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bushoarder
March 15th 2011, 16:07
I've been reading on here for years and thought i'd post a link to my resto - on VZI..

http://www.volkszone.com/VZi/showthread.php?t=514502

http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0396.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0392.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0381.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0388.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0340.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0339.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0328.jpg~original

some taster pics! I've pretty much finished the body now -couple of cosmetic bits to weld up before I can commence modifications :D

Porsche 901 gearbox loosely fitted whilst awaiting my NOS 1800 Type 4 motor. I'm planning on injection and have several T4 injection systems along with a knackered turbo i'm going to use for pipework mock up!!

Hoping to get the chassis rust repaired shortly - there isn't much to do - then maybe I can get the new suspension and brakes started.

oasis
March 16th 2011, 03:13
Yikes! You're taking on some tough duties. Obviously, you have some mad skills. Well done so far. Performance will be the easy part.

wrenchnride247
March 16th 2011, 20:39
You are off to a very good start so far! Keep the updates coming!

NO_H2O
March 16th 2011, 23:23
WOW. Thats a lot of cutting, fitting and welding.

bushoarder
March 17th 2011, 16:55
Here are some of the earlier pics showing some of the work i've had to do:

http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/Bulkhead%20repair/Photo0508.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/Bulkhead%20repair/Photo0372.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/Bulkhead%20repair/Photo0342.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/Bulkhead%20repair/Photo0343.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/DSC01072.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/DSCF0007.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0291.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/Photo0734.jpg~original

bushoarder
March 17th 2011, 17:00
http://i208.photobucket.com/albums/bb306/bushoarder/Photo0679.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/Photo0687.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/Photo0691.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/Photo0683.jpg~original

Particularly proud of this handmade panel!

http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/Body%20off%20and%20chassis/Photo0778.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/Body%20off%20and%20chassis/Photo0781.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/crossmembers%20and%20quarter%20panels/Photo0563.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/crossmembers%20and%20quarter%20panels/Photo0558.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/crossmembers%20and%20quarter%20panels/Photo0107.jpg~original

bushoarder
March 17th 2011, 19:54
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/crossmembers%20and%20quarter%20panels/Photo0090.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/crossmembers%20and%20quarter%20panels/Photo0581.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/NS%20Strut%20support%20and%20inner%20wing/Photo0392.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/NS%20Strut%20support%20and%20inner%20wing/Photo0490.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/strut%20support%20and%20inner%20wing%20repair/Photo0255.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/Roof%20and%20Guttering/Photo0210.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/1303%20Resto/Roof%20and%20Guttering/Photo0206.jpg~original

Just a taster!!!

wrenchnride247
March 17th 2011, 20:45
:eek: That is alot of metal repair! :eek:

I've got to do some of that to the lower corners on rear window... not looking forward to it. You're doing a graet job! Keep it up!

volkdent
March 17th 2011, 20:56
Jayzus!!! You wouldn't by chance work at a dairy that makes swiss cheese wud ya? Nice work patching her up!

Jason

bushoarder
March 20th 2011, 15:41
I measured this up at 2mm, then looked at a bit I had left over from a previous floor pan I had fitted - generally have never used this part - and found it to be 1mm thick!!

So moral is don't use this bit off pattern pans!! I made a piece up in the end from 2mm sheet.

http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0400.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0401.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0402.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0403.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0404.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0406.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0405.jpg~original

So all repaired and awaiting the pan repair that I've made but not fitted :D

Oldskool1303
March 20th 2011, 19:31
Wow!! nice metal work

Wally
March 25th 2011, 04:49
Well done on the rust repair! Its such a accomplishment if the body is solid again as in your first pics.
I know exactly what it takes as you may have seen in my thread on the first page ;-)
Keep the pace and get her painted and driving asap since that gives extra motivation, then you can upgrade later as much as you like :-)

bushoarder
March 26th 2011, 15:05
Hi Wally,

Thanks, i've looked intently at your work and it is an inspiration to me for my bug! If mine turns out half as good as yours I will be very happy :D

I have a turbo on the bench lol!!

bushoarder
April 2nd 2011, 14:39
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0437.jpg~original

http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0436.jpg~original

Not much to report.... maybe get more done next weekend.

bushoarder
April 6th 2011, 16:16
Hi All,

Here is my latest thoughts on the bug...

http://i208.photobucket.com/albums/bb306/bushoarder/BugonATS.jpg~original

ATS rims for that classic German Look motor

Opinions invited.....

bushoarder
April 27th 2011, 15:09
Here is my weekend's weldings....

http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0503.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0501.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0500.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0508.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0507.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0506.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0505.jpg~original

now awaiting some more box section to make the end brackets - replacing my mocked up bit on the end of the 25x25 box.

bushoarder
April 27th 2011, 15:10
Welded in the rear half moon vent cover, cleaned up and aligned the front valence, but decided not to weld until i've cleaned up under the front and sorted the gearbox position. Got the engine mating surface to within 0.5 perpendicular to the top of the tunnel :D

http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0466.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0467.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0469.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0470.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0471.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0472.jpg~original

That's it for another week :( Gonna design the gearbox front cradle this week on CAD.

ricola
April 27th 2011, 15:59
I know it's a bit late, but the torque reaction on the trans at the front has a lifting force which is considerably greater than the static weight of the assembly which is why they are normally done the other way around...
Rich

bushoarder
April 28th 2011, 14:49
Hi Ricola,

I did read that the nose cone lifts on dropping the clutch, but rarely trust all the internet stuff i see.

Thanks for the comments, I did over think this a bit and was trying to avoid putting the bushes in tension, which with lift i guess i will see on my bracket / bobbins. I have always planned on running the T2 engine brace bar to eliminate this affect - always seems odd that VW never fitted one, but i guess on 50hp not necessary - hence why i opted for the design I have.

In your experience, would you be overly concerned with the set up including the rear brace bar? I would expect this to reduce the moment on the trans, but the force at those mountings would be pretty high too i imagine.

I do note that the Bug@5speed chaps and porsche seem to use a doghnut type mount with a steel sleeve in the centre meaning they must have shear in the rubber, I see this is the type you are using on your bar.

Any feedback welcome on experiences

Jon

ricola
April 29th 2011, 05:14
I'm happy with using the OEM solution as it has obviously been designed with the loads in mind, the other one I do like is with a transverse bar with bobbin type bushes with their axes horizontal. I'm pretty sure I've seen pics of this on this site but can't remember which thread!

The nose definitely lifts on acceleration. Bringing it back to basics, imagine turning the axles to drive the car forwards at the inner ends and what the reaction force would be..

bushoarder
April 29th 2011, 06:01
Yeah thinking about the reaction I can visualise the reaction torque applied, I was thinking about the stock mount and it is purely in shear at this point - axis of the mount is along the body, but unlike the mounts you mention [wrenchride's thread] there is no compression in the mounts.

I'm considering two approaches now, I think MK2 Golf engine mounts - round type with a bolt through the centre following the axis of the crankshaft would make a good solution since in all reactions it is compression and not tension.

Or reversing my current solution - these mounts are a lot lot cheaper than the Golf ones.

Steve C
April 29th 2011, 09:49
Hi

Cant wait to see more of your work.

When people cut down the 944 spring plate bush retainers they are usually left with two beautiful bobbin style mounts but nothing to use them on. Maybe someone has some left over that they can donate?

Steve

bushoarder
April 29th 2011, 14:56
So I posted some of the gearbox bracket images and Ricola pointed out I'd got the mounts in tension - for some reason I have brain deadness and missed the torque reaction lifting the gearbox nose :rolleyes:

Thanks, glad I hadn't cut the chassis as I had planned to do today!!

So I took another look at what I had bought and had to hand, several ideas floated by - once again the use of Golf Mk2 rear engine mounts 2, one either side of the gearbox in a modified cradle, then I thought I would continue with what I had - spare urethane bushes for the track control arms and the previously shown bobbins.

A bit of thought, pizza box and ingenuity led to the following:

http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0512.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0520.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0511.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0518.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0522.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0515.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0519.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0510.jpg~original

Need to finish the ribs tomorrow and make the brackets for the chassis. This is quite heavy, I may decide to get one of the toolmakers at work to machine an aluminium version from billet, which would look a little more factory.

Tension strut mock up tomorrow if I'm lucky....

bushoarder
April 30th 2011, 12:59
Looked at the gearbox bracket and decided to do some tidying and added the raising pad on the topside. No other mounts available via G&S today so have to consider the other mount idea for the future..

http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0525.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0524.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0536.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0537.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0538.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0540.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0541.jpg~original

bushoarder
April 30th 2011, 13:08
Fitted the car's old engine case and basic tinware to gauge the gearbox position since with the body back down it looked a bit wrong:

http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0527.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0526.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0533.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0529.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0532.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0528.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0530.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0531.jpg~original

Measuring the other bug I have I get 30mm to the front of the return of the rear tinware off the firewall, here I got 55mm :eek: so I got underneath to investigate. 49Rag whom I purchased the box off had it fitted to his car on the rear cradle that you see here, therefore I used this since if it fit his it would fit mine right!!!

Looks like the bellhousing is 23.25" from the torsion tube and possibly 10-12mm further back [towards engine], the body is sitting 5mm out of position. Looking at the box position there is only 5mm between the gearbox and torsion tube so can't go back any further.

Any comments on this appreciated, but since I'm going to run a T4 and make the tinware I can obviously make it all fit in there, just won't be stock.

I will ponder this a bit and see what others have done, but looks like I'll be making some custom tinware if I ever fit a Type 1 back in there.....

bushoarder
May 1st 2011, 14:36
I just pottered and decided to fit up my T4 mock up engine and some other bits:

http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0546.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0549.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0542.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0545.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0551.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0554.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0555.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0557.jpg~original
http://i208.photobucket.com/albums/bb306/bushoarder/IMAG0559.jpg~original

In the pictures you can see a stock T2 rear engine bar and my old JMR turbo muffler - ran this on my first bug back in 2002 and saved it since it has a great low sound. It goes without saying that the pipework will need changing!

So I plan to run a polo front muffler under the O/S and the turbo under the N/S with a connecting pipe under the gearbox which will be set back from the flywheel oil seal location. I'll make an aluminium splash shield so that if I get an oil leak it won't end up on the hot exhaust!

Additionally, I figured out that I can mount a clutch slave cylinder along side the 901 box and use a steel rod to connect to the clutch lever, probably with a rod end for connection. This should give me a nice adjustment free reliable clutch connection.

The T2 bar will have late 1600cc bay window mounts used at the ends with a fabricated bracket to the bumper mounts and I'll probably use another 2 of these to remake my gearbox cradle - still not 100% happy with that design.

So happy that now I can begin the 'exciting' part which is laying out how the mechanical parts will fit - I will do this with the body and chassis as it is on my trolley then I'll pull out the chassis at a later date to repair the rusty areas since these are really small :D!

I want to make up all the mount bracketry for the engine bar and the exhaust before I finish the cosmetics of the body.