Down and out in 2008
 

Hi Guys,

Looks like I will not be able to make any 2008 dates for shows / meets with the beetle :bawling:

I've been meaning to replace the floor pans and heater channels as the rust has been getting worse every year. My motor build is behind schedule so I've made the decision to pull the insurance for a year and get this fixed properly.

I've got the tools and will be doing the work myself, I've ordered the Bug-Me DVD's to help so hopefully I can get it right the first time.

I'll try to make some shows with the Honda and show some support ... its looking like 2008 is THE YEAR to be rolling (Thanks to Lanner) as there are many VW related activities planned.

Maybe we can have a meet at my place ... a "raise the body off the pan" meet ... I've got a BBQ and a patio in the back .... :D Would be cool to have the front yard covered in VW's ...:lmao:

Later

Sandeep

Sandeep,

Sounds like a plan! Floors and channels aren't too bad if you take your time. I've done em both! if you need a hand just holler! and if you need any tools just let me know, I got 'em all!

Let's get Sandeep rollin!

Alex

hey Sandeep that's To bad but like Alex Said it's that that hard of a Job to do the Floors and channels I have a 110 welder if ya Need and other Fab and Body Tools too. I'm Down for A BBQ and pullen a body off the pan lol

I know you Said you were Behide but have you gotten a Chance to take Some pics and Measurements for that 901 I'm ready to pull the motor and tran this Weekend coming,

Soo Common guys Lets help him out

Chris.

Too bad bro, we'll miss the yellow monster.

Fire up the grill, burn some meat and I'm there. But that theory can turn on you.... I had a BBQ/pond digging party a few years back. I have nasty clay in the backyard, and digging is a killer. Well, all the boys and girls showed up, had a good meal, a few drinks...a good time all around. BUT, the festivities monopolized the schedule, and one (yes one) guy actually grabbed a shovel..... Still was fun though :)

BTW: Anyone need any pond goldfish? These guys are worst than bunnies...

Lanner

Booo that sucks, i'll miss it. Was watching the compilation clip on youtube yesterday.

I'll help pull the body.

My suggestion, keep the beers locked. I have a fridge in the garage. When people come by to help, they help themselves to the fridge, and we talk BS while nothing gets done. I will be installing a padlock on the fridge very soon. :lmao:

Lanner, I'll take some Goldfish. The pond isn't opened yet.

Pete

Sounds like my garage!

Alex

P.S. was that the vid i tossed together?

I don't know, did you put it together for Sandeep? Here's the clip:

http://www.youtube.com/watch?v=z_vJTRr6GT4

oh THAT compilation vid! No, as much as I'd like to take credit for it it's not mine. For some reason i thought you were talking about the dyno day vid that I did (which was also a compilation, but so was Disney's Fantasia...) MY BAD :D

Alex

Sorry to hear you've got to deal with the Red Monster. I'll get that CD out to you ASAP, now I know why you are getting deeper!!!

Jason

Hold on a sec....

Since you'll be spending some serious $$$ doing this, ohhh boy do i have a deal for you! :D

I'll call you tomorrow, or ask Lanner/Greg. ;) They know all about it. Right here in Toronto, wicked driver/sweet deal for the summer. Can plate ASAP, so you can roll aircooled.

Thanks for the support and comments.

I'm guessing I can replace the pan halves with the body still on from what I have read on the internet ... that alone should save me quite a bit of time.

Perhaps I can replace the pans, drive it this summer, and then replace the channels in the fall after the season is over.

Chris,

I've taken the pictures and am now taking the measurements, hope to have this information to you this weekend.

Pete,

Give me a call if you can.

Thanks All,

Sandeep

Pan Off
 

I'll help pull the body, just get the Jerk Chicken Rolling Biggg Yella.....
Just give me a weeks notice( Got Kids ) ......LOL

Cheers

Too bad you won't be out this year, but cool beans on the pan-fixin-body-pullin-beer-drinkin-bbq :D

Count me in..... I think at some point I'll be in the same spot :lmao:

Rob.

Pete,

I'll have to pass on the '65. My beetle has sentimental value and I've been wanting to tackle the rust issue for a couple of years now.

If I can find some pans at the "Wet and Chilly", I'll put some plans together for a "Raise the Body" BBQ :D

Sandeep

John usually has pans in stock, the ones I got from him were real nice too.


Like I said earlier, I'll be there for the barn, errr body raising. But if you need a hand doing the actual work, want to pick my brain, or just borrow my tools! Let me know, I'd be more then happy to assist in anyway. It can seem daunting that first time.

Cheers bro,

Alex

Some update pics
 

Progress ...

http://i10.photobucket.com/albums/a1...6.jpg~original

http://i10.photobucket.com/albums/a1...7.jpg~original


Old pan vs new

http://i10.photobucket.com/albums/a1...8.jpg~original

Sandeep

Why did you end up going with A/W intercooler? I'm really in a toss up, I think the A/W might be better on the street, but the added complexity and weight I'm not sure makes the trade off worth while. What did you come up with on your search?

Jason

Sandeep, looking good.

At this rate, you'll be back ont he road before the snow falls.

I used the A/W due to size restraints but that was to cool the original 2.0 and TD04-13T turbo.

The new 2.4 with GT3071R will overpower my current system (390cfm capacity) easily.

I wanted an A/A but could not figure out how to package it well, until Wally showed pics of his system. That is the way to go about but I will have to redesign my intake plumbing.

Sandeep

That is the plan !

Sandeep

Update
 

I've stripped the frame of everything that was rusted out and removed the front and rear suspension.

http://i10.photobucket.com/albums/a1...0.jpg~original


I'm building a proper 915 front mount now ... something that looks factory and will confuse the techs if I ever have the car up on a lift.

http://i10.photobucket.com/albums/a1...1.jpg~original


I plan to use the stock trailing arms (refurbished) with urethane bushings and dipped (zinc chromate) stock spring plates.

I think I have found a coilover (QA1) to use with relaxed trailing arms but will have to check if they fit.

I need to strip the rear arms and prepare the chassis for a coat of POR15 ... hope to do that this weekend.

Sandeep

Keep up the good work!

Jason

NIce Job Sandeep
Keep the Pics coming :)

Chris.

You're committed now bro!:D

Looks good, and I like the plans you have in store for it! Keep up the good work.


Alex

Wow man, when you dive in, you DIVE in !
Good work!

Rob.

How much 'massaging' did you have to do in the crotch area to fit the 915 in there?

Also Sandeep, do you have pics of your A/W setup?

I'll take some pics of the 'crotch area' :lmao: but I notched it enough not to harm the torsion bar area. The 915 bellhousing surface sits about 6mm further to the rear than the stock gearbox, no adapter parts for the 915 required as I built all the peices myself.

Sandeep

Sandeep, what kind of welder do you use ?

Rob.

Christmas break update
 

Having 2 week off really helped :D

I welded up the pans and sandblasted them, and then acid etched with phosphoric acid.

http://i10.photobucket.com/albums/a1...9.jpg~original

http://i10.photobucket.com/albums/a1...1.jpg~original


Some POR15 ..

http://i10.photobucket.com/albums/a1...7.jpg~original

http://i10.photobucket.com/albums/a1...1.jpg~original

And then some "tie coat" primer

http://i10.photobucket.com/albums/a1...2.jpg~original

http://i10.photobucket.com/albums/a1...4.jpg~original

And then two coats of Tremclad yellow to closely match the body :D

http://i10.photobucket.com/albums/a1...4.jpg~original

http://i10.photobucket.com/albums/a1...6.jpg~original

I'm almost done the top now, just waiting a few days for the POR15 to cure before adding the tie coat primer and tremclad yellow.

http://i10.photobucket.com/albums/a1...5.jpg~original

http://i10.photobucket.com/albums/a1...7.jpg~original


Then I can start assembling the pan :D

http://i10.photobucket.com/albums/a1...8.jpg~original



Sandeep

Wow! You did get alot done! The POR-15 stuff is great! It's coming along really good. Keep it up! :D

Awesome work Sandeep.
So you need a special primer over the POR15 before you can cover it with the Tremclad ?

Do you have a heated garage or does the POR15 cure in low temps as well ?

Thanks,

Rob.

Looks good Sandeep, your really commited you did all that work on your own? Will ET of finish, is by summer?

Good Job

You need a primer to bond to the POR 15 called Tie Coat primer made by POR 15. Other paints then bond to the tie coat primer.

I have a BBQ propane tank with a heater attachment, so the area around the pan stays at about 15C :D

All work has been done by myself. Now I just have to bolt the whole thing together :shocked:

Summer 2010 is the goal.

Sandeep

Nice work Sandeep, props on keeping the project going. My attention span is way too short for long-term ones like that, I need to be able to drive it!!

Remember I'm not far away from you, if you find yourself in a situation where you need an extra set of hands while working on it.

Looking forward to seeing the car and getting a ride in it this summer. ;)


cheers
Ed N.

Looks really good Sandeep! Cant wait to see this monster back on the road.
I am stuck at the "wait for bodyshop" stage, my goal is also summer 2010

Good stuff. You will love the Tilton pedals. I have installed a set in the Herbie X project. There are some problem ares you will have to work around but they will fit and work. I want to put a set in my car but have not had the time or funds to do it.

Another Saturday, some more progress :D

http://i10.photobucket.com/albums/a1...1.jpg~original

http://i10.photobucket.com/albums/a1...0.jpg~original

http://i10.photobucket.com/albums/a1...2.jpg~original

http://i10.photobucket.com/albums/a1...0.jpg~original


And a Christmas present from Santa ;)

http://i10.photobucket.com/albums/a1...3.jpg~original

Sandeep

Sandeep, what brand are the throttle bodies? And how do the air filters get mounted on those?
Oh, and nice project going on there, I love everything about it :D

The TB's are tapered 50mm / 45mm extrudabody.com units that flow more than 48mm TWM's. All the information is on their website.

Sandeep