort of moved out of the Cal-look scene for a while. Really gotten heavy in to the buggy scene. Here is a shot of the buggy as a roller and a home built tubing bender I made based on plans from Got Trikes:


Vroom, Vroom! Still missing a few pieces but man what a difference from the start.

(http://images.thesamba.com/vw/gallery/pix/769265.jpg)

The single hoop is an original Meyers Manx hoop I picked up cheap. I am trying to figure out how to work it into the full cage but I may just end up using it for a template. I need to figure out how close the gap between the bottom to the tubes and the 1/4 x 1.5 flat stock that I will use as the base of the cage. I am toying with the idea of using some 2x2x.125 tubing I have left from the bender build but I have to think about it some more.


Speaking of the home brew bender:

(http://images.thesamba.com/vw/gallery/pix/769266.jpg)



My very first 92 deg bend  ;D Still working on figuring out the spring back. That is a piece of 1.75 x .125 DOM tubing.

(http://images.thesamba.com/vw/gallery/pix/769267.jpg)



A rather blurry pick of the other side. Like the HF Orange paint I chose? 

(http://images.thesamba.com/vw/gallery/pix/769268.jpg)



Look! Its Kid N Play!

(http://images.thesamba.com/vw/gallery/pix/769269.jpg)

Actually just my 40 IDFs waiting to get rebuilt here soon. Some more realistic 3" elements are already on order. I just sent my Bosch 010 to Dizzymeister Glenn Ring today for rebuilding (I hope) and once that gets back I should have everything to start assembling the engine.

--louis

Keep the updates coming it's a cool car  8)

louis you're buggy would be coolin orange with those american racing wheels  and  you look like a little boy who plays behind the wheels from his toy  ;D ;D........ ;)

and keep the updates coming

Thanks guys, I will keep posting updates. Its been a while since anyone has called me little.  ;D As a compromise with my better half I let her choose the color. She wants it purple so that is what is going to be.

Thanks,

--louis

PS: Here is something else I am working on. A Manx Club event to be held on the Outer Banks of North Carolina:

http://www.thesamba.com/vw/forum/viewtopic.php?t=449191 (http://www.thesamba.com/vw/forum/viewtopic.php?t=449191)

Finished rebuilding my 40 IDFs today. I had previously cleaned them in a little sonic cleaner I picked up from HF but there was still some corrosion from where moisture had gotten into the carbs. To clean this out I rigged up a little soda blaster using a HF spot blaster and some Baking Soda. It worked surprisingly well. The carbs are Italian IDFs that have seen a good bit of use before I got them and were pretty dirty. Now they looks almost like new.


Corrosion from the moisture:

(http://images.thesamba.com/vw/gallery/pix/772324.jpg)


(http://images.thesamba.com/vw/gallery/pix/772325.jpg)


Shot of me blasting the carbs. And yes, the baking soda got everywhere.

(http://images.thesamba.com/vw/gallery/pix/772327.jpg)



Carb body getting a quick dip in the sonic cleaner to remove any remaining baking soda. These little sonic cleaners from HF are about $80.00 and work really well for cleaning small parts.

(http://images.thesamba.com/vw/gallery/pix/772326.jpg)


Carb on the left is my "good" carb, the one on the right is my "parts" carb. (Also Italian.) It doesn't really come out well in this pick but both carbs were in about the same shape and now after the soda blasting the one on the left looks almost brand new.

(http://images.thesamba.com/vw/gallery/pix/772331.jpg)



Here you can see where it removed all of the corrosion:

(http://images.thesamba.com/vw/gallery/pix/772330.jpg)


(http://images.thesamba.com/vw/gallery/pix/772329.jpg)



Don't try this at home, at least not when the wife is around   ;) 

(http://images.thesamba.com/vw/gallery/pix/772332.jpg)



Clean carbs, check
Carb rebuild kit, check
Air cleaner bases, check
Brass stack, check
Tools, check
Scented Candle, check  :D

(http://images.thesamba.com/vw/gallery/pix/772333.jpg)



Finished product sans air cleaners. Still waiting on the 3" cleaners to arrive. I set up the carbs according the directions on Mark Harney's site.

(http://images.thesamba.com/vw/gallery/pix/772334.jpg)


Mark Harney's site: http://www.carburetorclinic.com/index.htm


Last shot is of my recently rebuilt Bosch 010 dizzy. I sent it off to Glenn Ring and he worked his magic on it and it looks like new. This is the second 010 I have had rebuilt by Glenn and his work is very good. Thanks Glenn!

(http://images.thesamba.com/vw/gallery/pix/772335.jpg)

Link to Glenn Ring's site: http://www.glenn-ring.com/bosch/
                                                                                       

I hope to start engine assembly here in the next few weeks.

Thanks,

--louis

Intersting device  :)

I saw those @ Rosmalen last month @KWF.

http://www.hbm-machines.nl/comasy/templates/Cats.aspx?contentid=237&catid=219&cat=Ultrasoon%20Reinigers

Carbs looking great!!!

gr
Wout

louis any updates ???

Funny you should ask:  ;D

Spent the day stripping the underside of the body of accumulated grime and paint to get it ready for the last of the 'glass work and hopefully paint. I picked up a Harbor Freight soda blaster for $99 and a 50 lbs bag of XL blasting media, $35, and went to work. I have to say that I was really impressed with the soda blaster. It stripped everything off except the 1/4" layer of crap in the back that looks to be a combination of dirt and engine oil. That stuff even gave the wire wheel mounted on a grinder a hard time. I was able to get 90% of the body done with the one bag of media so I will finish it next weekend after I run by HF and pick up another bag.


(http://images.thesamba.com/vw/gallery/pix/794667.jpg)


(http://images.thesamba.com/vw/gallery/pix/794668.jpg)


(http://images.thesamba.com/vw/gallery/pix/794669.jpg)


(http://images.thesamba.com/vw/gallery/pix/794670.jpg)


(http://images.thesamba.com/vw/gallery/pix/794671.jpg)


In other news, instead of fixing my hood I decided to order a new replacement hood for the Meyers. I am waiting on it to ship and it will hopefully be here in the next couple of weeks.

I also found out that Bruce and Winnie Meyers are going to be coming to the Manx Club event I am organizing in October. To bad it doesn't look like my buggy will be done by then. It would be really cool to get a picture of my buggy with the man himself.

--louis

Coooool!!  8)

New hood showed up today from the Meyers. It cost as much to ship the hood as it did to buy it. Also shown is the new dash I ordered a couple of weeks ago:

(http://images.thesamba.com/vw/gallery/pix/798826.jpg)


(http://images.thesamba.com/vw/gallery/pix/798827.jpg)


I am thinking of metal turning the aluminum insert for the dash. With any luck the body will be ready for primer in a few weeks. Budgeting for paint I figure I am in to this body for almost $2,500. Of course mine was in pretty sad shape when I started.

--louis

looking nice

More fiberglass work today. (itch, itch)


Started by hot gluing the wiring tubes to the underside of the body, then laying some cloth over that to make it permanent. Early Manxs came with these from the factory but my II, which was produced after Bruce left the company, didn't have them so I decided to add them:

(http://images.thesamba.com/vw/gallery/pix/802366.jpg)


(http://images.thesamba.com/vw/gallery/pix/802367.jpg)


(http://images.thesamba.com/vw/gallery/pix/802368.jpg)


(http://images.thesamba.com/vw/gallery/pix/802369.jpg)



The top lip of my new dash was warped so I am trying to straighten it some here in this pic:

(http://images.thesamba.com/vw/gallery/pix/802370.jpg)



Hood Part Deux. Waiting on the filler to dry so I can sand it:

(http://images.thesamba.com/vw/gallery/pix/802371.jpg)


(http://images.thesamba.com/vw/gallery/pix/802372.jpg)



Here you can see the 3" extension I added using a section from the original hood. The plan is to make the new dash removable and run the front hoop of the roll bar behind the dash. we will see how it works.

(http://images.thesamba.com/vw/gallery/pix/802373.jpg)


In other news I am buying the last of the engine parts I need. I did decide to go with a small stroker crank and picked up a 74mm CB 4140 crank a few weeks ago. That will give me a 74x92 or a 1967 which is also the year of the pan. If for no other reason I could not pass it up just for that. It should help out with the taller tires and possible Bus reduction gear boxes in the future.

--louis

good work louis as usual  ;)

Looks like your getting real close! So no more itching HUH ?? Looks ggod louis !!

Louis, what kind of tubing are you using? If it's clear poly tubing it's gonna be a bitch to pull thru, might want to get some clear wire pulling soap at an electric supply house, will save you a lot of mother f€%#ing when that time comes

Thanks for the tip, I will remember that.

Also thanks to everyone for the encouragement. Been dealing with a bad case of project burnout for the past couple of months. Hopefully make some more progress here soon.

Thanks,

--louis

I know that feeling Louis. But everybody tells me it will come back...  I will start to re-polish the Porsche 5 lug Erco's soon... ;)

I think all that fiberglass would get to me after a while, also. Will say I'm jealous, though. I'd enjoy a cool buggy project.

Yeah I much prefer working with metal to fiberglass. I am also itching to get on to the next project. (sorry, couldn't resist  ;) ) I am thinking of doing an all out baja next and I know of a rather crusty Oval sunroof car that would be the perfect candidate. Of course I still have that rust free '66 I need to do something with as well. So many cars to build and so little time.

Thanks,

--louis

Louis, whenever I get that feeling, and I get it a lot with the house I'm buiding, I just tell myself "it's not gonna do it itself", put my head down and get after it

Took a week's vacation in Arizona with the wife and while I was there Donny B. took me around to some of the Phoenix area VW shops. I think my favorite was Competition Engineering, they had some serious cars going together there. That got the juices flowing again so I was eager to get back home and do some work on the buggy. I decided to go ahead and start the engine assembly but first I had to build an engine stand using an cheap EMPI bench mount stand and a HF floor stand. It took about an hour of cutting and welding to get a useable roll around engine stand for a VW. Next a friend and I stripped down an old 1600 dual port donor motor for small parts. (crank gears, dizzy gear, etc) Then it was time to mount up the new aluminum case to trial fit the bottom end for clearance. The 74 CB crank and I-beams dropped right in and it doesn't look like I will need to do any additional grinding. Tomorrow I will finish mocking up the bottom end and check my deck height, then send everything out for final machine work. I should be able to get to final assembly in a few weeks.


Engine Stand:

(http://images.thesamba.com/vw/gallery/pix/811660.jpg)


Checking crank & cam clearance

(http://images.thesamba.com/vw/gallery/pix/811661.jpg)



ooo, shiney

(http://images.thesamba.com/vw/gallery/pix/811662.jpg)


Final specs on the engine:

Size: 1967
Aluminum Case bored for 94s & full flowed
74mm CB 4140 forged crank
5.4 CB I-beam rods
92mm thick wall AA cylinders
Webcam 163 Grind (falls between a 110 & 120)
40x35 small oval port heads
40 IDFs w/ 32 vents

This coming weekend I will be at the Outer Banks of NC to scout out the area for the October Manx Club event. Vince SurfNC is going to show me and a friend around and with any luck I can talk him into taking me for a ride on the beach in his blue Manx. It should be a lot of fun.


--louis

Louis, Hope you had a good time while you were here.  The engine looks nice.  Keep it up!

Decided to stay home today and recover from my recent trip to the OBX. And of course by recovering I mean spending some time in the garage working on my engine.  ;D

Whipped up a quick crank holder by welding an old gland nut to a piece of 1.5" tubing. Then hung the rods and checked the clearances. Everything was spot on.

(http://images.thesamba.com/vw/gallery/pix/814076.jpg)

Then buttoned up the case to check deck height. I came out with a positive deck height of .050 which was to be expected with the 5.4 rods, 74 crank and 92mm "A" pistons. My heads are set up to give 8.5 comp @ .060 deck height so I need to order some custom .110 shims. With the big bolts torqued to stock specs the crank turned nice and smooth.

(http://images.thesamba.com/vw/gallery/pix/814077.jpg)

I still need to check the crank end play but I don't have a socket big enough for the Scat gland nut. I need to order the shims and a few other small parts and then it will be time for final assembly.

--louis

PS: Here is a link to some pics of my buggy trip to the Outer Banks of North Carolina. It was cool to ride in my friend Vince's blue Manx on the beach.

http://www.thesamba.com/vw/forum/viewtopic.php?t=467411

Just get some .100" shims, close enough ;)

lol, I think you should stick to stitching.

--louis

Ouch! ;)

Seriously though, I can't see the harm in having a tenth or two more compression, especially if it means it saves you time, and money.

Your probably right but I already ordered the .110 shims from Brothers Machine. They should be here next week. Plus I didn't want to go below .060 deck just to be on the safe side.

--louis

I am waiting on some small parts to arrive for the motor so I decided to bend some tube this weekend. After a couple of false starts I managed to bend a rear hoop that fit. Fortunately I ordered 20" of extra tubing so I could screw up a few times. Tubing is 1.5" x .095".


Always remember, measure once, cut twice ;D  As you can see I am wearing proper eye and ear protection. A lot of good it did me when I dropped one of the dies on my foot while wearing sandals.   :-[


(http://images.thesamba.com/vw/gallery/pix/816458.jpg)



Drawing everything up on the floor. I used an original Manx roll bar as a guide. Mine goes all the way to the floor though.

(http://images.thesamba.com/vw/gallery/pix/816460.jpg)


It is sitting about 2" too high but that is better than 2" too short. I will shorten it when I make the base for the cage.

(http://images.thesamba.com/vw/gallery/pix/816461.jpg)


We mounted the windshield to the new hood so we could get the proper angle for measurements. Almost starting to look like a real buggy.

(http://images.thesamba.com/vw/gallery/pix/816462.jpg)


Hopefully next weekend I will get the front hoop and cross bars done.

--louis

PS: It's 105 deg F here today.

looks good louis , now just waiting for a nice metalflake paint and the manx will be ready  ;D

 ;)

Yeah I am still leaning towards a bright purple metal flake paint job.

--louis

Finally got a chance to get back out in the garage and get some more done on the roll cage.

A couple of shots with the main and front hoop mocked up with the hard top in place. I really like the look of the hard top but after climbing in and out a few times I don't think I am going to be able to use it. Folding my 6'4" frame up to get through that little opening is a pain and that's without the steering wheel.  I think I will have to go with a soft top of some sort instead.

(http://images.thesamba.com/vw/gallery/pix/826832.jpg)


(http://images.thesamba.com/vw/gallery/pix/826833.jpg)



Front and rear hoop mocked up into place. I found packing tape works real well to hold every thing up.   :D


(http://images.thesamba.com/vw/gallery/pix/826834.jpg)



A few shots showing how the front hoop will pass behind the dash:

(http://images.thesamba.com/vw/gallery/pix/826835.jpg)


(http://images.thesamba.com/vw/gallery/pix/826836.jpg)


(http://images.thesamba.com/vw/gallery/pix/826839.jpg)


Top and rear bars mocked up. I am still trying to decide if I like the kick up in the top bars. I bent them up so they would follow the hard top contour.

(http://images.thesamba.com/vw/gallery/pix/826837.jpg)


(http://images.thesamba.com/vw/gallery/pix/826838.jpg)


Final shot shows the bottom mounting plates for the cage being measured. When finished they will bolt on top of the body.

(http://images.thesamba.com/vw/gallery/pix/826840.jpg)


Thanks,

--louis

Tubes  look and fit as good as any I have ever seen! Good job and it looks cool with that hard top setting on body, Kinda swoopy. could you cut it up to fit around the cage ? Anyway keep up the good work !

Thanks for the kind words Danny. The top will fit with the roll bar but I  can't get in the car with the top on.  :D

--louis

So have you done any more on this project or has it stalled.  Curious to see how it's coming along.

Hey Donny,

Not much progress lately, been waiting for it to cool off some. I got pretty badly dehydrated working on it about a month ago made myself sick. I did get the main cage tacked together. This has been the first weekend where the heat was not triple digits but it's raining due to the tropical storm. It should be cool enough to get some progress here soon. How are things out your way. Here are a couple of more shots since my last update.


You can see I decided to go with straight top bars. I have also relocated the rear down bars, added the seat belt bar and front cross bar.

(http://images.thesamba.com/vw/gallery/pix/831913.jpg)


(http://images.thesamba.com/vw/gallery/pix/831912.jpg)


(http://images.thesamba.com/vw/gallery/pix/831911.jpg)


Engine mocked up so I can build the engine cage:

(http://images.thesamba.com/vw/gallery/pix/835043.jpg)



I am a little concerned about the clearance between the exhaust pipes and the intake manifolds. I may end up having to find some narrower intakes and have them match ported.

(http://images.thesamba.com/vw/gallery/pix/835044.jpg)


Also not shown are the bolt on side bars which are about half way completed.

--louis

Looking good Louis!  I can relate to the heat issue.  It's been a bear here in Phoenix this August with an average temp of 108.  This makes this August the hottest August on record.  It's so hot in the garage you need to start working before 6:00 and stop by 10:00, but cooler weather is coming (I hope).  We've had at least 32 days with a high temp over 110 this summer and the max was 117.  Keep up the good work.

It's insanity down in Phoenix. Luckily I've only spent the weekends down there so far, gotta finish up my engine before I move down full time. Remind me again why I'm moving there?

Sorry, back on topic. Buggy is looking great, Louis!

At least you can get good Mexican there. I have not been able to stand anything here since I went out with Donny to that restaurant in Phoenix.

--louis

Yeah, Carlos O'briens rocks!

Louis you gotta make another run to Phoenix, but when it's cool, like in the winter time...

Yeah...the August heat slowed me down on finishing the chop too.  Could not force myself to go out and bake nor be soaking wet to work on the car.  Will start things back up now that the night time temps are dropping.

Rick M

Rick you should be starting back up pretty soon. 

Been a busy past couple of weekends getting the main cage and the engine cage tacked up.


A couple of the cage where I added the seat belt bar and the front cross bar:


(http://images.thesamba.com/vw/gallery/pix/853378.jpg)


(http://images.thesamba.com/vw/gallery/pix/853376.jpg)


(http://images.thesamba.com/vw/gallery/pix/853377.jpg)


Here are the bolt on side bars. They run outside the body:

(http://images.thesamba.com/vw/gallery/pix/853373.jpg)


(http://images.thesamba.com/vw/gallery/pix/853375.jpg)


(http://images.thesamba.com/vw/gallery/pix/853374.jpg)



And here is what I spent most of last and this weekend doing. I had it all tacked together last weekend. Stepped back to admire my handy work and realized one side was an inch lower than the other. #$)*&%&@#@

Tore it all apart this morning and refit everything. This time I triple checked my measurements to make sure it was all level.

(http://images.thesamba.com/vw/gallery/pix/853372.jpg)


(http://images.thesamba.com/vw/gallery/pix/853371.jpg)


(http://images.thesamba.com/vw/gallery/pix/853369.jpg)


(http://images.thesamba.com/vw/gallery/pix/853370.jpg)



The square lower tubing is 1.5" .125 and will be where I will mount a trailer hitch. That way if I decide to drive it to Big Bear next year I can pull a small trailer for extra storage.   :)

(http://images.thesamba.com/vw/gallery/pix/853368.jpg)


(http://images.thesamba.com/vw/gallery/pix/853367.jpg)


(http://images.thesamba.com/vw/gallery/pix/853366.jpg)


I still want to add some protection for the heads to the engine cage and maybe a skid plate. Other than that it is ready for some finish welding.

Thanks,

--louis

Lookin' good Louis,  I look forward to seeing it done.  I still remember when they were all over the place... a dime a dozen.  Now they are golden.  Keep up the good work!

Hey Louis...........how did them SS brake hard lines fit up for ya??

Nice work, love this Build not long to go now Louis keep it up..

I will let you know as soon as I install them.  :-[ 

I may need to have some more made since I switched to rear discs. I still have not decided how to mount the lines with the calipers.

--louis

Simply eliminate the tube that runs down the axle tube.     Replace it with a flexible hose.  I can build SS braided flex hoses as well.  I can build the hoses to fit up properly to the tube end.  I just need to know what the caliper port is. 

Okay I will get up with you when I get to that point. Probably not till after the first of the year.

Thanks,

--louis

Nice project! Don´t stop updating!

What´s the wheel size (width, ET) and what tires are mounted.

Did you go for the mentioned:
"(2 14x6s & 2 15x8.5s) and I am looking at 205/70R14s (same height as 165/15s but wider) & 235/70R15s BFGs w/ raised white letters front and back. "
???

Wondering what I could fit on my dune buggy... :-\

Hi,

I did go with the 14X6 & 15X8.5s and my tires are 225R75X14s front and 235R70X15s rear. Depending on how that setup works off road I may switch out to a 15x6 front and go with a 29" front/30" rear combo. I fond it difficult to get a 14" AT tire but if your going to run street tires that should not be an issue.

thanks,

--louis

Thanks for the input Louis. There's not much info you can find about rims and tires on a Buggy.

Hey Louis

Is your Manx ready?

gr
Wout

No it is still in hibernation. I promised my better half we would do some home renovations this year so not much money to make any progress with. Hopefully I will be able to get back to it next winter. I am thinking of sending the engine off and have someone else assemble the 1967 in the fall. I just have not decided who to send it to yet.

Thanks,

--louis

Good luck!

gr
Wout

Any updates Louis?  Time to get back into the project...

Hi Donny,

I hate to say it but I had to let this one go. I couldn't get any motivation for the last year to go out and work on it so I decided it was time to pass it on to someone who would finish it. A guy in my local club bought it and already has the chassis finished and the body in the paint shop. I still have the 74x92 motor w/ Denham heads for the Manx but I have not decided what to do with it yet. Sell it or store it until I get the itch for another VW.

I have also gotten frustrated with VWs in general, the poor quality of parts, the cost and hassle of shipping things across the country, the lack of local resources like a decent machine shop, etc. (I don't see how you guys overseas do it.) I have come to the realization that I just don't have the time to rebuild a car from the ground up right now so I am taking a break from cars for a while. About the closest I have come is looking at some '50s and '60s pickups as a daily driver.  I have been spending what little free time I do have getting some stuff done around the house. (new floors, remolded bathroom, general repairs, etc) I am also in the process of job hunting which may require me to relocate. (I have actually applied for a couple jobs out your way in Tempe.) Once that is out of the way and we pay off a few more bills I will look into another older car though I don't know if it will be another VW. Hope all is well with you.

Thanks,

--louis

Very nice project,keep up the good work!

thats a shame, was looking forward to seeing this finished!

I can understand the frustration, but don't give up.  Just take some time off.  You still have a rust free '66 don't you?