Eastcoast Berrien build

JamisonWorkshop · Posted: Mon Jul 18, 2011 1:15 pm Post subject: Eastcoast Berrien build

New guy here from Maryland. Figure I would get this up here for some criticism. Still learning but rolling along.

So I picked it up on 7/1 just before the 4th of July weekend. Spent Friday night staring at it while drinking.

Been wanting to build up a VW bug for as long as I can remember. Next thing I know I am knee deep in Toyotas for 15 years. SO since I am never one to sit idle and need something else to work on since the Toyota toys are pretty much done I picked this thing up.

1970 Bug chassis with a running 1971 1600 dual port engine. IRS rear. ball joint front.

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I have been around them in the past but never got to sit down and go over it to get all the concepts in my head. Nice with no body so it is easy to see just how simple these things are.

So simple that by the end of the day on Sunday the front end was already done.

Lucky for me it was all in really good shape. Ball joints are good. Looks like new wheel cylinders, shoes have material. Brake lines are good. bearings were good.

I removed 6 of the small torsion leaves from each of the tubes to soften the front up a bit since I will not be going with a full bodied bug.

So with that said. Hit up Lowes. $20 in paint and tape and the front end is back together. All I need to get are tie rod ends and shocks.

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I needed to get the engine out so that I can begin on cleaning up the back. I anticipate the same as the front for the most part. Strip clean and reassemble.

Once I got the engine off I got it torn down to giveit a look. Not going to do anything at this point internally aside from clean the heads check the valves and put it back together clean and swap parts as needed and chrome the hell out of it. Cool

All stripped down. Took all of 20 minutes. Laughing

So that is where we sit right now. I have like a whopping 8 hours into this thing so far.Will get into the back this weekend I guess.

If I would have known how quick and easy I would have gotten one a long time ago. Already want another.

For the plan. I am doing a berrien buggy. will be making my own pans and rails for a solid foundation for a full cage out of 1.5" dom with some lowback PRP's and simple interior. Supposed to be a winter project but I can't help myself. Once I get going I go.

Updates will be slow on new parts as I need to save for the body first thing so I can mock up the tunnel cut and the pan layout. Will be kind of stuck until I do that. Atleast I can get the engine and suspension cleaned up in the mean time.

JamisonWorkshop · Posted: Mon Jul 18, 2011 1:17 pm Post subject:

Still rolling along here. I have been trying to keep myself busy with getting the back taken care of. Here is all the parts for one side.
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Not much to it. Still need to get to cleaning them all up. Will need new bearings and seals for the back. All bushings for the torsion seem good as well as nose cone support.
Will definitly be getting tranny mounts.

Since the next step is to get it shortened the needed 14 1/2" for the body I went ahead and made the cut. They say it is much better to work on things in pieces right.
I am horrible for doing things in order, but the more paint the better. I was going to wait to put it together until I got a body. Since I wanted to still stay busy I went ahead and cleaned up both sections and primed and painted them.

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To deal with the lines running through the tunnel takes a little finess.

There is clutch tube, accelerator tube, (2) emergency brake tubes, fuel line, and (2) heater tubes that will not be used.

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The ebrakes get cut off at the rearmost cut and left as it moves them closer to the ebrake handle. The clutch, accelerator and fuel all stay long attached to the front end and massaged back through the rear section and out original holes. Was not too terrible.

Last night I went ahead and squared the chassis up and measured all night long until thoroughly pissed frustrated and wore out. Then I welded it all back together.
Took forever as Iwas getting varying numbers depending on where I measured from and then had to break out 4 ratchet straps and start tweaking it this way and that.

Suprisingly once it was all said and done I was happy with it and feel it is pretty spot on.

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I still need to flip it over this evening and weld the underside and that should all be completed. touch up that area with paint and the tunnel is all done.

I was in a hurry to get that completed as I am going up to Acme Car Co. tomorrow to pick up the body. Smile

Should be waiting for me.

Red Berrien body, Bubble side pods, windshield frame and dash/column support. Very excited. I know once I get going I cant stop. Smile

I know the bodies are made for roughly the 14 1/2" cut so I went ahead and did it and will massage as needed. The side rails I will be able to start on once body is in hand as I know the bodies do vary in dimensions from side to side and want to make sure the outside edges are flush to match the body.

Will update tomorrow or Sat. once I have something fun to look at.

Then I have this stuff still to clean up

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and this stuff.

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Ned to make an order at the end of the month that will include all misc. things I need to button the chassis up and start on body work.

Breaking it down into chassis, body, engine, wheels.

One thing at a time.

JamisonWorkshop · Posted: Mon Jul 18, 2011 1:19 pm Post subject:

The following is from this past weekend 7/16. Two weeks in.

Weekend update report.

Friday I took off and headed up to New Cumberland to Acme Car Co. to pick up the body. Real big hurddle to get out of the way since without it I would be dead in the water for progress.

Uneventful trip. Cool oldschool place to get anything you need. Engine and tranny work as well.

Got the body home for a test fit.

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The front sits on the horsecollar pretty good.

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JamisonWorkshop · Posted: Mon Jul 18, 2011 1:20 pm Post subject:

I got a front crossbrace kit that supports the steering column as well as gives a place to mount the stock wiper motor assembly. Seems to really stiffen up the chassis.

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Side pods. Really nice touch to finish off the sides. Will have to wait a while for install as they are in the way of everything to keep them attached.

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Windshield frame was the biggest bummer of the weekend. It comes assembled. They say in the instructions to bend the ends to match the angle of the hood.

Alright easy enough. Well the passenger side has to be bent so much to get it flush I snapped the damn thing off. :doh: Mad

:doh: Pisseed me off. $300 windshield to shit in less than an hour. It was so close too. Just wanted a little more to get it flush. Guys are saying it is the most nerveracking part. I can agree.

Pre break.

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After the body was good enough to sit. I got the rear all finished up. control arms in and greased. all hardware in. bearings are good.Brake drums back on and the trans in.

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JamisonWorkshop · Posted: Mon Jul 18, 2011 1:21 pm Post subject:

the rear brakes still need rebuilt. Got the CV's apart and just need the boots.

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I will have to pull the trans again while I work on a few things but it is just two bolts at this point.

My buddy brought over a good pedal assembly for me to use. I got that cleaned up and ready.

Right now I have no parts left to clean and go on. All done.

Aside from the body and initial purchase I have $75 in the thing so far. That was for the paint, tape, rear trans mount and torsion covers. Very Happy

but the big hurdles are over. Need to get the steel and finish sub frame and get the body mounts all good and then I can start adding the smaller things.

mstevens · Posted: Mon Jul 18, 2011 3:40 pm Post subject:

Wow, you are cruising through this build! I should bring over all 3 of my Manx projects so you have some other stuff to work on while you wait Very Happy

Mike_CNYBuggy · Posted: Mon Jul 18, 2011 5:02 pm Post subject:

Lookin good! sorry to hear about the windshield, what are you going to do?
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Kristen's Buggy (UltaViolet) Build Thread

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JamisonWorkshop · Posted: Mon Jul 18, 2011 5:21 pm Post subject:

not in a hurry to get it fixed since there is still plenty to do but I guess I will give Dino a call and see about just getting a new frame and hope for the best yet again.

Sucks that you have to do all that to get them to fit. It snapped right at the screw to the cross bar.

Would be nice to have them pre bent a bit on that side for piece of mind.

vincent9993 · Posted: Mon Jul 18, 2011 5:29 pm Post subject:

Vealmonkey · Posted: Mon Jul 18, 2011 5:49 pm Post subject:

You're a machine. LOL Nice progress. I think your buggy will be nice when done. Now if only I could get you to work on my Tow'd! LOL It's taken me a while longer and nothing fits the Tow'd, it all has to be tweaked. Best of luck with that windshield.

bornred62 · Samba Member Joined: January 09, 2005 Posts: 187

Call Dino and get the mounting flange not sure what its called. Goes up inside the groove on the windshield. I also have a berrien body and I put the gasket on the frame set it on the hood used his whatchamacallit to make the bend on the car and you know exactly when to stop as you have found out you can go to far.You can order a new windshield through the manx club. Ships on greyhound bus was real easy if you have a bus depot close to you. Good Luck

MURZI · Posted: Mon Jul 18, 2011 6:09 pm Post subject:

On the windshield I used a huge pipe clamp and pulled in that passenger side slowly.......
_________________
PENNY LOAFER MAFIA..step up or step back...
1962 Beetle Convertible http://s23.photobucket.com/albums/b374/MURZI/new%2062%20vert/
1968 BAJA http://s23.photobucket.com/albums/b374/MURZI/testmule/
My old Dune Buggy http://s23.photobucket.com/albums/b374/MURZI/

Quit playing...build a 2276 and be done with it.......

JamisonWorkshop · Posted: Mon Jul 18, 2011 6:24 pm Post subject:

So there is a way to bend the frame while on the car?

I did it with the windshield in. Is that not good either?
Was a bit worried as I could feel the frame flexing around the glass.

I had an old driveshaft laying around that I stuck the frame in wrapped in a shirt.

Wondering if the 2x4 method may take the strain off of the edges and help.
Deal with it later. Got to think positive.

just waiting to fill the piggy bank.

vincent9993 · Posted: Mon Jul 18, 2011 6:28 pm Post subject:

JamisonWorkshop · Posted: Mon Jul 18, 2011 6:34 pm Post subject:

I think simple is best. Stock bug Speedo and maybe oil temp gauge.

I have the column from the chassis with ignition and both turn signal and wiper levers. Either going to go that route and modify to fit or I will get an early column.

Want to keep dash clean for now. Will add as needed.

MURZI · Posted: Mon Jul 18, 2011 6:57 pm Post subject:

What I did was use carriage head bolts for a clean look....no bolt heads showing. I bought super long ones for the passenger side and large fender washers. I clamped the big pipe clamp in place and tightened it slowly and then tightened the carriage bolts.....did that a couple of times until it sucked in. I then buzzed the extra length off of the bolts under the dash. Easy but nerve wracking.
_________________
PENNY LOAFER MAFIA..step up or step back...
1962 Beetle Convertible http://s23.photobucket.com/albums/b374/MURZI/new%2062%20vert/
1968 BAJA http://s23.photobucket.com/albums/b374/MURZI/testmule/
My old Dune Buggy http://s23.photobucket.com/albums/b374/MURZI/

Quit playing...build a 2276 and be done with it.......

crack monkey · Samba Member Joined: March 12, 2004 Posts: 232

i am right in hagerstown... i will be watching the build close. rock on

andk5591 · Posted: Thu Jul 21, 2011 4:51 am Post subject:

Very nice work - I was planning to get a body from Acme this fall for our buggy, but the engine in my woodie went south, so I ended up spending the money on a longblock.
_________________
D-Dubya Manx clone - 63 Short pan,1776.
Rosie 65 bug - My mostly stock daily driver.
Woodie 69 VW woodie (Hot VWs 7/12).
Maxine 61 Cal-look bug - Cindy's daily driver.
Max - 73 standard project at wife's request and your gonna die when you see this one.

MDmanx · Posted: Thu Jul 21, 2011 12:08 pm Post subject:

Looking good Mike! That is a total bummer about the windshield frame, I'm sure we could find somebody local that could weld it back together so you'd never be able to tell it was broken.

Seeing you progress so quickly is making me feel a little guilty for taking the tags off mine. I'll definetly have to have mine back on the road for next spring. Hagerstown cruise night usually has lots of cool VW's.

Keep it up! -Brian

JamisonWorkshop · Posted: Mon Aug 01, 2011 6:14 am Post subject:

Weekend update.

Got the floors complete. All welded up painted.

Went with 1/8" floor pan and 2x2 3/16" side rails. Plenty sturdy.

Went with the 2x2 since with the side pods mocked up there was exactly a 2" gap between the body and pod. Figure that is a good area to make up and have a nice strong connection and the bolts going through both.

Once I get my order in I can start on the systems. First up will be pedals, with clutch brakes and throttle. Shifter and linkage as well as getting the tranny in with all mounts and axles. I have everything to make the brakes complete. Steering can start to get finished up to the wheel.

The dirty work is over.

Will pick up some indoor outdoor carpet this week to get the floors covered. May leave tunnel open not sure yet.

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