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joescoolcustoms
Samba Member
Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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 Posted: Sun May 19, 2013 12:27 pm Post subject: Early Sears Rascal Build for MOTB '13 |
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After some prodding by friends and the wife, some deep retrospect, I just do not have the time to rebuild my Manx II in time for MOTB '13. It is in 11 total pieces and two different pan pieces. To build it for October, I would have to cut too many corners and that is unacceptable.
Stumbling around ebay I came across a nice early Sears Rascal body and pan already shortened. This I can build as a simple buggy, not lowered, not raised, no performance engine, just a very reliable stockish buggy with a cage.
Here are the start pictures:
While in the area, I had to stop and get some Jeep Wrangler parts.
At home unloading the new to me buggy.
The gell coat is too far gone to save the flake, so it will get a base/clear paint job and the misc. drilled holes will get filled along with the holes in the hood and the rear light section.
The pan is void pan haves, so it will get a perimeter frame and flat 14 gauge floor.
I hope to have it done in time so I can get some summer cruising in before MOTB.
_________________
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 |
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NJ John
Samba Member
Joined: September 21, 2007
Posts: 2224
Location: HdG, MD & NJ
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| Posted: Sun May 19, 2013 1:59 pm Post subject: |
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Cool find.
How far is that Summit store from your house?
_________________
1973 standard, yellow, lowered, 3” narrowed front, 1600 blo-thru turbo w/single dell 15.4@86, so far
11.41 et buggy. Long gone
Let’s go O’s! Let’s go O’s!
https://www.youtube.com/@AirSpooledGarage |
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BIGMIKEY
Samba Member
Joined: September 24, 2007
Posts: 1105
Location: North East Pennsylvania
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joescoolcustoms
Samba Member
Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Sun May 19, 2013 8:02 pm Post subject: |
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| NJ John wrote: |
Cool find.
How far is that Summit store from your house? |
4 hours to far.
They have a clearance area that is to die for.
_________________
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 |
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joescoolcustoms
Samba Member
Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Sun May 19, 2013 8:03 pm Post subject: |
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| BIGMIKEY wrote: |
Looking forward to seeing another great build.
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Me too!
(I had better get started)
_________________
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 |
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Muskrat
Samba Member
Joined: July 20, 2006
Posts: 184
Location: sacramento, ca
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| Posted: Sun May 19, 2013 9:43 pm Post subject: |
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just curious.
i just bought a buggy and after looking at DBA i thought it was a sears rascal except it didn't have the dogleg on the dash for the radio on the passenger side.
it doesn't look like yours does either. was that something they did on later models and how can i find out what years they we're made that way.
thanks for helpin out a buggy newbie.
-keith-
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Manx clone 62 pan 1500 single port
83.5 westy w/2.1 wbx...RIP |
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joescoolcustoms
Samba Member
Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Sun May 19, 2013 10:16 pm Post subject: |
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The early Rascal that I have is actually a 1968 Terra Buggy Cyote body that Sears sold as the Rascal. When they were unable to meet demand Sears is said to have purchased bodies from Glitterbug or a Glitterbug clone, and sold them as the 1971 Rascal.
The one I have is a real close clone to the first 100 Manx bodies produced with the small rear tail opening and the dash modeled of off the original plastic Manx dash (it was done in FG for the rascal though).
So, my guess is the early style did not get the "radio arm", just like the Manx. When Bruce went into the lawsuit is when the rear tail opening was changed more to help lesson Liable.
Which rear tail opening does yours have?
_________________
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 |
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Muskrat
Samba Member
Joined: July 20, 2006
Posts: 184
Location: sacramento, ca
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| Posted: Sun May 19, 2013 11:15 pm Post subject: |
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it's been cut open i'm guessing.
gonna hafta get some pictures up.
the dash is very similar to yours but just a bit different. everything else really looks like yours though as far as body shape and hood and fenders. i'll get some pix up tomorrow.
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Manx clone 62 pan 1500 single port
83.5 westy w/2.1 wbx...RIP |
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tlcurtis
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Joined: October 08, 2010
Posts: 38
Location: Kent, Wa
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joescoolcustoms
Samba Member
Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Mon May 20, 2013 3:26 am Post subject: Re: Sears Rascal |
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| tlcurtis wrote: |
I have a Sears Rascal in the works check out my build pictures, best of luck with this new build.  |
Yours is an early body also. I am going to have to have at least a 1" body lift like yours due to the upper shock towers hitting the body at the wrong spot and holding the body up off the pan about 3/4 inch.
You have a nice start on a cool buggy.
_________________
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 |
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wythac
Samba Member
Joined: August 02, 2004
Posts: 2791
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| Posted: Mon May 20, 2013 6:15 am Post subject: |
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No idea what you are talking about
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joescoolcustoms
Samba Member
Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Mon May 20, 2013 7:33 am Post subject: |
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| wythac wrote: |
No idea what you are talking about
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How big of a lift did you have to put on yours to clear?
I am going to take a close look at the body and see if it is warpped and has taken a set over the years before I lift the body.
_________________
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 |
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wythac
Samba Member
Joined: August 02, 2004
Posts: 2791
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| Posted: Mon May 20, 2013 8:43 am Post subject: |
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| 3" lift and a 6" wider beam gave me plenty of room even with 10" shock towers. I planned to replace the beam with a wider than stock model and also planned the 3" lift for wheel and tire clearance, so I didn't do a lot of measuring of minimum clearances unfortunately. I think the body would also have interfered with the torsion housings too, I'd check those out. |
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glassbuggy
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Joined: June 02, 2005
Posts: 897
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| Posted: Mon May 20, 2013 6:13 pm Post subject: |
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All the Sears Rascals had the radio boss, If your body is an early Terra Buggy it is a Coyote. Terra buggy had three successive tail designs of which this one seems to be of the first version (same as Manx early tail). I do have one documented that has the dash similar to yours, it has a battery box area (it has a Terra Buggy sticker inside on the passenger area that says not to exceed 35mph!) Unfortunately the tail was hacked so I cant tell you what it looked like.
There were a few manufacturers who used the single hood ridge and that tail style Kellison is one to note , this could be a Sandpiper |
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joescoolcustoms
Samba Member
Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Mon May 20, 2013 8:42 pm Post subject: |
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Wow! It must have been real cut throat back in the buggy manufacturing days.
Here are some extra photos that people have been asking for:
And one for the tail section showing how wide the tail cut out is compared to the Manx.
The body is thin, thinner than my late production Manx II, but very even thickness and has survived very well.
_________________
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 |
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sturgeongeneral
Samba Member
Joined: June 23, 2005
Posts: 2460
Location: Sacramento, California
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| Posted: Tue May 21, 2013 8:35 am Post subject: |
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Ya baby! Another Rascal coming back to life! They are great buggies!
_________________
Street legal fiberglass rocket ship
2005 Lotus Elise supercharged
1974 Chevy Corvette
My fiberglass car collection!
In honor of bowtie56jw:Another victim of the nasty "C" Praying for ya Jeff!
My exwife said if I towed home one more bug she would leave me. You know, every once in a while I miss her |
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joescoolcustoms
Samba Member
Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Wed May 22, 2013 5:29 pm Post subject: |
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Ordered materials for the buggy Monday.
From the local steel plant I ordered:
20 feet, 2 x 2 X 1/8 boxed tubing for the perimeter frame
20 feet, 1 X 1 X 1/8 boxed tubing for part of the 1 inch body lift
20 feet 3/16 X 1 1/2 strap for the body sandwich and roll cage weld to plate
20 feet 2 X 1 1/2 X 1/8 rectangular tubing for misc fabrication
10 foot X 5 foot 14 gauge plate steel for the flooring (cut into two pieces
From the local speciality metal supplier:
7 - 24 foot sticks of 1 5/8 X 0.120 wall DOM Tubing
1 - 24 foot stick of 1 X 0.120 wall DOM Tubing
This evening I picked up the steel from the steel plant. Turns out the two guys who loaded me are into Rail Buggys.
I should have enough material to last me this 3 day weekend and the plan is to knock out as much of the pan as possible. The roll cage material will be ready for pickup on Thursday next week.
Please note that I over bought materials because this will also be materials for my Manx build. Cheaper to buy in bulk.
_________________
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 |
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wythac
Samba Member
Joined: August 02, 2004
Posts: 2791
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| Posted: Thu May 23, 2013 4:04 am Post subject: |
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| Joe is posting metal fab porn again..... |
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joescoolcustoms
Samba Member
Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Mon May 27, 2013 7:51 pm Post subject: |
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| wythac wrote: |
| Joe is posting metal fab porn again..... |
Is it wrong to admit to liking metal fab porn?
I did not get done all the metal fab I had planned for this long weekend. Maybe due to my ADHD kicking in with so much to do on this buggy. I started out with metal fab and ended up bending conduit.
This body was either made in a poor mold, has aged and warped/sagged/shrank. It just does not want to fit a chassis very well. One thing that will help a tweaked buggy body to fit better is a small body lift. Since I am making a perimeter frame and a flat floor, I can use 2 X 2 boxed tubing and make a 1 inch body lift.
This first piece will slide over the Napol Hat area and weld in. The ratchet binder helps pull into the exact curvature and then hold it for welding.
Well, that is it for the metal fab. For good reason. I need to know exactly where the rear of the rails will sit and weld in both height and width wise. The standard beetle pan is 47 ½ inches wide at the rear of the pan. My body is 46 inches wide. Instead of narrowing the pan, I choose to widen the body. I slit from the pan mounting surface up to the rear shelf will allow enough flex to widen the rear the 1 ½ inch needed.
An old deck board cut to the correct length makes a good spreader bar and the ratchet bonder helps tweak the body so the slits are widen equally. Next is to taper the cut to a knife edge and start glassing. I used two layers of woven and then 5 to 6 layers of matt.
While I was at it, I also filled in holes on the front fender tops, holes in the forward firewall, holes in the battery well, holes in the rear valance, holes in the rear shelf and the license plate area. I used simple blue painters tape to back the holes. On the license plate area, I used real aluminum duct tape to back the opening. It worked very well. All finish surfaces are ready for final sanding , minor filling and primer, including the widened slit area.
It may appear like a lot of work for 1 1/2 inch. But it is the un-noticed details that lift a buggy build to the next level. And any one struggling to find and fit a set of seats in a narrow buggy would love to have 3/4 inch more per side to fit that custom seat.
Next it is time to think ahead and install some wiring tubes to conceal the wiring and keep it neat. I had two sticks of left over ¾ inch PVC conduit. I could not find my heat blanket for bending PVC conduit, and my propane torch was junk and thrown out. So, I broke out the old standby Oxy/accet torch, put on a rose bud and went to town. It does tend to singe the PVC, but makes for a quick job. These will get fiber glassed in which will hold them tight and also strengthen the sides of the buggy, just like Bruce Meyers did on the Manx buggy when he made them. They kind of look like a dual exhaust.
If the weather is good tomorrow, the two wiring tubes will get glassed in. At that point, the body repairs will be done and ready for final paint prep.
_________________
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 |
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karu
Samba Member
Joined: November 11, 2008
Posts: 229
Location: Cross Lanes, WV
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| Posted: Tue May 28, 2013 4:55 am Post subject: |
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| joe, nice to see you working on another buggy. Looking forward to all the updates. |
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