TheSamba.com :: View topic - Already searched Bug IRS into split no kit cut and weld

Thu Mar 18, 2010 10:54 pm

Please help! We were robbed and our computers were stolen with all of my saved posts. I have been searching cannot find the post that had pictures of cutting the torsion housing and bars using all bug donor parts. I already have the bug IRS parts. So if you know could you please send me the link? I have read a lot of posts and I see where you all stand however it is my bus. So I am looking for information on how to do it not why I should not do it. By the way I will have a complete big nut available - the nose cone and stick it only has 5 thousand miles on the rebuild ff. I really like my Bus :D Thank you for your help! :)

Fri Mar 19, 2010 10:36 am

Must not have searched too hard.

http://www.thesamba.com/vw/forum/search.php?search..._chars=200

BTW Bummer about being robbed

Fri Mar 19, 2010 12:30 pm

Thanks for you time however, not what I am looking for! I am not plannning on using a kit of any kind. I will be using all type one parts. I saved the posts that were related but like I said its all gone now. It has all been done before. I have re-searched and read a ton of posts I am looking for specfic posts that utilize all type one parts. Thanks Again 8) Please still need Help! :idea:

Fri Mar 19, 2010 12:35 pm

well if you saved them in your watched topics or bookmarked it on your account then it should be under your account go to your profile. and shame on you for what you are about to do :lol:

Fri Mar 19, 2010 1:01 pm

I did it on my deluxe. I cut the pivots off the beetle torsion welded them on the bus, cut the spring plates to match the Beetle trailing arms and made custom length axels to accomidate the new setup. I have been running them since 2004 with no issues.

Fri Mar 19, 2010 8:07 pm

Thanks for your vote of confidence! How long did you make your plates did you just measure so they would be centered in the wheel well? The Bug has two plates so did you just use a single outer bus one? Instead of the sandwich? I am going to narrow my torsion housing as well that way I can use the same axels. :D I really like the avatar "Why buy what You can build. I narrowed my front beam and flipped my own spindles and built my own stroker. I really like my Bus! 8)

Sat Mar 20, 2010 5:23 am

Most beetles don't have the double plates. I just have one. I never recorded the measurements. I measure and adjusted the toe in as a went. Here is the plate.

Sat Mar 20, 2010 6:49 am

rodgersbadassbus64 wrote: Thanks for your vote of confidence! How long did you make your plates did you just measure so they would be centered in the wheel well? The Bug has two plates so did you just use a single outer bus one? Instead of the sandwich? I am going to narrow my torsion housing as well that way I can use the same axels. :D I really like the avatar "Why buy what You can build. I narrowed my front beam and flipped my own spindles and built my own stroker. I really like my Bus! 8)

jeremyrockjock wrote: Most beetles don't have the double plates. I just have one. I never recorded the measurements. I measure and adjusted the toe in as a went. Here is the plate.

Measure trice, cut once! I almost made a big mistake when doing my IRS. I had "copied" the pattern from a phatchick T2 plate to the early plate. However, upon measuring the wheel base I realized I was a whole inch off!!! :shock:

I measured yet again a couple of more times and then relocated the bolt pattern to get the correct wheel base then proceeded to machine the slots. Basically what I'm saying here is that you will pretty much have to do as you go. Specially since you don't want a "kit", you are making your own. 8)

Sat Mar 20, 2010 9:33 am

Thank you both I have read your old posts and really appreciate your experience. I like the suggestion to keep the stock wheelbase. The word of caution is also appreciated. I found posts which lead me to Coach werks and Creative engineering. Two parts of the puzzle. It looks as if I will be narrowing my Torsion housing 1 1/4 on each side. I will then be using the stock center mounts and notching my tubes like the stock bug. If I am not going really low as I just have flipped spindles in the front would you suggest to just doing it like the stock bug. Any suggestions about the shock towers should i modify them or will I be able to leave them alone? Thank you very much :D

Sun May 02, 2010 9:53 pm

All welded up. Cut down the plates. Narrowed the torsion housing 3 inches. All bug stuff. Repacked the bearings. I will be using bug rear disks w/o e-brake. :roll: The Trans is back in sitting on the ground. I am excited. :D

Fri Sep 24, 2010 1:43 pm

PM sent rodgersbadassbus64 .

Fri Sep 24, 2010 7:04 pm

Did you take pictures of what you did or make any templates? I'd like to see what it looks like.

Sat Sep 25, 2010 3:40 pm

I am really bad with documentation. Sorry. When I did the TH i cut the end of the housing off 1 and 1/4 each side with a sawzall . I first marked my t springs with a shinny-wheel so I would know where the top lined up with the o on the end for indexing purposes. I cut my T springs with a miter saw with a cut off wheel. Next step I had my brother weld a piece of three inch tubing to the out side of TH that I cut off so it could be chucked in a lath and turned down the ends so they would slip into the remaining TH instead of drilling out the spot welds when this was done I lost another 1/4 of an inch to clean up my cut. Much faster. I re-indexed and welded up the TH. I used a IRS bug spring plate for a template. I cut out the center of the bug spring-plate with a torch. Just laid the bug plate on top of the bus plate clamped and marked everything out. I drilled two holes side by side for each of the bolt holes and used a die grinder to finish them up. Used a skinny wheel and a band saw to cut the bus plates down to the same size as the irs bug spring plats and finished up with a die grinder. Done

I reused the brackets off of the bug TH and radius for the larger bus TH. I cut the trans dog legs out on the inside to make room for the brackets very similar to the bug the are recessed as well. I should have just bought new brackets they are available. BTW before I cut them off I made a jig that looked like a big u. -i_I- I used two pieces of 1 1/4 inch tubing about 13/4 long large enough for the stock bolts to go through. Welded two legs of 1 inch sq tubing about 9 inches long onto a 22 inch piece of 1 sq inch tubing this made locating the brackets easier.

This was a very fun project. I do not like my shock brackets because I narrowed the housing when u don't narrow the housing they are in a better position. I had to collapse the shocks and put the bolts in the bottom then hurry and put the top bolts in they are gas so they expand. They are at a weird angle. Other than that. The lower trailing arms it is necessary to install the pivot bolts first and then raise arms into position. That was not easy. When It was almost complete I used a tape measure to get my toe-in correct by measuring from front spindle to rear axle center-line. I used a ratchet strap to apply tension and tightened bolts. If I could do this so can you. I did not have to clearance any of my frame rails. All bug stuff no extra parts. I did need all of the bug spring plate bolts. I used adapter plates so I need some 12 mm wheel lugs from wrecking yard. I also used bug disk brakes my only regret is I did not get the emergency brake kit I should have and it cost me dearly. Lessons learned.