Shane's Build Thread (Picture Heavy)

darkflaw · Posted: Sun Oct 30, 2011 1:30 pm Post subject:

Picked up a gallon of Zep-a-Lume from work, contains muriatic I believe. Spraying it on, scrubbing with a small brush and rinsing with solvent.

Vanapplebomb · Posted: Thu Nov 03, 2011 4:44 pm Post subject:

You were asking about the Jamar Super Shifter?

Thats what I got. Its a nice simple bolt on ready to go unit.

Mine didn't come with a shifting linkage, but It looks real easy to make a nice adjustable one with nothing more than threaded steel rod with the same threading as that on the end of the shifter, a hexagonal coupling bolt to hook the rod and shifter together as well as provide easy adjustment, an early donut style style shift coupler for the transmission side, and four set screws. Then all that needs to be done is drill two holes in the hexagonal coupling bolt for set screws to keep the rod from twisting, and get set screws and stick them en the holes in the treaded coupler and the shift coupler.

Boom there you have it. Everything minus the VW donut style shift coupler can probably be had at a pretty much any hardware store for less than 20 bucks.

darkflaw · Posted: Thu Nov 03, 2011 4:47 pm Post subject:

Good to hear, I really like the looks of the shifter and will definitely pick one up!

Also called Todd at Averys again, spent more money! Arms are shipping tomorrow and also decided to just order all the bearings, stubs, and flanges from him, so next week should have some awesome pictures!

Vanapplebomb · Posted: Thu Nov 03, 2011 5:13 pm Post subject:

Oh, duhhhh...could just use a jam nut on either side of the hexagonal coupling bolt to keep things from twisting. Thats way easier than drilling for set screws. Sorry, that just dawned on me.

The shifter is pretty nice, but the push button lock out is interesting. It certainly keeps you from jamming it in reverse...if everything is adjusted right.

I think the best way to set it up would be while its in reverse to make sure the lockout works properly. Pop the transmission into reverse gear. Revers is all the way counter clockwise and pulled out when looking at the nose cone. Then push the reverse lockout button down and move the the shifter all the way to the left side. Start here, and adjust the hexagonal coupling until the shifter handle is at left middle when the transmission is popped out of reverse and into neutral. At this mid point the shifter should move freely from left to right. Check the other gears to make sure they engage properly. If nothing else, you can at least drive around in reverse all day Wink

Im not sure if thats the easiest way to do it, but thats how I am going to try it.

darkflaw · Posted: Sun Nov 06, 2011 5:01 pm Post subject:

Big updates soon, bear with me Very Happy

Started to paint the transmission parts, primed the nose cone for a test and it looks pretty bad-ass. Used some Rust-Oleum Self-Etching primer, guess it etches into aluminum for a better prime or something. Paint is still wet in the pic, it looks very very flat when dry.
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091 is finally cleaned and ready for primer, currently draining any excess fluids from the inside and air drying it fully.
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darkflaw · Posted: Sat Nov 12, 2011 7:06 pm Post subject:

Dooonneeee. Slight leak on the bottom of bell-housing, think I pinched a gasket Sad

85 pound box of amazing coming Tuesday!

darkflaw · Posted: Tue Nov 15, 2011 4:48 pm Post subject:

Got a ton of parts today!

930 conversion CV flanges installed courtesy of Averys
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930 conversion Stubs courtesy of Averys
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Dual pivot 3x3 Arms with HD bearing carrier (shown below) courtesy of Averys
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HD bearing setup, one large rear two stock outers
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Dual pivot bracket, had to remove everything behind it, see below
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Test fitting! They look amazing!
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And some interesting outer bearings they sent me!
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Thanks again to everyone at Avery's Air-cooled they are an amazing company to deal with and produce amazing products!

Have one more box coming with spacers for my stubs so I can put the rest together. Then once I pay all this off I will be buying axles and brakes!

darkflaw · Posted: Sat Nov 19, 2011 11:41 am Post subject:

Do they even measure when they make these stupid mounts? Not a single one lines up anywhere. Destroyed my mid mount trying to fix it because the bolt holes were about a 1/4" off. Type 1 to Type 2 tabs for the cradle are useless as they are about an inch off from the hole on the bell-housing and had to grind the crap out of the intermediate bracket just to even get it lined up. Don't know why I am building this thing.. nothing has gone right yet, just keep wasting money on parts that don't work as stated.. Doubt pacific customs will do any type of exchange since I have attempted to fix them myself.

darkflaw · Posted: Sat Nov 19, 2011 7:05 pm Post subject:

Finally got the dumb thing in, had to pretty much remake all the mounts.
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Now to just center it and weld in the rest of the tabs!

darkflaw · Posted: Sun Nov 20, 2011 12:23 pm Post subject:

Does anyone know how much offset one side is on the bus transmission?

From the inside of the flange to the out side of the bearing holder on the left side is 24 1/2" and the right side is roughly 24". Sound right?

Vanapplebomb · Posted: Mon Nov 21, 2011 7:20 pm Post subject:

The guy who builds Averys trailing arms has his act together. He put a lot of time and effort into designing, busting up, and tweaking his trailing arms until he got his designs just right. Those are some high quality trailing arms right there man. I'm jealous. Hahaha.
_________________
Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

darkflaw · Posted: Tue Nov 29, 2011 5:15 pm Post subject:

Started to assemble somethings, got the bearings and stubs all done.

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Pretty sure I am going to do a floor next.. Most people have one by now Very Happy

darkflaw · Posted: Sun Dec 04, 2011 3:46 pm Post subject:

Ditching the ball-joint front end.

Should I do a widened bugzyla conversion beam + widened chromoly arms or do an a-arm kit.

Vanapplebomb · Posted: Sun Dec 04, 2011 3:53 pm Post subject:

I think A-arms are silly. Yeah you can get a lot of travel out of them, but why not convert the front of your frame to accept a link pin beam. Trailing link suspensions soak up lots of rearward shock to the frame due to the geometry whereas A-arms can not. I have seen your fabrications skills, so modifying the front to accept the narrower link pin beam should be no problem. They are easy to strengthen and get more travel out of. It may not be as much travel as your A-arms, but it will be more than your ball join front end.

I really like trailing link suspensions. Just my opinion. Maybe I'm just old school. lol

I'm glad your thinking of giving the front of your buggy a face lift. That's an awesome rear end you got there. It would be a shame to leave it with the ball joint front end.
_________________
Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

darkflaw · Posted: Sun Dec 04, 2011 4:03 pm Post subject:

Yea kinda leaning towards the bugzyla beam.

Vanapplebomb · Posted: Sun Dec 04, 2011 4:41 pm Post subject:

I think thats a good idea.
_________________
Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

darkflaw · Posted: Wed Dec 07, 2011 5:28 am Post subject:

Stuck on a tire sire. Not sure what the 091 will handle with an ecotec.

It will never see high speed so the ride isn't important I am looking for grip.

I will be running low pressure bead-locks so wider may be better.

Common Size
31X11.50R15

Medium and Wide
33X13.50R15

Tall and SKinny
34X10.50R15

darkflaw · Posted: Sat Dec 10, 2011 12:54 pm Post subject:

Got my rod ends in yesterday. Having a hell of a time setting the toe.. Anyone have any tips? Don't have tires so its pretty hard.

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Also had to modify my frame horn supports as I had to move the transmission over a half inch to center it for the same axle lengths. Right is modified. Flipped it for easier access to starter and more adjustability.

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Berrien 295 Build Thread
http://www.thesamba.com/vw/forum/viewtopic.php?t=482673

billups · Posted: Mon Dec 12, 2011 12:15 pm Post subject:

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Shane's Build Thread (Picture Heavy)
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