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quadrazer
Samba Member
Joined: April 11, 2010
Posts: 293
Location: Castalia, Ohio
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 Posted: Thu Jun 17, 2010 3:32 pm Post subject: |
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| TC/TeamEvil wrote: |
Thanks for that link ! ! ! Although I bought assembled CV joints, it's still great to know how the inner and outer rings ought to align, I'm going to double check my new ones to be sure that they're correct.
I guess that clocking them means drawing a line down the axle and making sure that the wide area of one and the narrow area on the other hit the line. Seems like a small procedure, but an important one as well. Funny how that always seem to hold true.
It was VERY interesting to learn that the axles should NOT be rotated end for end to spread the wear over time, unlike tires I suppose. Evidently, they always have to be re-installed with the same end facing in (and out) and on the same side as originally. Makes me concerned about buying a good used pair of axles, how would I ever know it they were marked correctly.
Thanks SO much for this new (and really crucial) info ! ! Your project has inspired me to one day try to shove my Buick into my rail. It WAS in the Ghia . . .
http://img.photobucket.com/albums/v136/TeamEvil/File0003.jpg
http://img.photobucket.com/albums/v136/TeamEvil/File0002.jpg
http://img.photobucket.com/albums/v136/TeamEvil/File0001.jpg
A V6 in a rail must be crazy fast; any chance of a longer video?
Thanks !
T |
T,
No problem on the info...although I honestly can't take credit for it. HBB had posted it, along with TONS of other information, at this link:
http://www.thesamba.com/vw/forum/viewtopic.php?t=123315
You make a good point on buying any used axles, although I suppose it would be ok to keep a used set for spares, even if you don't know how they were mounted.
My V6 in the rail did very well last year at Silver Lake Sand Dunes in Michigan. Power was never a problem, and it hauled A$$ when you gave it the gas. The problem was the stock suspension I ran last year. Not even close to being up to the task of dune running. Which is why I went with the 2x3 rear arms and some mini coilovers in the front. As I free up more MAD money (AKA-money the wife lets me spend!  ), I want to upgrade the tranny, then get full coilovers front and rear. I'm sure you are well aware, no matter how much we do to our toys....they're never really done! 
I don't know how to get a really long video on here without a good camera. I shot a 30 second engine video and couldn't upload it because of the file size being too big to send from my phone...which was why I only had a 9 second video.  I'll figure something out when I'm all done with it! By the way....I totally want that "bird catcher" (or butterfly/ram air) air cleaner you have in your V6 pics!! SWEET!!!
As far as progress goes, my other rear seat 4 point harness came and I installed it, and the rear seat.
I hopefully have my front end alignment close to where it needs to be (by my measurements). We'll see when I go for that first test drive.
I'm still building my center console at the moment, which is progressing slowly, but steady.
Tomorrow, I am taking my rail to a local glass shop to have a DOT windshield custom cut and installed in it. Hopefully they get it done tomorrow (like they said they would), because it would kill me to not have it back, since I'd miss a weekend worth of working on the rest of my rail to-do list!
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My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845 |
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quadrazer
Samba Member
Joined: April 11, 2010
Posts: 293
Location: Castalia, Ohio
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| Posted: Mon Jun 21, 2010 6:41 pm Post subject: Center console |
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First of all, last Friday did NOT go as planned at the glass shop!  I took my rail in to them, with the Empi windshield rubber that is suppose to be used to mount the glass to an 1 1/2 tube chassis. The glass guy took one look at the rubber and said "No Way!" 
He told me it would never hold the glass in properly, it would be a liability, blah...blah...blahh. Long story short, he made a template out of cardboard for me to use to make an aluminum frame out of 1/8 diamond plate. After I make and install the aluminum frame, I have to take it back to him and he will use his rubber (a completely different style) to mount the glass. At least he was cool about it, and he said the price would be the same as he origionally quoted me, even though he made the template and is using his rubber. Ahhh....more work! 
Anyways, I thought I would post the pics of my finished center console, from start to finish. It was built using a combonation of wood and aluminum, which made for an interesting time...as I usually reserve any woodworking for the house! At any rate...here we go!
It started with a rough idea on cardboard, based on the measurements for available room in the cockpit area:
Which I put on 1/2" plywood....
....and cut out to rough shape....
....started piecing it together with screws, finish nails and elmers glue.
As it took shape, I made a small change to the leading edge of the console:
After the main box was assembled, it was sanded, cleaned, and I applied a skim coat of body filler to fill in the screw/nail holes and other imperfections:
After sanding the filler and more cleaning, I applied 3 coats of primer/sealer:
And topped it off with 2 coats of spray on Rhino liner to match the floor:
With the base pretty much complete, I moved on to the aluminum diamond plate cover in which everything would be mounted. I started with a 7"x24" flat sheet of 1/16" diamont plate, measured and drilled a hole for the speedometer, then made a series of bends to match the base:
Then drilled all remaining holes for gauges, switches, ignition, and mounting bolts:
After securing the new base to the rail chassis, I sprayed 2 coats of Rhino liner on the diamond plate console cover. Once dry, I mounted everthing into the new console cover, and bolted the cover to the base:
There are amber turn signal indicators above the speedometer, a turn signal switch on the lower left of the speedo, 4 toggle switches across the flat for horn, lights, electric fans, and windshield wiper. Below those is the oil pressure gauge (left) and water temp (right), with a red warning light between them for alternator, and the ignition switch.
Hard to believe how time consuming this actually was to make! While not perfect, I was happy with it overall. It was one of the biggest hurddles left on my to-do list! Now, I move on to the windshield frame.
_________________
I DID wash my hands....the rest is 'built-in' dirt!
My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845 |
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tanner_122
Samba Member
Joined: July 20, 2009
Posts: 1239
Location: Norco CA
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| Posted: Mon Jun 21, 2010 6:47 pm Post subject: |
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i want one!!!! hahah
looks good
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91 jeep Cherokee "TANK" |
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quadrazer
Samba Member
Joined: April 11, 2010
Posts: 293
Location: Castalia, Ohio
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| Posted: Mon Jun 21, 2010 6:48 pm Post subject: |
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| tanner_122 wrote: |
i want one!!!! hahah
looks good |
Tanner, if I had to do it again.....I'd BUY one!
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My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845 |
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quadrazer
Samba Member
Joined: April 11, 2010
Posts: 293
Location: Castalia, Ohio
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| Posted: Sat Jun 26, 2010 2:12 pm Post subject: |
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Here are the pics of my windshield frame build and installation. I didn't want to have to put one in, but in order to pass Ohio inspection for obtaining a title, I needed a DOT safety glass windshield and one windshield wiper.
I took the rail to the glass place, as I said in an earlier posting, and found out I needed to build an aluminum frame based on a cardboard template they made using my rail. Here's how it went:
Here's their carboard template, I layed out on a 1/8" piece of aluminum, I just traced it out with a marker:
Then cut it out:
Painted it in flat black and mounted it to my chassis:
After that....I took it back to the glass shop where they custom cut and installed the safety glass. In this picture you can also see the wiper arm I mounted through the same aluminum sheet. The wiper motor/arm assembly came out of a 1991 Chevy S10 Blazer at the local salvage yard:
I need to build a cover for the motor, but I did clean and paint it for now. At least it's relatively small:
Moving on to the last "major" task.....a parking brake setup. This should be fun! 
_________________
I DID wash my hands....the rest is 'built-in' dirt!
My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845
Last edited by quadrazer on Sun Jun 27, 2010 6:40 am; edited 1 time in total |
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Barentine
Samba Member
Joined: December 31, 2009
Posts: 78
Location: Colorado
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| Posted: Sat Jun 26, 2010 5:56 pm Post subject: |
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| quadrazer wrote: |
Then cut it out:
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You, my friend, have got some mad cutting skills with a 4" disk!  |
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ts39136
Samba Member
Joined: January 30, 2010
Posts: 715
Location: Pocatello, Idaho
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| Posted: Sat Jun 26, 2010 6:14 pm Post subject: |
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| quadrazer wrote: |
| DOT safety glass windshield |
That sounds dangerous? Is this the layered kind? I sure hope it's not just tempered glass.
Looking good.
| barentine wrote: |
| You, my friend, have got some mad cutting skills with a 4" disk! |
And a hole saw Yes, quad, looks very clean.
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quadrazer
Samba Member
Joined: April 11, 2010
Posts: 293
Location: Castalia, Ohio
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| Posted: Sun Jun 27, 2010 6:37 am Post subject: |
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| Barentine wrote: |
| You, my friend, have got some mad cutting skills with a 4" disk! |
Now that is funny! Yeah....cutting those 2 inch wide sections were fun with a 4 inch disc!
In all seriousness...I used three different tools for cutting this one out. I started with a 2 inch hole saw for the notched areas at the bottom. All of the long straight areas were done with the 4 inch cutoff. Then the long radius curves (as well as the really short straights), were done with a jig saw using a 24 TPI blade. While using the jig saw, I used a spray bottle full of water mixed with a teaspoon of Dawn dishwashing soap for cooling and lubrication of the blade. It was a fun little project! 
Tim,
This glass is the exact same as all other windshields, a laminated saftey glass. It has the laser etching on it which lists the DOT, ANSI, and CFR numbers for standard compliance.
And no....not tempered glass. That would be a guillotine waiting to happen! 
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I DID wash my hands....the rest is 'built-in' dirt!
My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845 |
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Russ Wolfe
Samba Member
Joined: October 08, 2004
Posts: 25689
Location: Central Iowa
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| Posted: Sun Jun 27, 2010 8:03 am Post subject: |
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| quadrazer wrote: |
Tim,
This glass is the exact same as all other windshields, a laminated saftey glass. It has the laser etching on it which lists the DOT, ANSI, and CFR numbers for standard compliance.
And no....not tempered glass. That would be a guillotine waiting to happen! |
Tempered glass is not physically dangerous. It will break into a million small pieces that are not sharp. Most sedans have tempered glass in the side and rear windows.
Most glass shower doors are tempered glass.
Windshields in USA cars by law are supposed to be made from laminated glass.
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Society is like stew. If you don't keep it stirred up, you end up with a lot of scum on the top!--Edward Abbey
Gary: OK. Ima poop. |
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quadrazer
Samba Member
Joined: April 11, 2010
Posts: 293
Location: Castalia, Ohio
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| Posted: Sun Jun 27, 2010 8:14 am Post subject: |
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| Russ Wolfe wrote: |
Tempered glass is not physically dangerous. It will break into a million small pieces that are not sharp. Most sedans have tempered glass in the side and rear windows.
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I stand corrected...my apologies Russ. My guillotine quip was a poor one. The difference is that the lamination, in itself, helps to prevent the spread of those small pieces of glass. Unlike non-laminated tempered glass, which as you pointed out, will break into small pieces and spread as inertia and gravity dictate. Maybe "buckshot" would have been a better analogy?
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I DID wash my hands....the rest is 'built-in' dirt!
My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845 |
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Russ Wolfe
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Joined: October 08, 2004
Posts: 25689
Location: Central Iowa
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| Posted: Sun Jun 27, 2010 8:34 am Post subject: |
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I am storing a pair of tempered rear window glasses for Type 34 in my shop right now. Very rare VW glass. I hope he comes and gets them pretty soon.
I hauled them from Southern Missouri to my house. He is supposed to come from Omaha to get them.
One ooops, and they are gone.
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Society is like stew. If you don't keep it stirred up, you end up with a lot of scum on the top!--Edward Abbey
Gary: OK. Ima poop. |
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quadrazer
Samba Member
Joined: April 11, 2010
Posts: 293
Location: Castalia, Ohio
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| Posted: Sun Jun 27, 2010 9:35 am Post subject: |
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Russ,
You had to haul the glass and store it? I hope it's for a good friend! Otherwise....that storage fee is gonna be HUGE!
Just curious...where do you get rare glass like that? I'm sure VW probably doesn't have/can't get it anymore.
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I DID wash my hands....the rest is 'built-in' dirt!
My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845 |
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Russ Wolfe
Samba Member
Joined: October 08, 2004
Posts: 25689
Location: Central Iowa
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| Posted: Sun Jun 27, 2010 11:59 am Post subject: |
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| quadrazer wrote: |
Russ,
You had to haul the glass and store it? I hope it's for a good friend! Otherwise....that storage fee is gonna be HUGE!
Just curious...where do you get rare glass like that? I'm sure VW probably doesn't have/can't get it anymore. |
This is called "The Samba Express". Someone in Oklahoma parted out a couple t-34's. The guy in Omaha wanted the glass. I hauled it from Carthage, MO. to my house, near Des Moines, IA. The guy from Omaha is supposed to pick it up soon. He was supposed to pick it up last Tues. but his plans got changed.
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Society is like stew. If you don't keep it stirred up, you end up with a lot of scum on the top!--Edward Abbey
Gary: OK. Ima poop. |
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ts39136
Samba Member
Joined: January 30, 2010
Posts: 715
Location: Pocatello, Idaho
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| Posted: Sun Jun 27, 2010 4:25 pm Post subject: |
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| Russ Wolfe wrote: |
| Tempered glass is not physically dangerous. It will break into a million small pieces that are not sharp. |
that's what I was thinking... No rock chips allowed. Glad it's the real deal. Smart.
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quadrazer
Samba Member
Joined: April 11, 2010
Posts: 293
Location: Castalia, Ohio
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| Posted: Tue Jun 29, 2010 4:00 pm Post subject: We're calling this finished!!! |
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Well....it's been a long and winding road. Long weekends and late nights have culminated into the following photos which, for all intents and purposes, represent my "finished" rebuild of my street legal sand rail! I say finished, but as we are all well aware....they are never really finished.  But this gets me to a point where it is usable, and ready for it's inspection next week by the Ohio State Highway Patrol...in order for me to obtain a title for the rail.
In any case, street legal or not, it's once again ready for action on the dunes for our mid-July trip to Silver Lake Sand Dunes in Michigan.
Here's what it looked like before the teardown began:
And here is the finished rebuild:
A very special thanks to everyone here on The Samba who offered their support, ideas and kind words, during the course of this rebuild! Thanks so much!!
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I DID wash my hands....the rest is 'built-in' dirt!
My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845 |
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tanner_122
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Joined: July 20, 2009
Posts: 1239
Location: Norco CA
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| Posted: Tue Jun 29, 2010 4:15 pm Post subject: |
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looks sweet man!
i enjoyed watching this build!
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ts39136
Samba Member
Joined: January 30, 2010
Posts: 715
Location: Pocatello, Idaho
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| Posted: Tue Jun 29, 2010 6:28 pm Post subject: |
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Nice, quick (re)build. Quality finish.
I even learned a few things along the way.
Don't forget us when you're off having fun... Take a picture or two to keep our spirits going, K?
Good luck with the politicians...
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quadrazer
Samba Member
Joined: April 11, 2010
Posts: 293
Location: Castalia, Ohio
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| Posted: Wed Jun 30, 2010 12:31 pm Post subject: |
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| tanner_122 wrote: |
looks sweet man!
i enjoyed watching this build! |
Tanner,
Thanks man! It's been fun, and a great learning experience.
| ts39136 wrote: |
Nice, quick (re)build. Quality finish.
I even learned a few things along the way.
Don't forget us when you're off having fun... Take a picture or two to keep our spirits going, K?
Good luck with the politicians... |
Tim,
Thanks! And I don't forget friends! Pics will be no problem once I get back from our dune trip. Plus....I plan on continuing to watch your build till it's done!
As for the politicians...here's hoping! 
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I DID wash my hands....the rest is 'built-in' dirt!
My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845 |
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riNR
Samba Member
Joined: June 28, 2006
Posts: 1213
Location: Whitby, Ontario, Canada
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| Posted: Thu Jul 29, 2010 2:59 pm Post subject: |
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| Have you gotten it dirty yet? I sure hope so. |
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quadrazer
Samba Member
Joined: April 11, 2010
Posts: 293
Location: Castalia, Ohio
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| Posted: Thu Jul 29, 2010 3:44 pm Post subject: |
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| riNR wrote: |
| Have you gotten it dirty yet? I sure hope so. |
Not only did I get it dirty at the dunes last week (it rained 3 out of 7 days we were there), I ran it hard enough to grenade 3 stock CV joints, in 3 days, in 3 different locations! It's all good though, I replaced all 4 of them with race-ready Type 2 CV joints from Appletree Automotive in Michigan. The race-ready versions have case hardened cages and are clearanced for less bind during travel. And yes....my little old Type 1 tranny held up just fine thanks to lots of tire slippage in the sand (i know there were some folks on here that were concerned )! Although I do see a set of rear coil-overs in my future!
The V-6 worked flawlessly, with PLENTY of power on tap and a sweet exhaust note thru the dual SuperTrapp's when I wound it out. There were no hills I couldn't climb just by easing into the pedal, and that was with my Goodyear Wranglers aired down to 10 PSI (I left the paddles at home for this trip). And I was actually glad to have the roof and the windshield with a working windshield wiper too, since the weather was bad!
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My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=409845 |
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