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The Road to Baja - Building Manxter DS-31 Baja Edition
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Iguana
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PostPosted: Mon Jan 05, 2015 10:18 pm    Post subject: So 103 days to go Reply with quote

Well he count down is almost on, I say almost as I never did like large numbers so figured I would wait till it hit double digits.

Winnie was to quick for me though and with 103 Days till Tech Inspection the Floor Pan for the Manxter DualSport arrived.

It is a VW Type 1 Super Bug pan and it will be getting submitted to the special Meyers Manx DualSports Over Haul which has been the result of months or research, weeks of planning and decades of experience.

Looks like it will at least need a pressure wash, I don't want dirt on the jig table ..

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Iguana
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PostPosted: Wed Jan 07, 2015 8:20 pm    Post subject: Reply with quote

So I took the pan over to Gonzalez Media Blasting today. I can't recommend them enough they did a great job and being what I call wet blasting it removes grease as well as all that horrible tar paper stuff VW's have. Louis and the boys have done a lot of pans for me and I have always been very happy with the result. I make sure I get the inside of the tunnel done and flushed as well.

It was to dark when he finished to get a picture but here is a link to his page and a quick video of some of the others he has done for me :

https://www.facebook.com/Gonzalezmediablasting


Link
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Glamis Addict
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PostPosted: Sun Jan 11, 2015 2:41 pm    Post subject: Reply with quote

What a cool build thread,looking forward to seeing the finished product.!👍
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Iguana
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PostPosted: Sun Jan 11, 2015 10:54 pm    Post subject: Reply with quote

Glamis Addict wrote:
What a cool build thread,looking forward to seeing the finished product.!👍


Thanks I am looking forward to seeing the finished product as well.

I have been building it in my head every night and hopefully as the parts continue to arrive, the design continues to be complete and all the awesome industry experts we are working with keep imparting knowledge on us the end grows closer.

I was lucky enough to spend a few hours down at B&R Buggie with Gary and his guys, wow what an awesome place that is, so much knowledge and experience and so happy to share. (http://bandrbuggie.com )

Got some great idea and greatly appreciated the time.
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Iguana
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PostPosted: Tue Jan 13, 2015 12:52 am    Post subject: Reply with quote

Got a chance to go and Visit PRP Seats (prpseats.com) today and have a chat to Aaron and the Team about our needs for the Manxter DualSports Baja Edition Build. It was a refreshing change to find a business that was receptive to our ideas and since PRP Still makes their seats 100% in the USA getting some custom changes was an easy process.

PRP was able to offer us a great range of custom fabrics, styles and trims. We got to walk around the show room and test fit the models that they had and discuses what would work best for the 2000 plus mill Mexican Trip we will christen the car with.

We got a heap of pics and videos of the seats being made and we will get it edited up and loaded onto youTube. It was very interesting to see how they did it and I was impressed by the variable height rotating fixtures they use to make the seat frames. By setting up each of the welders with a ergonomically sound work station it was plain impressive to watch them pump out quality welds join after join. The Fab shop itself was very well laid out and probably one of the cleanest setups I have seen in a lot of years.

Anyway we are starting to get very excited now as at least we feel like we are moving in the right direction as the days get less and less.

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Iguana
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PostPosted: Tue Jan 13, 2015 1:00 am    Post subject: Reply with quote

Plenty of seats on display to sit on and test feel ..

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I can see I am going to need a hand from someone a bit less colour challenged to pick from this lot and more ..


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Nothing hidden here, Jason was more than happy to explain how the seats were built and the way in which PRP have achieved one of the most comfy suspension seats on the market.

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PRP Also make a lot more than just seats with a full range of just about any sewn products you can think of.

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The steel fabrication side of the seat building process was pretty cool, the fab shop was very well setup and oh so clean. It gives you a good understanding of what it takes to keep quality in place and seats moving out the door.

From Shelf stock

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To CNC Bent Stock

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To Notched Stock

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To Shelf Stock

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To be continue ..
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Iguana
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PostPosted: Wed Jan 14, 2015 7:05 pm    Post subject: Reply with quote

So the pan has started .. seems to be weighing less each day lol

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mr_bill
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PostPosted: Thu Jan 15, 2015 4:42 pm    Post subject: Reply with quote

I saw that pan, on the bottom of the pile. outside the shop yesterday....... Laughing Laughing
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Dos Perros Motorsports
Orange, CA
1972 Class 11x/Stock Bug
'60's era "vintage" Tunnell-Buggy

"...no one here....get's out ALIVE...."

Motor = electric
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Glamis Addict
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PostPosted: Sat Jan 17, 2015 9:05 pm    Post subject: Reply with quote

Is the body for this project already laid up?
Are you using that pink/purple body from the other thread?
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Iguana
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PostPosted: Sat Jan 17, 2015 9:24 pm    Post subject: Reply with quote

Glamis Addict wrote:
Is the body for this project already laid up?
Are you using that pink/purple body from the other thread?


Nope body is not laid up yet, it is in the que and I expect it to be done mid Feb at this stage. That's ok as it works with our time frame so not having it in the way works well.

I do have another DualSport Body to use in setup so that I can ensure that the suspension cyles and everything should clear. The Baja Edition is getting upgraded everything over the other DualSport Manxters we have built so everything must be setup from scratch.

At this stage I am hopeful of getting 13" or better of travel in each corner.

Hopefully we will be looking just as happy as these past Buggy Drivers in around 96 or so days



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Glamis Addict
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PostPosted: Sat Jan 17, 2015 10:13 pm    Post subject: Reply with quote

Iguana wrote:
Glamis Addict wrote:
Is the body for this project already laid up?
Are you using that pink/purple body from the other thread?


Nope body is not laid up yet, it is in the que and I expect it to be done mid Feb at this stage. That's ok as it works with our time frame so not having it in the way works well.

I do have another DualSport Body to use in setup so that I can ensure that the suspension cyles and everything should clear. The Baja Edition is getting upgraded everything over the other DualSport Manxters we have built so everything must be setup from scratch.

At this stage I am hopeful of getting 13" or better of travel in each corner.

Hopefully we will be looking just as happy as these past Buggy Drivers in around 96 or so days



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PM sent!!
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Iguana
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PostPosted: Sun Jan 18, 2015 1:57 am    Post subject: Reply with quote

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ellobo
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PostPosted: Sun Jan 18, 2015 2:02 pm    Post subject: Reply with quote

Brad. You need one of those cool mustaches too.
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PostPosted: Sun Jan 18, 2015 3:32 pm    Post subject: Reply with quote

ellobo wrote:
Brad. You need one of those cool mustaches too.
ellobo,did you used to post a lot on RD's Place?Same handle?
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PostPosted: Sun Jan 18, 2015 5:43 pm    Post subject: Reply with quote

ellobo wrote:
Brad. You need one of those cool mustaches too.


One day maybe when I grow up lol Laughing
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Iguana
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PostPosted: Sun Jan 18, 2015 5:43 pm    Post subject: Reply with quote

Days are certainly moving quicker than the items on the to do list. I did get to tick off another item though with picking up my PowerCore Buggy Air Cleaner from Dans Performance Parts ([URL='http://www.dansperformanceparts.com/']http://www.dansperformanceparts.com/)[/URL].

We have heard more than a few horror stories about Dust and Silt and people killing engines. With that in mind we started doing some research into all the options available. The end result of that was selecting one of the 3 stage Powercore Filters Dan has on offer.

I must say when I finally got it in my hands the wait was well worth it and I was very impressed with it. At well under $200 delivered I will certainly be using them on my other buggies in the future.

The entire assembly is only around 15 " long and 8" high, it is very compact and has a pre filter, primary filter and finally an oh crap filter.

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To service you remove the top section and simply pull the cartridge backwards to disengage the huge rubber seal.

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Once you have the cover off you can remove the primary filter and see the final line of defence. This means that if you do happen to pull the primary in a dusty environment the final line will stop anything getting in.

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Lastly all apart, nice seals everywhere, high side intake to avoid issues

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The quality is exceptional and it can be mounted on any of the 3 sides. This one is designed to mount vertical but there is also a horizontal model as well. The horizontal model is accessed through the end not side.

I think it will go well on the DualSport and I will make sure I get some pictures of it in use and how much ust we get out of it. Hopefully on some of the shack out runs we will run some grease on the up stream side to test its effectiveness.

Big thumbs up to Dan for helping me out with it, another thing off my list.
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PostPosted: Sun Jan 18, 2015 8:24 pm    Post subject: Reply with quote

Quote:
ellobo,did you used to post a lot on RD's Place?Same handle?


Yessss. It's me. I've never gone away. PM me if you have a question. This is Brads Thread. Cool
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PostPosted: Sun Jan 18, 2015 9:17 pm    Post subject: Reply with quote

Iguana, thanks for posting pics of that airbox. I've been looking at a few different ones for industrial applications. I found one for a forklift that was a good size and optimal duct arrangement. I'll have to look at Dan's site and watch your thread to see how and where you mount this one.
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PostPosted: Sun Jan 18, 2015 10:32 pm    Post subject: Reply with quote

wythac wrote:
Iguana, thanks for posting pics of that airbox. I've been looking at a few different ones for industrial applications. I found one for a forklift that was a good size and optimal duct arrangement. I'll have to look at Dan's site and watch your thread to see how and where you mount this one.


No probs they are a GREAT filter when you get it in your hands it is very good quality.
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PostPosted: Sun Jan 18, 2015 10:35 pm    Post subject: Reply with quote

With the wheels moving on multiple fronts I was time to get the engine sorted. For the Mexican 1000 I will be running a Subaru EJ 25 SOHC Engine from a 2001 Subaru Outback. With some help from Chris SubieWorks at Temecula (www.subieworks.com) I will be using the Factory ECU and Loom. Chris has a wealth og knwldeg and experience and is also the same building the Subrau Transmission for the Manxter.

I picked the car up off CraigList for $500 with a suspected blown head gasket. It still runs fine and doesn't leak any water. Chris said he would do the head gaskets and check the heads out when he went through it. I will also get a new water pump and cam belt while it is apart as well as anything else Chris finds it needs.

By using the EJ25 it has a MAP sensor not a MAF meaning I can go straight from the throttle body to the Air Cleaner without issue and there is no dealing with a hot wire which would stop any sort of oil filter.

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It looks almost to good to wreck, oh well it will give its heart, loom and steering so a Buggy can live and a dream can be made.

The all powerful EJ 25 SOHC rated factory at 165HP Smile

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