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Yet another buggy build, here goes...........
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jakerot
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PostPosted: Thu Sep 03, 2015 4:08 pm    Post subject: Reply with quote

Thanks joem.

Frame head and tunnel are lined up. Look at the pix again and look at the hole in the FG body. You see the round button in there? That's the emergency brake release button which should be aligned with the CL of the tunnel/frame head.

However in this pix you will see the hump of the FG body is no longer centered on the napo hat due to warpege of the FG body. Who cares never gonna see it. As long as the body is centered over the tunnel I am ok with it. The lift compensates for this mis alignment.

The FG body looks like crap over the rear hump. Will address this soon enough. Still deciding plan of attack.
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jakerot
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PostPosted: Fri Sep 04, 2015 11:11 pm    Post subject: Reply with quote

More fiberglass work. More grinding.

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Laid up 3 layers of cloth

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Its progress, one layer at a time. Think
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joescoolcustoms
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PostPosted: Sat Sep 05, 2015 6:51 am    Post subject: Reply with quote

Nice!

Of the 10 buggy's I have built, only one did not need to be opened back to stock width.
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Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone
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jakerot
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PostPosted: Wed Sep 23, 2015 9:27 pm    Post subject: Reply with quote

It's a battle for sure. :2gunfire:

Added 2 layers of vectorply to the sides

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Working on the bottom of the corners.

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They turned out well

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jakerot
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PostPosted: Wed Sep 23, 2015 9:43 pm    Post subject: Reply with quote

The red line is the trace of the body lift

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So now I have it bolted back together while I contemplate the last part of the body I have to address structurally: over the hump.

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I don't like the way this looks. Want the FG body to site nice and flush to the body lift over the hump. So now I think I am going to hack the FG body flange over the hump and rebuild it. I can take this opportunity to rebuild the flange so it matches the body lift as well.

Yes I know some people could live with the way this looks; I can't. It's going to bug me. It's a curse. Very Happy
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Iguana
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PostPosted: Wed Sep 23, 2015 10:07 pm    Post subject: Reply with quote

Looking good, she will be a nice fit when done.

Another trick we use to do was put a flat plate up the front of the front lift kit yoke so you could bolt the body to it and avoid the issue we keeping the hump sealed as the body flexed. It was a major PITA when it leaked in the wet places we use to drive around.

Doing it your way you will have very little issue which is a great thing.
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jakerot
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PostPosted: Wed Oct 07, 2015 10:56 pm    Post subject: Reply with quote

Thanks Iguana, I hope so

More fiberglass work.

Marked up the cuts for the rear hump.

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Cut it up. Can I just say, these multi master tools are awesome. Used it to cut the body. Made nice cuts.

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Clamped

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Laid up some more vectorply.

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Made a lip going up (down) the side of the lift.

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Next up is profiling the piece over the hump I cut out to fit in new opening.

I'll fiberglass it in and then will be ready to flip the body back over.

In other news, started to assemble the rear trailing arms. Been cleaning and re packing bearings, etc. assembled one trailing arm, working on another.

Once body is done time to get the chassis on wheels for mock up purposes.

Been looking on CL for a JD2 bender without any luck. I'll tell ya what, if you didn't know any different, you would say it's a conspiracy. Can't catch a break. 3 times now one would pop up and I would reply within 24 hrs of posting to find out it has been sold, including the last time yesterday where I replied 12 hrs after posting to find it had been sold. Evil or Very Mad Mad Twisted Evil

Bought some 1 5/8" and 1" tubing, 20' lengths, and some 1 3/4" x 1/4" x 20' flat bar.

Progress progress. Very Happy
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jakerot
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PostPosted: Wed Oct 14, 2015 9:38 pm    Post subject: Reply with quote

Allright, more FG work. Rear hump area re-assembled. Filled in the curved lip area so I can reshape it to match the curve of the lift over the hump. Huh? Laughing

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Chassis here I come. Started working on the other trailing arm.

Still on the hunt for a tube bender.

Sprayed brake cleaner inside the spring plate tubes to get the rest of the grime and media out. I had these media blasted and primed. They didn't mask off the openings so media contaminated the grease. They said they would mask them off so I wasn't too happy about that. I had already cleaned them and greased them along with the torsion rods. Doing it again. Lesson learned. Tape off my own stuff from now on.
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jakerot
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PostPosted: Thu Oct 15, 2015 4:25 pm    Post subject: Reply with quote

Unbelievable. Another JD2 bender popped up on CL yesterday. I replied less than one hour after the ad was placed. No response. Today the ad is gone, assuming it was sold.

Now if you will excuse me, I am going to go bang my head against a wall. Many times.
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jakerot
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PostPosted: Sun Oct 18, 2015 2:34 pm    Post subject: Reply with quote

Ok I picked these up today. Saw an ad on CL from someone cleaning out a yard. For $160 I got 4 blocks and a tow bar.

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All blocks rotate. I am hoping to salvage the cases. For now I am trying to figure out what they are.

2 of them have codes under the oil filler.

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This one is a H case which I believe is:

H5 1968-69 1500cc 44bhp DIN, 53HP SAE M157 USA/Canada.

I have read these are SP and are junk because they can crack. Oh well.

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This one is a AB case which I believe is:

AB 1971-73 1300cc 44bhp DIN, Non-USA.

I don't see any stampings on the cases to lead me to believe they have been line bored or thrust cut.

There is one case that has this metal overlay where the case # usually is, and then this number stamped on one of the case halves

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Gonna have to do some research on this one.

Then there is this case. It says Germany on the case. Has no numbers stamped under the oil filler, but there are 3 dots there. No stampings on the top of the case I can find yet.

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Going to look into this one more as well.
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jakerot
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PostPosted: Sat Oct 24, 2015 11:29 pm    Post subject: Reply with quote

Got rear trailing arms and wheels mocked up today

Painted front drums too

It's progress. First time rear wheels have been installed.

Can't do the front wheels yet because off-road supply house sent me wrong parts. Ordered 4 sets of 4 lug stud conversion for mag wheels and off-road part supply house sent me 2 for 4 lug and 2 for 5 lug ( different stud size). Crap. Ordered them 2 years ago and one package is open so not going to even bother trying to get them exchanged. front end mock up on hold till I get correct studs. Oh well.

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Iguana
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PostPosted: Sun Oct 25, 2015 1:03 am    Post subject: Reply with quote

Looking good. If you are going to use the red rear trailing arm rubbers make sure you add some sort of pivot bolt retainers.

With any of the aftermarket rubbers the inner sleeve spins freely and thus the bolt undoes much more than it did with the factory style rubbers where the inner sleeve did not spin.
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jakerot
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PostPosted: Tue Oct 27, 2015 9:18 pm    Post subject: Reply with quote

Thanks Iguana. Yah I got a set of those buried somewhere in a box. Never knew the loosening mechanism however. That's a good point.

Well I pretty much got the cases figured out with the help of the samba community.

The 043 case is the best I believe, at least in terms of factory features/mods. Looks like 8mm case savers and there is a beefed up area behind #3 cylinder. Factory # 3 reinforcement I presume.

The H case will probably be used as a test subject.

The AB and T cases looks like they might have potential. But with all 3 I won't know until I split'em and see what condition the bearing saddles and thrust surfaces are in. I am sure there is a reason why they were sitting as they were.
Rolling Eyes
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jakerot
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PostPosted: Tue Oct 27, 2015 9:25 pm    Post subject: Reply with quote

So it's back to the roller build.


Got the front beam attached and spindles attached

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And I got 4 wheels on it now.

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A levitating roller.

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gr8cobbler
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PostPosted: Wed Oct 28, 2015 5:05 am    Post subject: Reply with quote

Kind of a new take on an air ride suspension....?


sorry
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jakerot
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PostPosted: Mon Nov 09, 2015 5:16 pm    Post subject: Reply with quote

Haha air ride.......nice. by the time I am done with this thing cars will probably have "levitation" as a standard feature. Shocked

Got tranny and long block mocked up.

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Disassembled one of the starters to clean it up. So much grease and grime. Took apart the solenoid as well to clean the contacts. Couldn't get this wire clip off though. Guess I'm not supposed to.

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Re assembled and installed in tranny. Gave it 12 v and it spun and pinion gear did come out.

And some good news.........I finally got a bender on Craig's list. Jd2 model 32. Clean no rust PO said used for one project. Came with stand and 1 1/2" x 6.5" 180deg and 1" x 3.5" 180 deg dies. Only problem: I already bought 1.625" tubing so I will have to buy another die. I read somewhere 1.5" die could be used for 1.625" tubing, or was it the other way around?

Slow progress, but it is progress I guess. Very Happy
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jakerot
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PostPosted: Mon Nov 16, 2015 10:08 pm    Post subject: Re: Yet another buggy build, here goes........... Reply with quote

More cleaning stuff. More engine mock up.

Got this low buck tube notcher on CL. Hopefully does the job.

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jakerot
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PostPosted: Thu Nov 19, 2015 9:06 pm    Post subject: Re: Yet another buggy build, here goes........... Reply with quote

Got the body and lift bolted to the chassis. Will post pix tomorrow in the light

So now I am starting to mount the windshield to the hood. i have a early style windshield which doesn't have the type of channel for a hidden fastening, so I am guessing I have to drill holes in the frame and bolt to the hood

My question is this windshield looks like it was mounted before, but how the heck did they do it with this frame profile?

I'll drill the holes no problem but if there was some other method of attaching these early windshield frames I would like to explore that option first.

This profile doesn't look like it would allow for a secure attachment however

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Thanks everybody !
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jakerot
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PostPosted: Tue Nov 24, 2015 10:34 pm    Post subject: Re: Yet another buggy build, here goes........... Reply with quote

Ok so my neighbor JT came through for me. He had a KEP st 1 PP sitting in his garage, not needed. Traded for it for "future considerations"

No centering ring, that's why he didn't need it. his buggy has a swing axle tranny.

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And I got the body on. Finally get an idea as to what it will look like.

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Progress progress
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joescoolcustoms
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PostPosted: Wed Nov 25, 2015 7:06 am    Post subject: Re: Yet another buggy build, here goes........... Reply with quote

Looks good!

Like to see that tubing notcher in action. It looks interesting.
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Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race

Everyone is gifted. Some just do not open the package.

Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone
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