Basket Case Manx II

Glasser · Posted: Wed Jun 18, 2014 8:06 pm Post subject:

Love to see it finished, hate the see the end of the thread. Loved watching the progress. Congrats on one heck of a build, Now go and enjoy it!!
_________________
Brent
My build up http://www.thesamba.com/vw/forum/viewtopic.php?t=265364&postdays=0&postorder=asc&start=0
Project#2. Neighbors build up. http://www.thesamba.com/vw/forum/viewtopic.php?t=327008

RedBaronofRedBud · Posted: Thu Jun 19, 2014 6:41 pm Post subject:

As its been said many times, a buggy is never finished! I look forward to seeing how the heater channels will be incorporated to extend the buggy season!

To be continued... Laughing

_________________
Or you can call me………Tim

My two pennies…your mileage may vary

I’m not a complete idiot, there are parts missing

joescoolcustoms · Posted: Thu Jun 19, 2014 8:28 pm Post subject:

Thanks again guys, appreciated!

Tim, no heater channels, it will just dump into the tub area right behind the seats on the lower vertical package shelf surface through a defuser, simple and easy to accomplish.

I had to work on Tuesday, so nothing got done. Wednesday I did tweak some more on the buggy. I could not stand the rear suspension setting and the D-Side torsion bar was sagging with respect to the same setting as the P-Side. So, I changed out the 21 mm torsion bars for 22 mm Beetle short bars setting them at 27* spring plate angle. Buggy sits level now.

Also, I put on the second of the 4 pieces of the top set up, (trimmed hard top, rear wrap around curtain, 2 side curtains = 4 piece) so I could test it at speed. Went and picked up Darlene at work so I ran the interstate. The rear soft section works really well at 75 MPH. A little flutter movement on the vertical wind leading edges, but a huge noise reduction with very little air movement reduction. Which means that in combination with the hard top, it greatly reduces the air buffeting and noise with it on. So, this is the way we will travel, and then when it rains, the side curtains will be on it of course.

Image may have been reduced in size. Click image to view fullscreen.

Tom (Tom Kathleen) had mentioned how the radiant heat will heat soak the floor of a buggy as we cross the desert area and start cooking our feet. He recommended to use some sort of insulation on the floor. David (wvbowtieman) is a great parts/materials finder for this project. Kind of like Morgan Freeman's character on the Shawshank Redemption, a man who know's how to get things. David found some high tech 3/16 thick insulation that in a horizontal position acts like R13 insulation, or equivalent or 2 inches of conventional fiberglass insulation. I will just trace the floor mats and install two layers of the material.

Don't worry, this project will never be "done". Since I will be keeping it, and I like to try "stuff", it will become my test mule and results of good and bad will get reported in hopes of helping others and just pure fun.

One long ago test I did on my '64 Chevelle drag car was a thought looking for just 0.001 improvement in ET, was to use a thinner lube in the differential. My thoughts were, this rear end only runs 6 seconds, so the lube that is thick causes friction and slows down the motion change, (spinning driveshaft - to- spinning axles), so, heat is not a concern. I ran Mobile 1 straight weight engine oil in the diff. It did improve the ET, but destroyed a very expensive pro racing Richmond Gears ring and pinion. Don't know until it is tried, which gives the moral of using the correct oil because it is needed for a reason.
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
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

ChadCook · Posted: Thu Jun 19, 2014 9:04 pm Post subject:

Where did you pick up the material for the floor mats?

wvbowtieman · Samba Member Joined: September 16, 2010 Posts: 195

Chad

http://www.ebay.com/itm/4-X-10-EZ-Cool-Automotive-...mp;vxp=mtr

wvbowtieman · Samba Member Joined: September 16, 2010 Posts: 195

Hey Joe

Maybe we could install this under the dash before we leave for Big Bear. Laughing

http://www.ebay.com/itm/UNIVERSAL-UNDERDASH-AC-EVA...&rt=nc

Oooops...it needs a compressor and a condenser! Embarassed

joescoolcustoms · Posted: Thu Jun 19, 2014 9:24 pm Post subject:

joescoolcustoms · Posted: Thu Jun 19, 2014 9:38 pm Post subject:

If anyone is thinking about the insulation as a last minute get, the seller David posted up was quick in getting it to me. We have 7 business days left, so it is possible to get it and install it before we leave for Big Bear CA. I ordered it Monday Evening, 6-16-14 and received it today, 6-19-14.

Chad, if you were asking about the rubber floor mats, I found a local rubber company that special ordered it for me. It is 4 foot wide safety walkway rubber floor matting and is sold by the foot, (4 foot wide by X foot long). I paid right at $ 15.00 per foot for it and used 3 feet to make the two mats, so, about $ 45.00 into them. Sounds expensive, but go try and buy a Mat Set to fit a VW floor pan shape, you will pay that and more, and may not fit very well.

The 4 foot width lacks about 1 1/2 inch from covering my complete floor pan. They are tough, add slip resistance and look decent. Not crazy about the diamond plate design, but looks acceptable and some people have thought I used diamond plate on the floor until I told them it was rubber.

On this buggy, I bought the three foot wide version:

_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
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

joescoolcustoms · Posted: Thu Jun 19, 2014 10:10 pm Post subject:

One last post and I am going to bed.

One concern on our trip to Big Bear CA is cooling of the engine. I have a 0.82 bus 4th gear set in my transmission, running a 28 inch tall tire and will be running with the pack around 60 to 65 MPH. At 60 MPH, my RPM is about 2500. Most will say it will overheat the engine, and it may. Tests so far in the low 90's show I will be fine, but we will be in 20* hotter temps through Death Valley.

One bandaid is to spin the cooling fan faster. Remember the "Power Pulley's"? Use a smaller lower crank pulley and it slows the cooling fan down so when running at high RPM's, it takes less horse power to turn the fan, giving more power for other uses.

Well, there is a reverse trick. I think Tim labeled it as a "Power Fan". Use a shorter fan belt to ride lower in the upper pulley making it spin faster. I used to do this 25 years ago and my hot street engine for daily driving, then switch fan belts for weekend fun.

Here is a couple photos with respective fan belts. You can see the difference in the top pulley diameter they run at.

This photo is of the "proper" VW fan belt to run. 15355 means, "15" is the belt width, and "355" is the length @ 35.5 inches.

This picture is of a belt that is 1/2" shorter length. 15350 means "15" is the belt width, and "350" is the length @ 35.0 inches.

It can be seen where the second, shorter belt rides lower in the top pulley reducing the overall rotating diameter.

So, what difference does it make on cooling? Measuring the diameter of the lower pulley based on the outside diameter of the belt, and measuring the outside diameter of the two belts as they ride in the top pulley, it is a change of right at 10%. At 3000 RPM on the crankshaft, the stock length 15335 belt will spin the alternator/generator at 4891.3 RPM. Switching to the 1/2 inch shorter belt will result in the alternator/generator spinning at 5431.0 RPM at the same crankshaft RPM.

Does it help? It did in the late 1980's on my street beetle. I will be running the smaller length belt on this upcoming trip and hopefully all the attention I paid to fitting the stock tins, type three cooling tins, stock dog house cooler and thermostat controlled fan assisted external cooler will help make the trip less eventful for us.

Edit: made mistake on the belt number even though it was photo'ed.
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
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

ChadCook · Posted: Fri Jun 20, 2014 11:02 am Post subject:

Did the same mod to my t4, but did it because I was in between sizes. Never thought of the increased cooling as a benefit. Joe, now your done modifying please clean up the pulley. Thanks. And thanks for the info. I had found the mats in a safety supply catalog, but they were north of $100 for a 3-4 ft mat.

joescoolcustoms · Posted: Fri Jun 20, 2014 12:27 pm Post subject:

FarmerJohn · Posted: Sat Jun 21, 2014 9:29 am Post subject:

Joe , that's where the "blue tape" came in handy , we used it to tape/seal the hood fender joint . Worked good & no sticky tape residue
_________________
Now I Drive A Hard Top Buggy !

joescoolcustoms · Posted: Sat Jun 21, 2014 7:40 pm Post subject:

Now that you mention that John, I do remember you doing that. I was going to do that, but internally as far as I can reach down the interior hood line. Most likely will also do your method too when we think we will encounter rain on the trip.

Today Darlene and I headed out early for a family reunion across the State of West Virginia. About 20 minutes into the 2 1/2 hour trip, it started raining and rained until about 15 minutes before getting there. Uggh. I did not finish the side curtains, so, we got soaked, (we did have on a motorcycle rain gear). I had water spray on both the inside and outside of my eye glasses. Still ran between 70 and 75 to whole way.

363 miles, 14.5 gallons of fuel. One problem, blew muffler almost off when downshifted and nailed the throttle, (a dumb @$$ puled out in front of me when we were going up a 7 % grade for 6 miles @ 70 MPH and slowed me to 50 MPH and out of my torque band, guess he could not see the orange, the fog lights and the head lights).

So, that gave me an average of 25 MPG. Woooo Hooo! 7 MPG better than I had hoped for for the ECVW trip.

The trip home was much nicer, but still cool enough we still had to wear the motorcycle gear to stay warm.

Did run some back roads in beautiful WV and went by Laural Creek, (named after the Mountain Laurals in the area), which is a native Trout stream.

Coming back into Charleston WV, the Capitol. On the ECVW return trip, we will pass this way on the 19th of July.

One cool item I picked up from the Jeep crowd is a roll bar, velcro cup/bottle holder. They were cheap at about $6.00 each, but I did have to re-locate the hook side of the velcro because they are made for 2 inch padded roll bar in a Jeep Wrangler, and I have 1 5/8 tubing. Worked great today.

I now have about 435 miles on the puzzle manx and other than a weeping oil leak at the distributor, it is running and driving nicely. Darlene told me it rode, seats felt more comfortable and has more room than all of the other buggy's I have had.
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
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

Roys_Big_Toys · Posted: Sun Jun 22, 2014 4:58 pm Post subject:

Fantastic, Joe. Who's seats did you use? I installed Scat Pro 90's and even Vince commented on their comfort. Driving long distance takes a toll on your butt. The older you get, the more padding you need.
_________________
I'd rather be an hour early than 5 minutes late. (Mine)
"It's not a hobby, it's an addiction" (My wife)
"Socialism only works in two places: Heaven where they don't need it and hell where they already have it." -Ronald Reagan
Original Meyers Manx
Berrien LKD Warrior Ecotec 2.2 w/ Bus 091 Trans
Original 2 sided Meyers Manx Dealership sign
Meyers Manx Surf Board #1 0f #100
Custom Meyers Manx Cornhole game

EVfun · Posted: Sun Jun 22, 2014 5:17 pm Post subject:

I bought the ribbed rubber runner. It comes in 3 foot and 4 foot widths and any length you want. The price for the rubber stuff is similar to what you paid, there is a black vinyl version that is a bit cheaper. I found the 3 foot stuff could be cut into 2, 18 inch wide lengths and one used for each side of the floor. That leaves the ribs running the length of the floor, a bit like the rubber floor mats in later model Bugs.

I bought a few of those removable black plastic rivets used to hold trim on late model cars to help hold the mat in place. I haven't installed those yet, but it only takes 1/4 inch round holes in the mat and sheet metal floor.

joescoolcustoms · Posted: Sun Jun 22, 2014 8:05 pm Post subject:

Roy, they are the same seats you have, except they are grey that (dumb luck) matches very closely the metalic silver poly paint I used on the roll cage. I largely based my decision on your feedback on these style of seats. Darlene loves them, and really enjoyed them yesterday on the 6 hours we were in it.

EV, did not realize there was other options, the rubber company I went to in search of it just presented this style to me and that is what I have been buying. Once I run out of the roll I bought, I will look around a bit before purchasing it again.

Today I focused on the work I postponed until the last task. Sewing the zippers and side curtains together. I had already sewed the perimeter together with the snaps, but had not yet sewed the zippers in and the clear glass.

Wow, that really sucked. I am not an upholster by a long shot. I got it done, and it will keep 99% or the rain out of the buggy and off David and I, but not my best work. A pro shop most likely would have done a better job with the zippers and straighter sewing. But, do to my cheap @$$ mentality, I bought a home sewing machine for $ 75.00, not a $ 1500.00 pro model. So, once you start the seam, you have to go full speed for it to work with the thick materials and you get what you get, and hopefully it is not sewn to your fingers when you stop.

But, 10 hours later, they are done, dirty with finger prints, but I am ready to take it on a long run into Ohio tomorrow and see how badly it may flap before putting away the sewing machine.

The FarmerJohn, or "FJ's" as monomanx calls them, can be seen on the lower portion that wraps over the body and fastens to snaps from underneath keeping the body from having snaps screwed into it. FarmerJohn bonded wood to the body and fastened the snaps to the wood, I welded a wing to the hidden roll cage to fasten the snaps to the "bat wings".

John's design has a added benefit that if your lady has on shorts, the snaps are not there to scratch her legs on when she gets in/out. A shot showing the underneath snap attachment.

Because I used long, spiral wound zippers, (70 inches long), the whole glass can be unzipped from rear to front and laid inside, tucked behind the seats if you are running in and out of rain and also giving a wide open "hole" to get into and out of the buggy.

Smudges and all, it is ready for a good cleaning, but basically "done". (yes, I will still tweak on things until leaving on 7-2-14)

The leading edge has an aluminum strip sewn in so it slides into the windshield channel to hold it. Since I have a roll cage, I picked up some snaps on it to keep that leading edge from flapping when the glass is zipped open and traveling on the road. In addition, where the leading edge crosses the body, it also has an aluminum strip sewn in to keep the body contour tight and not to flap or let air underneath.

Since I have the roll cage, I sewed male/female velcro at tight spots so it can be snugged up to reduce any flapping, and done quickly without more snaps.

The team took some hits and we lost a few soldiers.

But, for a under-rated sewing machine, and me having absolutely no experience in sewing, I like my top system. This little 30 year old used Kenmore will go into my tool collection just in case the top needs some repairs in the future.

_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
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

manxvair · Posted: Tue Jun 24, 2014 3:31 pm Post subject:

This is where I ordered the flooring material for my buggy.

http://www.americanfloormats.com/

Bennym777 · Posted: Tue Jun 24, 2014 4:54 pm Post subject:

If I ever need motivation to work on my buggy I just read this thread!

joescoolcustoms · Posted: Fri Jun 27, 2014 8:45 pm Post subject:

Wow Mike! I will be checking them out before buying more, they have quite the selection.

wythac · Samba Member Joined: August 02, 2004 Posts: 2791

Never thought I'd say this to another guy:

Nice rack.


Hello! Log in or Register \| Help \| Donate \| Buy Shirts	See all banner ads \| Advertise on TheSamba.com

Basket Case Manx II
Page: Previous 1, 2, 3 ... 12, 13, 14, 15, 16, 17 Next Jump to:

Forum Index -> Kit Car/Fiberglass Buggy/356 Replica		Share:
		Print View

	Forum Index -> Kit Car/Fiberglass Buggy/356 Replica	All times are Mountain Standard Time/Pacific Daylight Savings Time Page: Previous 1, 2, 3 ... 12, 13, 14, 15, 16, 17 Next Jump to:
Page 13 of 17