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Manx Style Dune Buggy Build (Litha Mark III)
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wvbowtieman
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Joined: September 16, 2010
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PostPosted: Fri Mar 02, 2012 4:36 pm    Post subject: Reply with quote

Decided against using the POR-15 Tank sealer after some reading on the products available. I have decided to go with Damon RED KOTE fuel tank liner. Lots of positive feedback about durability.

Forgot earlier photo's of the front body mount/headlight support.
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Fabricated the hood/dash leveling elevator bolts to level hood/dash at final assembly. 3/8" elevator bolt with felt stick-on pads and 3/8" lock bolt.
1/4" polyproplene sheeting and stainless steel piano hinge used for mounting future fuse block and electrical components. I will be able to keep fuses out of site and drop down for servicing without removing the hood. Very Happy
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herbsflat4
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Joined: February 20, 2012
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Location: Greenville, SC
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PostPosted: Tue Mar 13, 2012 8:04 pm    Post subject: Looks good Reply with quote

I am looking forward to seeing more pics of the project. I think I like the idea for the wiring but I am not sure I understand it. I'll keep my eyes on the build.
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wvbowtieman
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PostPosted: Wed Mar 14, 2012 4:11 pm    Post subject: Relocate fuel filler and fip top cap Reply with quote

Finally got my Aluminum Flip top fuel cap in from Great Britain. It was made for a cafe racer style of bike. 2" cap with 16 Threads per inch. Instead of trying to track down a 2" pipe with these threads we decided to cut or own threads into a piece of 2" DOM .120 wall tubing. (Using my Great Grandfathers Pre WWII metal lathe with thread cutting attachment) Shocked After only one practice run with a piece of 1 5/8" DOM tubing we were ready to make the cut.
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With a lot of patience...gently cut threads deeper with every pass.
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After some cleaning up with a thread file and trued the sealing surface... the cap screwed on with no problem.
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Got a rubber fuel neck grommet for a 69-72 Chevrolet truck off of eBay. Outside diameter of grommet measured 3" and inside measures 2" . I will only need a 3" hole cut into my hood to install over the 2" threaded nipple and install cap. Sweeeet...no hoses or hose clamps to deal with in the tight area under the hood/dash. Laughing
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After some measuring and centering up the fuel filler tube we drilled a 1/8" hole through the fiberglass hood and into the fuel tank. Used a 2- 3/4" hole saw for the FG hood and a 1- 7/8" hole saw for the fuel tank.
We welded the nipple onto the fuel tank and after cooling down we placed the hood with the grommet onto the 2" fuel filler tube....perfect! Very Happy
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The fuel cap is a vented cap and I am not adding a vent tube at this time...We can add later if it is needed.
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wvbowtieman
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PostPosted: Sun Mar 25, 2012 10:37 pm    Post subject: Reply with quote

Removed the FG body to complete all welds and begin clean up of the pan for painting and spray on bedliner.
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Front and rear bumpers ready for sanding and paint this coming week.
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Front body support/headlight support with FG body removed.
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Finished all welds on body/rear seat area.
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Borrowed a homemade rotisserie from MTN BUG made it a lot easier to complete welds. Simple and works great. Very Happy
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MTN BUG
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Joined: August 24, 2009
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Location: Lesage, West Virginia
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PostPosted: Mon Mar 26, 2012 8:56 pm    Post subject: Reply with quote

Nice rotisserie Wink . Looking good.
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wvbowtieman
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PostPosted: Tue Mar 27, 2012 6:08 pm    Post subject: Reply with quote

Today was better weather than was anticipated and was able to push the pan outside to prepare to lay down the epoxy high build primer and Summit Racing Semi-Gloss Chassis Black. 70 degrees and no humidity...no wind....perfect! Yes....I painted it outside! Wish my FG body was ready to spray.... I will paint it in a paint Booth. Very Happy

Scuffed all sides this morning with a 3M heavy duty stripping pad and cleaned metal w/ PPG paint prep oil and silicone remover.

My daughter was surprised I was outside painting and took a few action shots with her camera. Laughing

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I will let paint dry overnight and will scuff the pan tops and bottoms tomorrow leaving the head and torsion housings semi-gloss black and putting on truck spray-on bedliner...hope it looks as good as the paint.
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joescoolcustoms
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Joined: August 08, 2006
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PostPosted: Tue Mar 27, 2012 6:18 pm    Post subject: Reply with quote

WOW! Shocked

That turned out great. Can't wait to see how the bedliner lays down.
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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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gr8cobbler
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PostPosted: Wed Mar 28, 2012 4:41 am    Post subject: Reply with quote

x2 and your gas cap work is top notch too. Love the old lathe..spun a few chunks of metal on a similar vintage machine. Fun adventure Smile
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wvbowtieman
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PostPosted: Thu Mar 29, 2012 11:16 am    Post subject: Reply with quote

Everything taped off...paint scuffed and ready to spray the bedliner.
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Tape and paper removed...ExtremeLiner from eBay...Texture spray gun from Harbor Feight Tools W/Med tip and Rubber added to the mixture for the bottom of the pan has a much more course texture. No rubber used on the top side w/small tip gave a less course texture. Looks good and only have about $200.00 in materials and have enough left over to do a couple more pans in the future. This was very messy and can see paying someone to do this next time around. Very Happy
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Now... I hope this stuff dries! Rolling Eyes
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wvbowtieman
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PostPosted: Sun Apr 01, 2012 8:31 pm    Post subject: Reply with quote

Well my Vacation week is over and I did not get as much done on my buggy as I thought I would but still made good progress.
Painted the Transaxle, installed trans mounts, swingaxle boots, Torsion bars, spring plates, rear shocks.

The urethane bushings for the spring plate were too large diameter for the torsion housing.The inside diameter was 1 7/8" but outside diameter was too large. Thanks to joescoolcustoms quick thinking we used a belt sander and a piece of 1 5/8" DOM tubing for a inner guide and sanded down the bushing until it fit the torsion housing.
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Joe brought his VW jack/spring plate tool to index the spring plates.
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Installed the rear disk brakes and rear shocks.
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Welded in the adjustable shift tube fitting and installed the shift tube and made adjustments. Shifts nice using just one finger. Cool
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Painted front beam, installed front shocks, steering box, tie-rods, front brake backing plates and drums.
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OK...back to work for a week for some much needed rest. Laughing
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A E Numan
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Location: Portland Oregon
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PostPosted: Sun Apr 01, 2012 9:49 pm    Post subject: Reply with quote

That sure looks super nice ! What kind of shocks are you using, they stand out nicely against the rest of the chassis.
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wvbowtieman
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PostPosted: Mon Apr 02, 2012 2:24 pm    Post subject: Reply with quote

A E Numan wrote:
That sure looks super nice ! What kind of shocks are you using, they stand out nicely against the rest of the chassis.


Thanks

These are new stock oil shocks bead blasted and sprayed a nice Chevrolet Truck Victory Red.
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wvbowtieman
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PostPosted: Sun Apr 08, 2012 6:05 pm    Post subject: Reply with quote

Look what the USPS lady brought me for Easter....A new windshield from Bug Shields by Dino. Sent them a email with a detailed drawing of my windscreen and measurements and asked for a cost estimate....paid with PayPal... and 2 weeks later.... Very Happy
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Very well packed and also ordered the mounting kit....Nice looking windshield.
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wvbowtieman
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PostPosted: Sun Apr 08, 2012 7:04 pm    Post subject: Reply with quote

Started assembly of the motor but soon found a few issues with the crankshaft and connecting rods. Crankshaft has a flaw in one of the rod bearing surfaces and one of the connecting rods has gulded threads on one of the rod bolts. I will return these to the shop I purchased them from and get acceptable replacements. We will return to the motor assembly next week if replacement parts are available.

joescoolcustoms checking clearances before we found the flaws in the connecting rods and the crankshaft.
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Built custom brake lines front and rears. Stainless steel brake line clips. Installed the master cylinder and Volvo reservoir. Installed the clutch and accelerator cables. Installed the restored pedal cluster. Fabricated a new heavy duty pedal stop. Installed a new manual oil pressure line and fuel line inside the tunnel. Installed the emergency brake lever and cables. Installed the steering stablizer and billet aluminum bracket. Installed the transaxle cradle after many alterations. Rolling Eyes

Here are a few photo's of this weekends progress.
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herbsflat4
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Location: Greenville, SC
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PostPosted: Mon Apr 16, 2012 5:55 pm    Post subject: Awesome Reply with quote

This is a great build. Awesome work with the pictures too. Everything looks so good!

Maybe I missed it but can you elaborate some on what kit you picked up for the rear wheel disks?

Also, I am thinking about going with rear only disks on my buggy and just wanted to know if you had any other links or threads which you gained any information from on that subject.

Thanks in advance.
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Dan_Lorenze
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PostPosted: Wed Apr 18, 2012 7:47 am    Post subject: Reply with quote

great build, thanks for sharing
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wvbowtieman
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PostPosted: Sun Apr 22, 2012 5:53 pm    Post subject: Re: Awesome Reply with quote

herbsflat4 wrote:
This is a great build. Awesome work with the pictures too. Everything looks so good!

Maybe I missed it but can you elaborate some on what kit you picked up for the rear wheel disks?

Also, I am thinking about going with rear only disks on my buggy and just wanted to know if you had any other links or threads which you gained any information from on that subject.

Thanks in advance.


I really have not been following any particular links for my build. I have a long time friend (joescoolcustoms) here on TheSamba who I bounce ideas off of and consult with for technical information. The brakes that were used for my build are from SoCal Imports. Here is a link for the Rear disk brakes. Thanks for the kind words. David

http://www.socalautoparts.com/product_info.php/dis...05-p-13545
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wvbowtieman
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PostPosted: Fri May 04, 2012 7:08 pm    Post subject: Reply with quote

Been a while since I done a progress report. Wanted to be a little farther along on the painting of the roll cage and bumpers but the weather has not worked in my favor the last few weekends. I have been working on the motor and the emergency brake and clutch cables.

Silver soldered the emergency and clutch cables.
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Made some barrel clamps for the emergency brake cables.
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Clutch cable clamp made from brass round stock
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I was not happy with my stock forged crankshaft no. 2 rod journal. It was rewelded and turned but showed some pitting on the turned surface area. Exchanged it for a new forged counter balanced crankshaft w/ 8 dowel pins for a little extra insurance. Engle W110 camshaft and lifters.
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New 1835cc pistons and liners
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Mild port on heads and new high rev springs/retainers and keepers
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Installed heads and ss pushrod tubes and torqued.
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Installed Scat oil pump w/screw on filter
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Made some tabs and spot welded to the lower tins to keep secure and no wire and no rattling.
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Installed tins and the shround to tweek for a trouble free fit before painting.
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1835cc complete just need to paint the shroud Very Happy
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wvbowtieman
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PostPosted: Fri May 04, 2012 7:49 pm    Post subject: Reply with quote

Installed the 1835cc onto the chassis tonight and installed the Tri-Mil header! Very Happy

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Also painted the shroud tonight in between rain storms. Rolling Eyes
I think my paint guy hit the color perfectly...Jolly Rancher Sour Apple. Very Happy
This will be the color of my buggy.


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The roll cage and the bumpers will be the same color as my rear spring plates and front beam.
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You guys let me know what you think of the colors....the paint was expensive as hell....hope everyone likes it.....No Refund!! Laughing


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gr8cobbler
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PostPosted: Sat May 05, 2012 3:59 am    Post subject: Reply with quote

Quote:
the paint was expensive as hell....hope everyone likes it.....No Refund!!


In that case it's awesome....... Laughing

Kidding, I think it will look great, just like everything else on your buggy. I really like your detailing and color choices on the chassis, really pops and validates the work. Cool
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