Trimming the torsion bar end caps . . . ?

[TC/TeamEvil]

Is it possible to take a sawz-all to those tubes protruding from the end caps on the IRS rear torsion housing and shorten 'em up a bit? I have a small import body shell that need about one inch of that tube removed per side in order to slide all of the way down over the pan and "sit" with the right stance. I know that the swing axle is missing them entirely, I suppose that I could somehow use that set up in conjunction with the IRS diagonals and all, but I really just need a smidge of room and was wondering if a bob-job on the ends could be done without a big-assed hole in the world opening up and swallowing everything around me.

Excluding me, of course, 'cause I've got WICKED good luck ! ! ! ! !

Thanks !

TC

[slalombuggy]

Those tubes that stick out are actually the torsion bars and spring plates, you can't cut them. You can however, go to a shorter torsion bar and aftermarket springplates that get rid of the protrusion. I'm using them on my current Beetle project becasue hte raised torsion housing is now up in the body of the car

brad

[kustoms]

No, The splines are at the ends. You cut them off, "you gots nuttin." Your tail will hit the ground.
_________________
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Tom Thompson
Tijuana Kustoms Inc. (TM)
1-516-338-8746
www.tjkustoms.com

[kustoms]

[jsturtlebuggy]

Switching to the shorter torsion bar can be done. I have done it with several buggies I have owned.
Use to cut down the swing axle spring plates to fit the IRS supension before they started selling them.
Now just buy the cheap adjustable spring plates, it is a lot less work.
What I have found is using the torsion bars out of 1967-68 Bugs which are 21mm diameter. These are 1mm smaller in diameter then both the stock IRS and earlier 60s swing axle.
The 21mm short torsion bar is very close in spring rating of the 22mm IRS long bar.
Going to them really improved my ride being softer like what you would feel with using the longer bars and they will clear a 31in plus, tire with out any interference.
_________________
Joseph
Fair Oaks/Orangevale, CA
Elrod Motorsports
Motion Tire Motorsports
Having fun with Dune Buggies since 1970
Into Volkswagens since 1960

[slalombuggy]

Everything you need

http://www.cip1.ca/ProductDetails.asp?ProductCode=C26%2D501%2D315

http://www.cip1.ca/ProductDetails.asp?ProductCode=C24%2D113%2D511%2D115

http://www.cip1.ca/ProductDetails.asp?ProductCode=C24%2D113%2D511%2D116

http://www.cip1.ca/ProductDetails.asp?ProductCode=VWC%2D113%2D511%2D227%2DA

brad

[TC/TeamEvil]

PERFECT ! ! !

Thanks guys, I KNEW that you would have the answer for me ! ! ! !

TC

[jsturtlebuggy]

To bad CIP1 does not post the diameter of the torsion bar.
It may be that Bettles shipped to Canada did not come with the smaller diameter bar and the Z-bar overrider system.
This is the rating of the torsion bars I was talking about.
The 21 3/4in long 21mm diameter bar is rated at 488 in lb for 1 degree of twist.
The 26 9/16in long 22mm diameter bar is rated at 464 in lb for 1 degree of twist.
Really close in spring rate.

The 21 3/4in long 22mm diameter bar is rated at 588 in lb for 1 degree of twist.
From experience you can feel the difference the 1mm smaller make a big difference.
I still finding 67 and 68 Bugs in Pick N Pull yards. There out there.
And if you do use the aftermarket spring plates, they are a 1/2in wider across the face than stock one.
Without modifying the springs by notching or modifying the stops on torsion housing you may not get even stock travel.

This was on a Tow'd project that was using axles and CVs from a Porsche 924 and I was trying to get the most travel I could get.
_________________
Joseph
Fair Oaks/Orangevale, CA
Elrod Motorsports
Motion Tire Motorsports
Having fun with Dune Buggies since 1970
Into Volkswagens since 1960

[LeeVW]

Also notice how Joseph rounded the corners of the spring plate close to the three slotted mounting holes. If you don't clearance the corners like he did, you won't be able to slide the trailing arm far enough forward to acheive the proper amount of toe-in.

[slalombuggy]

We got Zee bars, far longer than you did. We had swing axle rear ends up untill 70s on some cars.

brad

[jsturtlebuggy]

If you had the Z-Bar for a longer period of time, then it should be easier to find the smaller 21mm diameter torsion bar.
_________________
Joseph
Fair Oaks/Orangevale, CA
Elrod Motorsports
Motion Tire Motorsports
Having fun with Dune Buggies since 1970
Into Volkswagens since 1960

[vincent9993]

I'm getting ready to place an order to convert my 69 IRS to short 21-3/4 torsion bars.

I need some advice on what will work best:
Torsion bars
1a) - CIP1 OE GENUINE VW LEFT&RIGHT REAR TORSION BAR - 21-3/4 : $125.90
1b) - CB Performance 7536 27mm Torsion Bars 21 3/4 : $205.95

Spring Plates
2a) - CIP1 HEAVY DUTY IRS SPRING PLATES FOR 21-3/4 : $69.77
2b) - CIP1 HEAVY DUTY CHROME IRS SPRING PLATES FOR 21-3/4 : $99.70
2c) - CB Performance 6343 Spring Plates - IRS T-1 21 3/4'' $84.95
2d) - CB Performance 2840 Adjustable Spring Plate - IRS (all chassis with short bar) 21 3/4 : $284.95
2e) - CIP1 ADJUSTABLE SPRING PLATES IRS REAR SUSP : $115.45

Plate Cap
3a) - CIP1 CHROME SPRING PLATE CAPS PR - BEETLE 60-68 : $11.50
3b) - CB Performance Racing Spring Plate Covers : $36.95

Torsion Bar Bushings
4a) - CIP1 SPRING PLATE BUSHING SET INNER & OUTER : $18.85
4b) - CIP1 URETHANE KNOBBY BUSHING : $35.60
4c) - CB PErformance Rear Torsion Grommets : $21.90

This is going on my 1969 IRS for the Manx Kickout-SS we are building.
Progress thread

Thanks for your help.

[joescoolcustoms]

Don't forget these fairly new on the market spring plate covers.

3c http://www.thesamba.com/vw/classifieds/detail.php?id=1235293
_________________
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

[crowe66]

[joescoolcustoms]

[BL3Manx]

[crowe66]

[vincent9993]

[joescoolcustoms]

[BL3Manx]

Get adjustable spring plates, the longer the torsion bar, the better the ride.

Standard Sway-a-way adjustable spring plates are high quality spring steel. The race ones are even better.

http://www.swayaway.com/springplates.php