Oval Bugster

[volkdent]

I really never saw this coming, but I'm starting a new build thread!!!

So, here's where we are at:

2004 Boxster S 85k miles purchased
Cutting out dented panels and generally cleaning stuff up and see what I have to work with.
Have made contact with a guy in Oregon who will sell me a '57 Oval Rag body and some later doors that I'll be fileting within an inch of it's life. Take heart that this body has already been stitched together at some point, so I'm not cutting up a complete car.

Here's some of the damage:

http://images.thesamba.com/vw/gallery/pix/954543.jpg

http://images.thesamba.com/vw/gallery/pix/954542.jpg

http://images.thesamba.com/vw/gallery/pix/954541.jpg

http://images.thesamba.com/vw/gallery/pix/954540.jpg

Some motivational reference:

http://images.thesamba.com/vw/gallery/pix/954539.jpg

The one with the red decklid is the one I've got my eye on, I'll be replacing all sheetmetal with fiberglass from CCC.

http://images.thesamba.com/vw/gallery/pix/954547.jpg

http://images.thesamba.com/vw/gallery/pix/954546.jpg

http://images.thesamba.com/vw/gallery/pix/954545.jpg



Jason

[owdlvr]

I'm so stoked on this build thread.

-Dave

[Wally]

That is awesome!
Extremely cool build and that 'motivational picture' indeed is. (not sure on the grammer of that tho)

[MX67]

Just do it! :D

[Humble]

I can't stop ogling your inspiration pic *drools* This will be one hell of a project, one I might have to inspect in person :)

[Jadewombat]

Are you grafting the oval to the boxster body, or building up a bug with boxster parts?

[volkdent]

More pics of the victim, a little nicer than I really want to cut up actually...:(

http://images.thesamba.com/vw/gallery/pix/954694.jpg

http://images.thesamba.com/vw/gallery/pix/954695.jpg

http://images.thesamba.com/vw/gallery/pix/954696.jpg

http://images.thesamba.com/vw/gallery/pix/954697.jpg

http://images.thesamba.com/vw/gallery/pix/954698.jpg

http://images.thesamba.com/vw/gallery/pix/954699.jpg

http://images.thesamba.com/vw/gallery/pix/954700.jpg

http://images.thesamba.com/vw/gallery/pix/954701.jpg

http://images.thesamba.com/vw/gallery/pix/954702.jpg

Jason

[Gerrelt]

This is going to be great! Very nice.

[volkdent]

Are you grafting the oval to the boxster body, or building up a bug with boxster parts?

Yep, grafting. I had orginally planned on making it a bolt on affair, not wanting to cut up the Oval too much, but the dimensions of the Boxster make that impossible, some of the suspension pick-up points are right in the middle of body areas.

The only way I could dodge the cutting would be to build a tube chassis with the Boxster components attached, but I'm just not up for building a whole chassis right now. Maybe later? What would someone spend for a tube chassis a bug body could be bolted to that has Boxster running gear? Any how many of those crazy people exist?

Jason

[hotsauce]

This project is rigoddamndiculous. Makes me think about buying a wrecked boxter to throw under my other project...

[Keltikrewser]

Where can I find some more info on the car in your inspirational pic.

Can't wait to see this one evolve.

[volkdent]

Where can I find some more info on the car in your inspirational pic.

Can't wait to see this one evolve.

No idea, it just showed up under the German Look Tuning section, the poster didn't know where it came from either...

Jason

[Humble]

the inspiration pic is a great photoshop of the 2012 911-gt3 rsr 4.0 and whomever did it should really get the credit.

here's the 911 for comparison
http://www.dgermancar.com/wp-content/uploads/2011/11/2012-Porsche-911-GT3-RSR.jpg

[Gerrelt]

I think this is the guy who created the picture: deviantart user (http://roof01.deviantart.com/gallery/?offset=24#/d2v50na)

He has another VW beetle photoshop:picture (http://th00.deviantart.net/fs45/PRE/i/2009/071/2/e/VW_ESCARABAJO_by_ROOF01.jpg)

Now, back to putting VW beetle body shells on Porsche Boxters! :)

[Wally]

Good find Gerrelt!
I very much love that style as it is indeed based upon Humble's picture which is a car with emphesis purely on function.

[Keltikrewser]

Too bad it's not real, but I like where your heads at! Now let's get to the cutting :dance:

[volkdent]

Its going to be mid-month at the earliest before I get the body. My wife and I are expecting our second little guy yesterday, so he should be here this week at the latest. Although she's a car girl too, I think I'll be pushing it if I take off for a day to get the body, it's about a 7 hour trip each way! I'll be doing more cutting and thinking on the Boxster though.

In doing so this weekend I realized the front top left corner of the car has had some structural tweaks due to the accident it was in. Fortunately it looks like the lower suspension pickup points are all in tact, but I'll find out with the use of a laser this coming weekend what is right and what is tweaked.

Jason

[dub_crazee]

il keep my eye on this one - looks like its going to be a fantastic build!!!

[riseabove]

a little link for some inspiration ... a almost finished full buildup of the same concept except the use of a 1303 bodyshell.... all things written in swedish though so mostly for the pictures .

http://rejsa.nu/forum/viewtopic.php?t=25745

[volkdent]

Awesome!!! The more info I can find the better. They took a lot of pics too. They are going a little overboard on strength(weight) where the Bugster seems a little flimsy to me. I think I'm going to settle on a happy medium. Great link, thanks so much!

Jason

[Wally]

They are going a little overboard on strength(weight) ..


Thats very much my feeling usually when I see very large build projects with alternate engines being used: usually the builders err on the safe side and over-engineer the whole thing and it weighs a ton. Which is understandable as most privateers can't (re)design a complete car for structural integraty(sp?), as we don't have those computer programs or equipment of course.
However, all of the added weight kills the intended superior performance of the project.

So Jason, pls look at every extra piece of steel reinforcement you intend to make very carefully (as if you didn't already). Think like a Lotus engineer ;)

[riseabove]

Awesome!!! The more info I can find the better. They took a lot of pics too. They are going a little overboard on strength(weight) where the Bugster seems a little flimsy to me. I think I'm going to settle on a happy medium. Great link, thanks so much!

Jason

The strengthening parts aren´t really that heavy but makes the car MUCH more rigid,

I know the builder in person and got som pictures from him from his TwinTurbo extractor manifolds / rotary mufflers :-) that are going into the bug..... power to weight ratio will be much much much better than boxsters or 911s for that matter.... :)

fully adjustable suspension and alot of other upgrades are also going into the car.....

[volkdent]

Wally, my thoughts exactly. One thing neither of them did was create a pie section and re-use the sills. Looking at the Porsche Boxster steel material diagram, both cut out the seat mounts which looks to be a sort of integral stiftening piece, and where I think Bugster should have included some sort of roll cage, the Swedes are turning this thing into a tank. It's easy to talk about what to do, I'll have to find my own way, I think possibly replacing each sill area with a 2" or 2.5" CroMo tube that is anchored on good plates may work out just fine.

Riseabove, I really like what they are doing, it's just that they are adding a LOT of extra weight in the amount and diameter of tubing they are using, but I don't know what sort of final use they have for this, if it will see a lot of time racing on a circuit, it may need the amount of re-informent they are adding. But for example, the addition of the old style engine cover added a lot of weight that probably didn't need to be added, as well they reduce the storage of the interior.

Jason

[riseabove]

His car will be a track day car first and foremost. We also have quite strict rules and regulations about these kind of modifications here in sweden . i also think he is going a bit overboard with the reinforcements ... but he is is a "do it once do it RIGHT!" kinda guy .....

I hope to see the progress on your oval bugster and se a real lightweight beeing built :)

[volkdent]

Almost done, only took me 10 minutes;)

http://images.thesamba.com/vw/gallery/pix/965804.jpg

http://images.thesamba.com/vw/gallery/pix/965806.jpg

http://images.thesamba.com/vw/gallery/pix/965805.jpg

More motivation!

http://images.thesamba.com/vw/gallery/pix/965807.jpg

JASON

[Gerrelt]

Some tie-wraps and ducttape, and call it done! ;-)

[volkdent]

I removed the whole right quarter(half) of the car in one piece, seemed a shame to destroy a perfectly good panel, even if it was a bitch to drill the spot welds. Now that the chassis is free and clear to be worked on I'm actually going to have to make a detour to the body shop to have the frame straightened. Seems the driver side front impact was heavier than I or the seller had realized, so there may be an issue with the strut mount and lower control arm mount that I'd like to get squared away before I remove too much strength out of the chassis. Should be done in the next couple of weeks hopefully.

Jason

[Steve C]

Hi

Love this build. How is the wheel base compared between the two cars?

Steve

[volkdent]

The Boxster is less than 3/4" longer than the bug, I'll center the rear and let the front get a slightly tucked look, I like that look on hot rods.

Jason

[Keltikrewser]

I'm more interested in the 10" difference in width. Are you planning on running it that wide, or are you going to narrow it? Hopefully you're going to run it wide:rockon:

How much wider was the UBRDUB over stock, I know I read it somewhere in you're thread, but I can't seem to find it.

[volkdent]

You mean track, I think it's going to be just a tiny bit wider than UBRDUB out back, so 3+" per side, may just fit. But to get it as low as UBRDUB out front and not rub on hard turning I'm expecting to have to modify the fender lip substantially, so probably have to go 3"+ compared to the 2.5" on UBRDUB. I really don't want to sacrifice the low-fat look too much if I can help it.

Jason

[TSAF]

I am sure that you have seen this: http://bugster.at/

If not you might get some ideas!!! Great project!!

[volkdent]

I am sure that you have seen this: http://bugster.at/

If not you might get some ideas!!! Great project!!

Thanks, yes, that was what got me going, and here is a guy in Sweden that is doing it currently. Awefully nice to have somebody going through this at the same time.

Bubster (http://rejsa.nu/forum/viewtopic.php?t=25745)

Jason

[TSAF]

Yes but both of them have used 03's. With the Oval is going to be a lot more difficult. Have you consider using a 03 or a 02? I think that it will be easier for you. Not to mention that the ovals are a lot more valuable at the moment.

[volkdent]

I just don't like the look of Supers, as we call them, at all. It will be more difficult, but worth the work I think. I got the Oval for a good price and it's not in great shape, I don't feel terrible cutting it up.

Boxster is at the body shop right now, just needed to confirm that there wasn't any chassis damage before I start. The word so far is that it is all within spec.

Jason

[Wally]

I just don't like the look of Supers, as we call them, at all.


Jason,
You must have a hard time here then :lmao:
Walter

[volkdent]

Jason,
You must have a hard time here then :lmao:
Walter

I like to look at others Supers, especially yours with the power and the wheels, but as a shape I can only get really into the older style!:lmao: The main thing is that I don't like bumpers, and old bugs look great without bumpers to me, but supers without bumpers look odd IMO.

Jason

[graham]

Love this project.

If I where to start a GL project again from scratch this would be the route I would be taking, oval beetle/ porsche underneath, ultimate wolf in sheep's clothing .

Sweeeeet !

[SuperRSi]

Damn it! I am not even finished with my STi Manx and now today I see this and an RS 4.2 V8 in a Boxster and my mind races. Oh no...

[TSAF]

I have seen Boxsters with 996 turbo engine conversions. I think it sounds easier!!!

[Panelfantastic]

Awesome Dent! Love this new project!
(Yes, I'm still around and I do spy on you guys from time to time):D


Jeff-

[volkdent]

Car is back from the body shop, oddly the chassis ended up being in spec, so it was $380 of insurance I guess.

Some more big news, not very sexy, but really hot if you are a Californian car owner. This project is officially registered as a 1957 Bug!!!! For those of you in other parts of the world or country, in California you have to smog(emissions test) every car newer than '72 I believe. So, this car would have had to have been registered as a 2004 Porsche Boxster, having to be smogged every 2 years. Instead it will never get smogged, have lower insurance rates, and is all set for twin turbos!!!

Back to the juicy stuff, the boxster is completely stripped, very close to the deep cuts it will need to allow the bug to fit over it. Pics to come, sorry.

The whole area from the apron to under the dash is gone from the bug.

Today a set of KW V3 coilovers arrived so I can start to set up ride height.

Good to see you Panel, does this get your juices flowing?!!!

Jason

[Panelfantastic]

Sounds like you are getting a run of good luck on the new project!

I would love to do what you are doing to a notch... but my AWD wagon project is all-consuming in time and funds.

http://pic40.picturetrail.com/VOL267/1824562/21668057/397107069.jpg



Jeff-

[Steve C]

Hi

Cant wait to see more of this.

I wish our registration authorities were as enthusiast friendly as yours appear.

Steve

[Wally]

Thats great news Jason! A boxster disguised as a '57 bug: cool!

Good to hear from you Jeff! Awesome project you have going as well.

[TSAF]

Thats great news Jason! A boxster disguised as a '57 bug: cool!

Good to hear from you Jeff! Awesome project you have going as well.

Better yet a twin turbo powered boxster disguised as a 57.:cool:

[volkdent]

What is that thing Jeff? What is the running gear?

They really aren't that enthusiast friendly, this one is definately in the grey area, but as long as it's registered as a '57, has '57 VIN plate, and no other VIN #'s are able to be seen, it's a '57. I suspect if there was a big accident and push came to shove I would probably be in trouble defending myself, but it's all a gamble isn't it?

Jason

[Humble]

You dodged the bullet for sure, with no smog-check you're free to do anything you'd like. No smog years are pre-1976, anything '76 or newer gets smogged every 2 years and has to pass smog rules from year of manufacture.

If I remember correctly for split body/chassis cars you can go by either the chassis or body vin as long as only one was visible. This was to eliminate reg issues on repaired vehicles but became a thorn in the side for stolen part recoveries. It's common practice to go by the older vin to get around smog issues or having the car inspected for smog compliance which is a huge pain.

Panel, not to highjack a thread but you can't just leave us hanging, that looks awesome!

[volkdent]

I purchased KW V3 coilovers for her. Did a lot of head scratching and the cost/value ratio was just too good to pass up compared to competitors.

http://images.thesamba.com/vw/gallery/pix/984629.jpg

Got the inner panels cut out of the bug, and got the whole thing ready to go onto the frame table

http://images.thesamba.com/vw/gallery/pix/984630.jpg

http://images.thesamba.com/vw/gallery/pix/984619.jpg

Unfortunately, the wheels on the frame table are not rated for enough weight, they are barely up for the weight of the table, let alone a 3000lb car. So that was a big waste of time. I'll get some better casters for the table and also I think the legs should be triangulated so they don't fold in if it hits a bump moving it from shop to shop.

http://images.thesamba.com/vw/gallery/pix/984618.jpg

Jason

[el argentino]

great work! Followed by Italy
pablo

[TSAF]

Great work, keep the photos coming!!!!

[Jadewombat]

I think you should race the Vortex 'Super' Beetle project car when all is said and done, like on a dragon (1/4 mile drag strip then track course) on street tires.

http://www.vwvortex.com/features/project-cars/superbeetle/super-beetle/

Great work. Can't wait to see how this turns out.

[volkdent]

I've been following that build too, pretty sweet! I'm hoping to get a look at it as I'm lucky enough to get to go to SEMA this year! I want to have a chat with the Garrett guys on what turbos might be a good option for the Ragster.

Jason

[vw1303]

http://i7.photobucket.com/albums/y256/equilibrio/sema-outside-12.jpg~original

If your at SEMA check out the Karmann Ghia with Boxster running gear.

[volkdent]

Oh sweet!!! Any name to go with it or a booth number? I've got the catalog so I can look up the booth number if I have a name.

Jason

[vw1303]

Saw it on Speedhunters. They say its in the outside area of the show.

[volkdent]

I looked and looked and looked for that Ghia, no dice. I even found the exact spot the pics were taken at but no trace. Looking at the pics some more, they grafted Ghia panels to the Boxster, while the Boxter stayed largely in tact.

I found the build here!

Translog GT (http://www.transloggt.com/)

That would have made my job a lot more simple, but the lines of a bug are hard to duplicate, as Volkswagen has learned now with the new-new beetle. I saw the APR one there, it is very understated for having 500hp.

Jason

[Wally]

Indeed a cool build also, but doing a bug makes for so much more understatement in the end result imo.

[volkdent]

Indeed a cool build also, but doing a bug makes for so much more understatement in the end result imo.

Agreed!

In talking to different vendors there, I was encouraged to make the Ragster into a SEMA build, or at least get lots of vendors on board as sponsors. Reading up on the Internet last night about the Ghia, I found out that Road and Track's favorite picks of the show were that Ghia (http://www.transloggt.com/), and the APR Super Beetle (http://www.vwvortex.com/features/project-cars/superbeetle/super-beetle-volkswagen-official-sema-press-release/). Maybe the writer loves VWs, but gauging the crowd response watching the SEMA Cruise, it became apparent that people really got emotional about older cars, and not so much about newer. I'm hoping the Ragster can bridge both and may be a good candidate for sponsorship. I'm just not sure I'll be happy with being held to some sort of contract...

Oddly the highlight of the show was a potentially revolutionary new material that was just amazing. I got chills thinking about its potential given it is stronger than carbon fiber, lighter than steel, flame retardant, AND biocompatible! The inventor worked at DOW and by accident created this material years later. It would be used similar to an epoxy resin, and can be ratio changed and filled with additional additives to have a consistence ranging from water to foam. I'm very excited to pursue the material use as possibly a wheel material initially, just has to be strong and light for that, but it may be able to be use as a joint replacement, a tooth, or even to fight cancer!

Jason

[volkdent]

More Ghia/Boxster pics, "Ghia Monster"

http://images.thesamba.com/vw/gallery/pix/987957.jpg

http://images.thesamba.com/vw/gallery/pix/987956.jpg

http://images.thesamba.com/vw/gallery/pix/987955.jpg

http://images.thesamba.com/vw/gallery/pix/987954.jpg

http://images.thesamba.com/vw/gallery/pix/987952.jpg

Jason

[Jadewombat]

Incredible. Love the slots on the rear fenders. So many questions though, mostly how the heck did the wheelbase length and width wind up fitting the ghia body. The centering and width is spot-on with the wheel wells.

[volkdent]

http://www.transloggt.com/

Jason

[volkdent]

https://sphotos-b.xx.fbcdn.net/hphotos-snc6/189687_10151156738583310_545044407_n.jpg

4" to go, the last 4 are the hardest 4, just trust me. Running into ABS system and strut tops now...

Jason

[Wally]

Ha! Getting there. Very cool!

[judgie]

as much as i know how much work went into that ghia it just dont quite sit right to me, maybe its the boxtser dash and them roll hoops but something just looks odd with it.
loving the work on the oval, have a oval shell in at the shop at the moment thats getting a full tube frame and big turbo type 4 motor in it.

[dub_crazee]

Starting to take shape now, nice work :)

[ricola]

you'll have to write a 'how to' when you're done!

[Rule09]

Nice!! :cool:

[SportyBug]

you'll have to write a 'how to' when you're done!
Yes, please do

[volkdent]

I probably could write a little how-to now, getting very close. Still have some major hurdles to overcome like moving the steering column to the right a couple of inches...

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/479742_10151175640268310_1360788265_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/424783_10151175640333310_1780210791_n.jpg

Some more motivation...

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/67770_10151175784963310_2011078548_n.jpg

Jason

[owdlvr]

Awesome!!

That is starting to look rather mean, in a good way.

-Dave

[Humble]

Okay, I need a chassis table, stat! You've only just started and I'm already drooling. :eek:

[ricola]

Are you moving the pedals to go with the column? Great work, I havent' even finished my cab and you go tempting me with this!!

One concern though... how are you going to get decent airflow up front? This would be the big driver to use a 1303 for me with it's valance panel suited to slats.

[volkdent]

The same way I did on the UBRDUB, just duct up from underneith. Corvette is a good example of how you don't really need a lot of big openings if you get the air to the right spot. Same with Porsche.

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/480734_10151178382693310_1212074400_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/549565_10151178396363310_47051087_n.jpg

http://images.thesamba.com/vw/gallery/pix/713112.jpg

We tend to look for big holes, but if you direct the air the right way, gather it if you will, I think it can be forced where it needs to go.

Jason

[Wally]

Inspiring stuff Jason, which will also apply to intercoolers me thinks...

[volkdent]

Some candy...

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc1/424841_10151179666263310_2086019461_n.jpg

Like a glove...

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/556871_10151177395403310_1733445471_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/66033_10151177395243310_424958658_n.jpg

Jason

[Panelfantastic]

What is that thing Jeff? What is the running gear?

Jason

1954 Chevy wagon (often called a Tin Woodie). Running gear is the full frame and drivetrain from a 2007 Trailblazer AWD SS, LS2 engine. Doing a body drop and full air ride.

You are making great progress! I am very envious, seems there is constantly something else keeping me from mine.

http://pic40.picturetrail.com/VOL267/1824562/21668057/401613496.jpg

http://pic40.picturetrail.com/VOL267/1824562/21668057/404649985.jpg

Jeff-

[volkdent]

Wow!!! Cool Jeff! How's the track, was the TrailBlazer wider than the car?

Last shot of her before she goes next door to Nor Cal Sand & Off Road owned by Eric Jenkins. His forte is offroad, but he's a heck of a fabricator and I need a chassis, so that's a good mix.

Here's the last shot of her:

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/403768_10151196562703310_1401492147_n.jpg

I had to leave 1.5" between the bottom of the body and the chassis bottom, I simply didn't have any more room at the top of the fender for the strut tops. As it is I have some grinding to do before the fenders will be low enough:

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/528350_10151196562803310_149088719_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/406662_10151196562898310_1044024951_n.jpg

Jason

[Panelfantastic]

You know it! All this modern stuff has crazy wide track, especially a AWD sport ute. I'll be doing some creative fender work to get it right.

This build of yours is soooo kick-ass! I'm looking forward to the updates. Don't skimp out on us! I want to hear about ALL the little bull**** things you have to do a long the way to pull this together. I've seen several builds like this but everyone glazes over how hard it is and all the stuff that has to be done.


Jeff-

[MarnixGSR]

Some think about doing it...you just DO it. Respect!

[surfbeetle]

This looks incredible. I have comment regarding the dmv in California. There is a rule that refers to what the car most resembles. The car would be registerred based on the year that the vehicle looks like rather than what it was. In my case, I have a 68 VW pan with a 67 VW body so it's registerred as a 67. I had it inspected by the highway patrol and then properly registerred with the dmv. So i would think that you could be able to do the same, just ask the CHP to see how they would do the paperwork and make sure you have all of your receipts.

[volkdent]

This looks incredible. I have comment regarding the dmv in California. There is a rule that refers to what the car most resembles. The car would be registerred based on the year that the vehicle looks like rather than what it was. In my case, I have a 68 VW pan with a 67 VW body so it's registerred as a 67. I had it inspected by the highway patrol and then properly registerred with the dmv. So i would think that you could be able to do the same, just ask the CHP to see how they would do the paperwork and make sure you have all of your receipts.

It's already registered as a '57, but if it wasn't they use the numbers. The most difficult number to change on ACVWs is the the chassis # under the rear seat, so I'm surprised they used the '67 for you, they registered my '60/'68 as a '68. There aren't any VW numbers left on the '57 body so they most definitely would have used the Boxster numbers. They are gone now and once I re-rivet the '57 tag on the Boxster chassis we should be all good.

Thanx for the kudos Marnix, just have to keep going! The chassis guy is finishing up another project, so no real progress on it.

Jason

[noslzzp]

This an awesome build. It never ceases to amaze me, the talent that people have!

[wrenchnride247]

Looking great Jason! Should be a blast to drive!

[Panelfantastic]

It's already registered as a '57, but if it wasn't they use the numbers. The most difficult number to change on ACVWs is the the chassis # under the rear seat, so I'm surprised they used the '67 for you, they registered my '60/'68 as a '68. There aren't any VW numbers left on the '57 body so they most definitely would have used the Boxster numbers. They are gone now and once I re-rivet the '57 tag on the Boxster chassis we should be all good.

Thanx for the kudos Marnix, just have to keep going! The chassis guy is finishing up another project, so no real progress on it.

Jason

You could do the SB100, yes?

Jeff-

[volkdent]

You could do the SB100, yes?

Jeff-

I don't know what that is?

Jason

[Panelfantastic]

It's a Cali registration thing for kit cars and the like.

http://www.replicarclub.com/Newsletters/Tech_articles/Registering_your_car_in_California.pdf

Jeff-

[volkdent]

Random build shots(boring ones for Jeff!):

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc1/600673_10151297588638310_990923579_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/163318_10151297588708310_358305117_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/48110_10151297588858310_1958678855_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/379361_10151297588928310_906809006_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/580685_10151297589018310_1954197965_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/549191_10151297589163310_1415768881_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/72681_10151297589273310_1202400505_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/549320_10151297589538310_1622300194_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-snc7/600887_10151297589793310_1743715652_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-snc7/481435_10151297589878310_2072799946_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/307336_10151297589983310_1291659419_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/541603_10151297590073310_1590187060_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-frc1/603938_10151297590203310_1918817441_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/426388_10151297590328310_1367962526_n.jpg

Thanks to Eric at Nor Cal Sand and Off Road (http://norcalsandandoffroad.com/) for his awesome fab skills and attention to detail!

Jason

[Panelfantastic]

Looking good Dent! That's some serious heater channel repair :lmao: ...


Jeff-

[volkdent]

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/541659_10151331614378310_1758771530_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/67019_10151334314838310_812277241_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-snc6/268112_10151334315403310_1951016998_n.jpg

Jason

[volkdent]

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/562166_10151376053978310_2120575726_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/164198_10151376053943310_1611492502_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/602075_10151376053903310_648961109_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-frc3/480302_10151376053818310_234430615_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-snc6/221720_10151376053608310_598843602_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/527717_10151376053523310_2125278806_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/559275_10151376053488310_1803878837_n.jpg

Front and back are joined again.

Jason

[NO_H2O]

Nice work.

[70Turbobug]

Awesome welding! Looks very solid!

[wrenchnride247]

Nice progress Jason! The welds do look nice :D

[Humble]

Making progress, slowly but surely. Looking at the front strut mount it looks like it will interfere with the fender, or maybe it's just the camera angle?

[TSAF]

You welding skills are extremely good. You are welcome to work in a shipyard at any time.

Seriously now top work.

[volkdent]

Hey guys, thanks for the kudos, but I'll have to pass them on to Eric, I've got neither the time nor the skill to work this area right now, so I've farmed this out. It's back in my possesion now so I can work on non-structural things like moving the steering column and the pedals over about 5cm.

I'm worried it's a little too beefy, but I guess better stronger than not strong enough. This car will be seeing the race track regularily, so I want to feel comfortable about my chances of good health should a shunt occur.

Will, the strut top and the fender literally touch each other, that's another part I have to work on, I may have to grind on that mount just to clear the fender!!! It's a problem that is not really a problem for supers, but I'm the only guy I'm aware of that's attempted this union with a standard beetle so I have additional challenges to face.

Jason

[volkdent]

I'm Lovin' it....

https://sphotos-a.xx.fbcdn.net/hphotos-ash3/524666_437756989649734_543483761_n.jpg

Jason

[Humble]

That's a very RWB (Rauh-Welt Begriff) look, is that the direction you're leaning?

[volkdent]

I do like the look, I just don't think it will work for the street, track or show only, doesn't have the travel for a decent street car. I'll have to play with the fenders when I get there, but I wouldn't mind incorporating the look.

Jason

[volkdent]

This would be cool!

http://www.precisionchassisworks.com/uploads/2/5/1/9/2519425/647376_orig.jpg?334

http://www.precisionchassisworks.com/uploads/2/5/1/9/2519425/8491764_orig.jpg?336

Precision Chassis Works (http://www.precisionchassisworks.com/index.html)

Jason

[Humble]

I've been looking at air jacks for years but haven't been able to justify the cost... yet. I may end up with a set down the road if I ever pull the trigger and go tube chassis but for now I just dream :)

[owdlvr]

Same here. Seriously want a set on my next ride (which will be tarmac oriented).

-Dave

[volkdent]

This turned out to be one of the largest problems I didn't even realize I would face. Turns out the steering wheel needed to be moved to the centerline by 3.25". Well, also turns out the steering column and the pedals are one unit. Also turns out the steering shaft is sitting very near the gas tank. Also, the master and accompanying booster aren't really the moving-type. SOOOO

I took a wild guess and tried a step in the right direct by just moving the whole assembly over by the distance between the 2 main mounting studs, 1.75".

The hole on the right is the new one, the other 2 are backed by some sort of aluminum casting that transmits the load right to the MC. I figured half is better than none.

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/11879_10151412354893310_1026974595_n.jpg

Well, my decision turned out to be a good one, as the steering shaft just clears the gas tank by the width of a zip tie, the master cylinder extender arm just clears the steering column if you turn it 90 deg, and the heater/ac core just fits back in next to the assembly with less than a 1/4" to spare.


https://sphotos-b.xx.fbcdn.net/hphotos-ash3/537921_10151412354178310_1974422971_n.jpg

I had to hack open the hole for the steering shaft as it would have fouled now, and I have to figure out some sort of reasonably safe way of transmitting the brake pedal motion to the MC extension arm. This is what I'm most worried about, I'm taking a really well designed double-shear and perfectly centered brake pedal system and building a single shear and slightly side loaded force vector. I've got a couple of ideas, rod ends to be exact, but I will have to play it by ear and get the opinions of a couple of the engineer types on GLF when I get that far.

Jason

[volkdent]

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/969142_10151449308523310_812519596_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/249059_10151449308733310_386927054_n.jpg

My first plan included using a male heim, but I just couldn't let myself feel comfortable with that in a single shear load. I'm not worried anymore, the pedal will break before this thing does.

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/934061_10151449309623310_454100357_n.jpg

This is my friend Michael who has done the beautiful lathe work. He's from the old school and can machine ANTHING! Thanks Michael!!!

https://sphotos-a.xx.fbcdn.net/hphotos-ash3/942082_10151449309688310_69125704_n.jpg

[volkdent]

Roll cage nearing completion:

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/941567_10151495049538310_1137852953_n.jpg

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/983968_10151495049383310_1514968821_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc3/993065_10151495049233310_498535981_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-ash3/1017086_10151495049143310_877569764_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/1011691_10151495049088310_182010115_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/184467_10151495049033310_1311597978_n.jpg

Not sure how "legal" the rear mounts are, but they seem stronger than a plating type so not sure why that would be a problem. I don't think this think will ever race but I try to follow FIA/NASA/SCCA rules as much as possible.

Jason

[cookvw]

cage is looking sweet!

[volkdent]

Starting to put her back together. Figured I'd just start at the front and work my way back!

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash4/1005971_10151513318753310_1181820695_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/931181_10151513318828310_1152787745_n.jpg

Notice the drivers side connection and the passengers side connection to the "bumper" bar are at different heights. The drivers side is where the impact occurred on the Boxster, so the height difference is about 3/8". I had thought about having the frame straightened here, but it was just more work/$ than it was worth as it affected a large area.

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/1002943_10151513318863310_1403604027_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/1010928_10151513318913310_680488725_n.jpg

The holes filled in nicely, low so I can fill. The whole front apron has been tweaked so I was just looking for a seal and a low surface.

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/1002785_10151513318988310_235789823_n.jpg

Jason

[NO_H2O]

Mad Skills. Nice cage.

[volkdent]

Rad arrived. I might have overdone it, this thing is heavy and a bit bigger than I wanted, but I think bigger is better if a turbo is on the horizon.

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/1002779_10151542513213310_428199200_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/995701_10151542513113310_1372142156_n.jpg

Jason

[volkdent]

This is the closest example of the color combo I'll have when I'm done, except in satin not gloss:

http://www.vwvortex.com/artman2/uploads/1/beetlers2.jpg

http://www.vwvortex.com/artman2/uploads/1/beetlers3.jpg

http://www.vwvortex.com/artman2/uploads/1/beetlers4.jpg

http://www.vwvortex.com/artman2/uploads/1/beetlers5.jpg

Jason

[NO_H2O]

Nice color combo.

[70Turbobug]

Nice! A dark satin gray would look good too..

[Jadewombat]

Purty...

[volkdent]

Getting the radiator to fit has been a challenge. Working out airflow through the hood.

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1025915_10151566496803310_173459176_o.jpg

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash4/998210_10151566496958310_853546325_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-frc1/1006296_10151566497063310_1108111294_n.jpg

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/1078745_10151561711838310_1928887513_o.jpg

Walkaround (https://www.facebook.com/photo.php?v=10151562203233310&set=vb.735178309&type=2&theater)

Jason

[70Turbobug]

Fantastic work!! Looks great!

[Steve C]

That looks mean

[Gerrelt]

+1
Looks brilliant allready!

[Clatter]

There's a vision many have had but none have achieved... Just beautiful...

I'm sure that you can set me straight,
but, because the Boxter is mid-engine,
Isn't there some room behind the current motor where the beetle motor useta sit?

It seems, (from here at my computer screen :-)) that it would be a smart/dandy place to put the radiator.
You could use some decklid venting, maybe some scoops under the car, or quarter window NACA ducts or some such to put it in back?
Always loved Wally's intercooler tail idea, too.

If ever you need an armchair quarterback, without a dog in the race, I'll be sitting right here at my computer happy to help! :D

[volkdent]

Thanks guys, coming from you I feel honored!

Slowly but surely!

Clatter, it's not as big as you might think under the deck lid with the transaxle in there! Then the Boxster already has the rads up front, so you want to go with the flow as I'm already nervous that I've moved the COG rearward with the front overhang being much shorter and the cage being more rearward. Finally I'm trying to keep as much storage inside as I can to transport a set of track tires, so ducting is out(I think it's fugly too!). I may do something with ducting to the engine compartment through the roof though....;)

Jason

[Oval]

amazing build...

[dub_crazee]

that looks awesome :D

[volkdent]

Picked this little guy up for the A/W intercooler rad. It's a stock 996/986 center rad, about $170 so I thought that was reasonable. Has about 3/4" inlet/outlet. Unfortunately I don't have any more room around the rad, so it's going to have to find a place somewhere else in the car...

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/972107_10151579593798310_907635871_n.jpg

Jason

[volkdent]

Getting there, working on the A/C system and getting the stuff under the hood to work out nicely...

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/1184773_10151613490148310_483553186_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn2/1186232_10151613490253310_1599715771_n.jpg

https://sphotos-a-sjc.xx.fbcdn.net/hphotos-prn2/1185937_10151613491168310_279772951_n.jpg

https://sphotos-a-sjc.xx.fbcdn.net/hphotos-ash4/1013293_10151613491313310_1118394275_n.jpg

https://sphotos-a-sjc.xx.fbcdn.net/hphotos-prn2/1186220_10151613491973310_1591905898_n.jpg

https://sphotos-a-sjc.xx.fbcdn.net/hphotos-prn2/1185380_10151613492018310_1091275857_n.jpg

https://sphotos-b-sjc.xx.fbcdn.net/hphotos-ash4/1146615_10151613492088310_1691094240_n.jpg

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/1150361_10151613492163310_778222133_n.jpg

https://sphotos-a-sjc.xx.fbcdn.net/hphotos-ash3/1176240_10151613492233310_1608038409_n.jpg

Jason

[Rule09]

Nice!

[70Turbobug]

Awesome work!!!

[SuperRSi]

What a great build. I had considered this and your posts have convinced me not to! But Wow will you end up with a nice ride.

[volkdent]

What a great build. I had considered this and your posts have convinced me not to! But Wow will you end up with a nice ride.

Honestly, though having it in this state ads a bunch of extra ease for finish work, I would seriously consider just building a tube chassis and mounting all the components onto it next time. I like everything this chassis has to offer, but what a biotch to fit!!!

Jason

[volkdent]

Back at it, just grinding through the details.

Fabbed up these steering column brackets, I now have a tilt AND telescoping steering wheel!!! This little bracket was a lot of work but now I can adjust the wheel for almost any seat or seating position. The nutsert tool is already paying for itself!

https://sphotos-a.xx.fbcdn.net/hphotos-prn2/1234865_10151638495198310_1426666443_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn2/971965_10151638495278310_2122532922_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn2/1234873_10151638494668310_911666522_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-frc3/1157638_10151638494743310_816528036_n.jpg

Finished up moving the clutch master over 1.75" as well. It's not what I would call pretty, but I'm working on my side under the dash so cut me a little slack. It is all sealed and if I ever do a renovation of this thing I can pretty it up then.

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/1004708_10151638495123310_589121094_n.jpg

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/1186242_10151638494983310_2055634056_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn2/1175146_10151638494868310_1004781063_n.jpg

Steering column back in and we have steering again!!!

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/1231208_10151642088188310_1608086189_n.jpg

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/1236742_10151642088278310_76254614_n.jpg

Finalized the angles, routing, and rotation of the tubes for the cooling system. I think Erik at norcalsandandoffroad (http://norcalsandandoffroad.com/) got them welded up for me today. I do all the fiddley work and I let the pros do the talent stuff!

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/1234222_10151642088458310_1754295149_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-frc3/1240634_10151642088418310_2029694179_n.jpg

These are the details I'm most proud of, I was able to utilize the stock coolant pipe bracket even though my pathway is totally different.

https://sphotos-a.xx.fbcdn.net/hphotos-ash3/1208995_10151642088388310_1360507800_n.jpg

Jason

[70Turbobug]

Fantastic work! Looks like things are getting a little tight now eh?

[graham]

This build is just bonkers:eek: so much work :cool::cool::cool:

[ricola]

Hi Jason,

Good to see things progressing at a constant pace, nice to see the go-kart, must give some good motivation!
I might not be commenting much but rest assured I'm watching ;)

Rich

[volkdent]

More coolant work. Had to "massage" the area above the front lower control arm attachment point to allow space for the rad. Not pretty but necessary. Also welded a tunnel through two body layers for lower rad hose.

https://sphotos-a-lax.xx.fbcdn.net/hphotos-frc3/1235465_10151650922743310_1663258738_n.jpg

This is where the tunnel exits, then up and over the rack bellows. Tight fit.

https://sphotos-a-lax.xx.fbcdn.net/hphotos-frc3/1234528_10151650922923310_375101036_n.jpg

The top and bottom hoses join next to the gas tank. Also this is a high point for the lower tubing, so a bleed bung has been added that ties into the stock Boxster coolant bleeding system. Hopefully this makes for trouble free bleeding. Very excited to be able to use the factory coolant hose bracket!

https://sphotos-a-lax.xx.fbcdn.net/hphotos-ash3/1174978_10151650923063310_801701844_n.jpg

The previously dual rad system now only has one pathway. Both side bleed tubes can be seen and will be used. On a technical note, I am now aware that there are special hose clamps for silicon hoses. They have an additional internal sleeve that offers a smooth surface for the silicon to be squeezed by.

https://sphotos-b-lax.xx.fbcdn.net/hphotos-ash4/1209438_10151650303333310_2007621350_n.jpg

https://sphotos-b-lax.xx.fbcdn.net/hphotos-ash4/1174614_10151650923178310_1363077504_n.jpg

I've been able to just squeeze this monster in there, next up add the A/C condenser...

https://sphotos-b-lax.xx.fbcdn.net/hphotos-prn2/1174807_10151650922478310_1022741332_n.jpg

Jason

[wrenchnride247]

Coming along Jason. Very cool project!

[volkdent]

Small update, big progress.

I finally got the floor pan welded to the frame. It sounds simple enough, but the floor pan has a nice thick layer of German underbody sealer on it, and it all had to be ground back from the welded edge. A big mess. Then, to make it just a little more messy, I seam sealed the whole area. I forgot to get a pic, but I used a honey consistency seam sealer so I could really flow it into all the nooks and crannies. Trouble is I'm doing this upside down so I looked like I pigged out at the chocolate fountain...

Also got a jack point welded in, seen it the top part of this pic.

Anyway, here's a shot pre-sealer.

https://scontent-b.xx.fbcdn.net/hphotos-prn1/558184_10151665682153310_83792484_n.jpg

And a couple more of the rad area.

https://scontent-b.xx.fbcdn.net/hphotos-ash3/543923_10151665682393310_720646262_n.jpg

https://scontent-a.xx.fbcdn.net/hphotos-ash3/1237178_10151665682423310_442974796_n.jpg

Jason

[volkdent]

Big day, I finally came up with a structural solution that is also elegant in its design. It ties the inner and outer Boxster chassis, the new frame rails, and the roll cage together, all while allowing a nice edge to finish the bug/Boxster seam along.

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/q80/s720x720/1237123_10151680596473310_1284078532_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/q71/s720x720/1236541_10151680596583310_1977634780_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-prn2/q71/s720x720/954891_10151680596648310_1126126717_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-frc3/q73/s720x720/1236159_10151680596348310_768460668_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash3/1236864_10151680596228310_1611546750_n.jpg

Also finishing up a factory-like re-attachment of all the lines running back to front.

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash3/579085_10151680165018310_1319901253_n.jpg

Jason

[volkdent]

Starting to get fun. Installed the stock Boxster trunk latch.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1383065_10151693878083310_1758562936_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1383518_10151693877978310_235928109_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/q87/s720x720/960004_10151693878258310_565200045_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/q77/s720x720/1186184_10151693878313310_1916288989_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/q86/s720x720/1013122_10151693878183310_151814064_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/q87/s720x720/558349_10151693877923310_1365873892_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/q72/s720x720/734111_10151693877823310_1655275867_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/q71/s720x720/1378846_10151693877538310_1762070908_n.jpg

Jason

[volkdent]

Devil is in the details. There was a fatigue fracture through this area. Hope this makes it better and the decklid easier to seal against water.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/q74/s720x720/1385260_10151694548358310_862572045_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/q77/s720x720/1010970_10151694548303310_1796832355_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/q72/s720x720/1377496_10151694548043310_1870404975_n.jpg

Jason

[Jadewombat]

Just curious about something, I scrolled back a few pages but maybe I missed it. How does the wheelbase look front to back? I mean does the top curve of each wheel line up with the curve of the fender? My super was in an accident years ago and I went through quite a bit just with small changes here and there to get everything to line back up.

[volkdent]

I can't see a difference, although apparently there is one. Keep in mind I have fiberglass fenders, so it's really easy to modify the opening too. I believe the difference is less than 3/4"' and I like my front wheels a little tucked forward a la Foose.

Jason

[volkdent]

More body mods. Not too many things good about getting old, but a couple are patience and knowledge, so I scraped up as much of each as I could and this is what happened.

https://scontent-a-pao.xx.fbcdn.net/hphotos-frc1/q80/s720x720/1383909_10151703162818310_1171667986_n.jpg

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https://scontent-b-pao.xx.fbcdn.net/hphotos-ash3/q74/s720x720/541895_10151703162583310_972869743_n.jpg

[volkdent]

Slow, tedious progress, but progress nevertheless.

Built the template for the side storage pods, the drivers side will house the rear relay block.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1375707_10151705444598310_241137063_n.jpg

To close off the frame rails, I built a plug that also includes a nut to affix a bracket for the trailer hitch. I see myself building a trailer that I can haul track tires with and that is also a tent someday.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1378024_10151705445043310_1518620866_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1378878_10151705445083310_1944934077_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash4/1383090_10151705445013310_692682715_n.jpg

The inner fender seam between the Boxter and the bug is almost complete. Built a panel that merges the strut mount to body.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1381190_10151730333233310_554505894_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1391738_10151730333298310_633183846_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash4/1380731_10151730333503310_1944716544_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/1376494_10151730333648310_210552230_n.jpg

Jason

[volkdent]

Little update:

Got these aluminum mufflers, yes, I said aluminum. Got a buddy that builds big HP cars and he swears by them, very, very light, no cracks yet for him. I'm doubtful, but they aren't that expensive and I could flange them to a stainless system if I wanted and still get big weight savings.

https://scontent-a.xx.fbcdn.net/hphotos-frc3/1382385_10151737660453310_1482146545_n.jpg

Ditto for cheap Chinese headers. They are supposed to be stainless, and they are except for the severely warped flange. Had to spend a bunch of time on them to get the flange flat and to open the bolt holes up. Really surprising how simple some of the mistakes are, but equally surprising how little a complete header setup was.

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/859837_10151737660538310_1492183244_o.jpg

Working on the fitment to the fenders, these will have to be widened ever so slightly unless I like the smell of burnt rubber around every corner. Looks kinda cool though...

https://scontent-b.xx.fbcdn.net/hphotos-ash4/1390626_10151756158063310_558302321_n.jpg

https://scontent-a.xx.fbcdn.net/hphotos-frc3/1394792_10151756157963310_1673219011_n.jpg

https://scontent-a.xx.fbcdn.net/hphotos-prn2/1383568_10151756157908310_1835340928_n.jpg

https://scontent-b.xx.fbcdn.net/hphotos-prn2/1452064_10151756157853310_733837085_n.jpg

Finally got the condenser attached to the rad, used aluminum spacers my wife uses for her business, re-threaded them for metric, and had Eric at NorCal Motorsportz weld them on for me.

https://scontent-a.xx.fbcdn.net/hphotos-ash3/1450885_10151768985053310_1466570364_n.jpg

https://scontent-b.xx.fbcdn.net/hphotos-frc1/1451353_10151768982628310_116145612_n.jpg

https://scontent-a.xx.fbcdn.net/hphotos-ash3/999723_10151768982358310_648473959_n.jpg

https://scontent-a.xx.fbcdn.net/hphotos-frc3/r90/1424379_10151768982138310_1063643835_n.jpg

A before shot of the area I need to fill between the Boxster chassis and the tubing.

https://scontent-b.xx.fbcdn.net/hphotos-prn2/1395348_10151768982953310_1715329369_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1461089_10151768983613310_1152902058_n.jpg

The mess I have yet to tackle...

https://scontent-a.xx.fbcdn.net/hphotos-frc3/379663_10151768986253310_130647322_n.jpg

Jason

[ricola]

Looking good Jason.. Did you see that there's another one that appeared recently, on the front cover of the new Ultra VW magazine..

[volkdent]

cOOL!!! How can I get UltraVW over here?

Jason

[ricola]

I'm pretty sure you can either buy a single issue or they do electronic copies too..

[Kafer_Mike]

cOOL!!! How can I get UltraVW over here?

Jason

UltraVW Website -- http://www.ultravw.com

http://www.ultravw.com/uploads/uvw/april2011/novcover.jpg

It's available in iTunes -- https://itunes.apple.com/gb/app/ultra-vw-magazine/id525983654?mt=8

[owdlvr]

Just noticed you're using Vibrant mufflers. My first job out of Uni was with Vibrant, product development and tech support. Nice choice!

-Dave

[Luismj]

UltraVW Website -- http://www.ultravw.com
http://www.ultravw.com/uploads/uvw/april2011/novcover.jpg
It's available in iTunes -- https://itunes.apple.com/gb/app/ultra-vw-magazine/id525983654?mt=8

The same?!

http://www.vwheritage.com/blog/2013/08/15/porsche-beetle/

:cool:

[volkdent]

I bought the online version. The interior is amazing, but it's clearly a street car that won't see much track time, like the Bugster (www.bugster.at), and I really wonder what the thought process was on leaving the rear edge of the rear fender as odd as they did. In the article they mention doing an early version, boy are they in for a surprise. Every one of these conversions I've seen have been Supers, the early body is soooo much smaller, like building a ship in a bottle!

Dave, what are your thoughts on aluminum exhaust systems? I'm sure they would have a hard time holding up on multiple rally stages, but what about a street car?

Jason

[volkdent]

The details continue - gauge cluster now.

Cut the stock speedo ring and moved it over 1.5". It was really tricky because I couldn't put the cluster in level, didn't flow with the curves, and it couldn't flow with the curve because it would look too tilted, I ended up with a compromise between the two.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash4/1462917_10151794708018310_869449247_n.jpg

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https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/q71/s720x720/62458_10151800914808310_2037121392_n.jpg

Jason

[volkdent]

Front and rear latches will be controlled by stock solenoids. Deepest part of front latch aluminum will be embedded in fiberglass to bond it to inner hood surface.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1461030_10151779575313310_1004152730_n.jpg

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https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1441317_10151779531218310_752182829_n.jpg

[volkdent]

Dirt is still being moved on our hillside, should have a flat spot to build a 26'x40' shop next week. 0 progress on this project, of course things take more time than you expect to get rolling.

Here's a shot of a Super/Boxster S from Sweden, hope to be doing this in my bug next year.

https://vimeo.com/m/99021642

Jason

[Bogara_ZO]

Here's a shot of a Super/Boxster S from Sweden, hope to be doing this in my bug next year.

https://vimeo.com/m/99021642

Jason

That is a cool car, hated to see it being crashed at Mantorp - Bugrun...track was wet btw :mad:

A bit off topic but that porsche look alike track car is an awesome built as well!

https://plus.google.com/app/basic/photos/102066375728933723740/album/6025402285974299633?authkey=CM-y78Ly8M76bw&source=appredir

[graham]

digging this build big time
:cool::cool:

[Jadewombat]

Updates?? :driving:

[volkdent]

Nada, I've been tinkering with the UBRDUB, hope to have fixed a coolant leak, but really just treading water till I get the finals for permits on the new shop. It's very strange to go from working on something so complicated and exciting to essentially nothing. For the past year I've done less mechanical work than changing the oil... I'm seeing maybe 4 or 5 more months before I'm into the thick of it again. I can promise you that unless I die or something really crazy happens I'll be finishing this thing. I definitely have not lost any interest, in fact the delay has made me want it even more and given my mind a little rest that it probably needed.

On a side note, looks like using images off of my Facebook page wasn't a great idea, most of the link look broken, I'll have to get everything repaired and maybe host on Instagram?

Jason

[Jadewombat]

You seen this?

http://vtwoconcept.com/2-7l-boxster-beetle/

Also, this guy say the wiring harness can be simplified a lot:

http://forums.pelicanparts.com/porsche-911-technical-forum/834243-911-long-hood-restomod-mid-engine-awd-2.html

[SportyBug]

I'm glad this project is still going. It is just amazing to watch it go together. It is too bad so many of the pictures are missing. I was wanting to share this project with a friend and did my best with what we can still see. I use photobucket for what I post online. Definitely looking forward to seeing more when you are able to work on the bugster again

I can promise you that unless I die or something really crazy happens I'll be finishing this thing. I definitely have not lost any interest, in fact the delay has made me want it even more and given my mind a little rest that it probably needed.

On a side note, looks like using images off of my Facebook page wasn't a great idea, most of the link look broken, I'll have to get everything repaired and maybe host on Instagram?

Jason

[Fiatdude]

All the pictures have disappeared?!?!?!

[volkdent]

I had used Facebook as the picture host, and apparently they don't want to be a picture host, so while the pictures still exist in my Facebook account, the links are different so I'll need to go through and find them then host them on the Samba!

Just seen this morning from one of my Facebook friends from Norway! I TOLD you guys it could be done! Just makes me want to get back on mine so badly...

http://images.thesamba.com/vw/gallery/pix/1404415.jpg

http://images.thesamba.com/vw/gallery/pix/1404414.jpg

http://images.thesamba.com/vw/gallery/pix/1404412.jpg

http://images.thesamba.com/vw/gallery/pix/1404411.jpg

http://images.thesamba.com/vw/gallery/pix/1404410.jpg

http://images.thesamba.com/vw/gallery/pix/1404409.jpg

http://images.thesamba.com/vw/gallery/pix/1404416.jpg

Beautiful! Hoping to get ahold of the builder to get some build pics.

Jason

[Steve C]

wow

[SportyBug]

:shocked: Wow is right! I really like how cleanly the dash(es) where integrated into the car.

Any news on yours?

[Scotts73SB]

Wow talk about a sleeper! That things beautiful!

[Wally]

Amazing!

[Flintstones]

Impressive!

[wrenchnride247]

Holy crap :shocked:

[Jadewombat]

Very tempting:

http://www.ebay.com/itm/111853320581?_trksid=p2055119.m1438.l2661&ssPageName=STRK%3AMEBIDX%3AIT

the price has dropped $1000 twice in the last couple of months meaning they'd probably accept an offer just North of $10K. Maybe in a couple of years I'll do one of these hybrid VW/Boxsters. I need to finish my bus and get my garage in order though.

[H2OSB]

damn, that car is just gorgeous

[Jadewombat]

It's says it's a 2.7L in the ad. but I think that's a typo. Should be the RS60 3.4L 303hp version, correct?

Add a VW fastback body, just get in an go, right?

https://www.youtube.com/watch?v=BCo52yaMJq0

http://images.auction123.com/2f69d74b-50ee-44c1-9b19-6dc7674c6bab/WP0CA29858U710594/13.jpg?webimage001l

Sorry for the hijack...

[volkdent]

Looks like a great starting point!

I've started a BMW M3 Touring project that is sucking up funds, but it's a very smooth swap, not nearly as much custom as the Bugster, and it will be my daily driver, so it has priority.

Still waiting on finalization of my shop, may be as close to a week away, but I wont start back up on the Bugster till the summer at earliest.

Jason

[volkdent]

Can't believe it was Jan of '16 since the post about the Touring! It's STILL not complete, but will be going under the knife in the next couple of weeks. Bugster is still tucked away in the shop, which will be finally getting power in the next 3 weeks too, so good things happening here. I don't expect to get anything done on it till this winter, but after the power is installed it leaves the door open to get the lift in there and get the Bugster back on the build again.

Jason

[SportyBug]

Any updates on this Bugster in the last 3 years Jason? Would it be possible to reupload your images too? All those seem to be missing now sadly