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sxuxrxf Samba Member
Joined: May 18, 2005 Posts: 1338 Location: Oceanside, CA
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Posted: Fri Jun 19, 2009 1:20 pm Post subject: |
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Roof Rack 101: The Basics
I used a standard VW rack as the base for the new one. This way I could clamp tubing to it and back up to see how it looked. I made the lower hoop to fit inside the legs of the stocker, added some temporary legs to the new section to hold it in place and then unclamped and lifted off the stock rack. From here I added the top section, center runners and new legs. Total weight is about 35lbs, without lights, using all .065 wall mild steel. I tack welded most of this with MIG and had to throw a blanket on the roof to keep the sparks from burning the paint and sticking to the windows. When it was all tacked together, I pulled it off and welded it on the ground. It came out perfect, no twist, everything straight and level.
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sxuxrxf Samba Member
Joined: May 18, 2005 Posts: 1338 Location: Oceanside, CA
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Posted: Wed Nov 11, 2009 10:12 pm Post subject: |
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I've been driving this thing more than working on it. Can't complain about that!
Did some work on the interior: new dash pad, home-made gauge panel with VDO gauges, 15" steering wheel, carpet, door panels, rubber mats, stereo and Mazda Miata seats from a junkyard (for $30 each).
I got the oil cooler mounted in the roof rack. Everything is working good - still a bit sloppy on the freeway, but not anything to worry about.
I learned what others have already figured out: the firewall tar board from Mid-America Motorworks sucks! I have never dealt with a firewall before, having had only buses, so I didn't know any better. It is so thin that even with all of the firewall tabs holding it to the metal, it still got hot and curved against the shroud. I pulled the engine and started over.
Also, the long clutch release arm from "Bruce" works great. The Stage 1 Kennedy pressure plate feels like a stocker now. Much better in traffic.
Still trying to get the speedometer issues worked out. I got the pulse ring and VDO sender bracket from "Zancat" @ desert-craft.com for use with the electronic speedo since I don't have a hole for the stock cable. I think the 1/8"+ space I had might be too much. I just moved it closer last weekend, to about 1/16"-, but haven't had a chance to recalibrate. The needle bounces around like a tach, too. Thought about using the diode trick, but which wire do I use it on?
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AZ-BUG Samba Member
Joined: January 27, 2008 Posts: 477 Location: AZ
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Posted: Wed Nov 11, 2009 11:06 pm Post subject: |
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You do some really nice work... just keeps getting nicer. |
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ottvw Samba Member
Joined: February 28, 2006 Posts: 928 Location: Auburn,WA
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Posted: Thu Nov 12, 2009 3:03 am Post subject: |
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Your not worried about getting oil everywhere when you take the filter off? _________________ Save a tree eat a beaver |
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DirtGhost Samba Member
Joined: September 19, 2007 Posts: 547 Location: Greensboro,NC
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sxuxrxf Samba Member
Joined: May 18, 2005 Posts: 1338 Location: Oceanside, CA
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Posted: Wed Nov 25, 2009 7:25 pm Post subject: |
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Thanks guys. I feel like a total amateur when I see stuff in other build threads! There is some serious talent in the Off-Road Forum.
As for the oil, I have a plastic container that fits in there to catch the overflow. I just cut away enough from one side that I can slip it in there and then be able to twist the filter.
I'm dragging the car behind the motor home to Pismo for the Holiday weekend. I went in June also. No dunes, just figure 8's and screwing around on the hard-pack until I swap the 4.12's for 4.86's. Engine has lots of torque, but the gearing is just wrong for the soft stuff. Some pics next week. _________________ (ignore the X's ) |
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shred625 Samba Member
Joined: October 10, 2007 Posts: 1328 Location: Huntington Beach Ca
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Posted: Wed Nov 25, 2009 9:36 pm Post subject: |
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Really great looking 11 car. I know you dont plan on racing it but I would love to see a cage, seats and a cell in that car!
Hats off to you!
sxuxrxf wrote: |
I've been driving this thing more than working on it. Can't complain about that!
Did some work on the interior: new dash pad, home-made gauge panel with VDO gauges, 15" steering wheel, carpet, door panels, rubber mats, stereo and Mazda Miata seats from a junkyard (for $30 each).
I got the oil cooler mounted in the roof rack. Everything is working good - still a bit sloppy on the freeway, but not anything to worry about.
I learned what others have already figured out: the firewall tar board from Mid-America Motorworks sucks! I have never dealt with a firewall before, having had only buses, so I didn't know any better. It is so thin that even with all of the firewall tabs holding it to the metal, it still got hot and curved against the shroud. I pulled the engine and started over.
Also, the long clutch release arm from "Bruce" works great. The Stage 1 Kennedy pressure plate feels like a stocker now. Much better in traffic.
Still trying to get the speedometer issues worked out. I got the pulse ring and VDO sender bracket from "Zancat" @ desert-craft.com for use with the electronic speedo since I don't have a hole for the stock cable. I think the 1/8"+ space I had might be too much. I just moved it closer last weekend, to about 1/16"-, but haven't had a chance to recalibrate. The needle bounces around like a tach, too. Thought about using the diode trick, but which wire do I use it on?
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_________________ “It takes a big man to cry, but it takes a bigger man to laugh at that man.”
~ Jack Handey |
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sixty9fasty Samba Member
Joined: April 12, 2004 Posts: 1066 Location: crockett, ca
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Posted: Wed Dec 09, 2009 9:12 pm Post subject: |
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Totally digging the use of what looks like Thing exhaust on the rear bug...
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HamburgerBrad Je suis Napoléon!
Joined: February 21, 2003 Posts: 6957 Location: SoCal
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Posted: Thu Dec 10, 2009 10:14 pm Post subject: |
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sixty9fasty wrote: |
Totally digging the use of what looks like Thing exhaust on the rear bug...
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way awesome photo. _________________ OGST | CU05 | OGJHC
1970 baja|1953 oval
Wanted: two beat up, ugly, curb rashed 6" phone dial wheels |
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sxuxrxf Samba Member
Joined: May 18, 2005 Posts: 1338 Location: Oceanside, CA
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baja72 Samba Member
Joined: January 17, 2008 Posts: 456 Location: Bremen , Ga.
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Posted: Fri Dec 11, 2009 6:04 pm Post subject: |
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Very nice! Keep it comming. _________________ I suffer from a serious disorder : Volkswagenitis |
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Fitz. Samba Member
Joined: October 06, 2009 Posts: 362 Location: Montavilla, Portland, Oregon
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Posted: Wed Jan 13, 2010 7:15 pm Post subject: |
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Will the oil cooler get hot enough to cause damage to a board-bag, or worse, a board? _________________ Settle down, it's a car. |
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sxuxrxf Samba Member
Joined: May 18, 2005 Posts: 1338 Location: Oceanside, CA
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Posted: Wed Jan 13, 2010 10:30 pm Post subject: |
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No worries on the heat, boards go next to it. Plus the wind is blowing right through it so it doesn't get too hot. _________________ (ignore the X's ) |
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sxuxrxf Samba Member
Joined: May 18, 2005 Posts: 1338 Location: Oceanside, CA
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Posted: Wed Jan 13, 2010 10:50 pm Post subject: |
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I'm already thinking of more changes.
I've got new ball joints that I'll be clearancing in hopes of more travel - every little bit helps. Another set of trailing arms and hooks to go with 'em.
I'll be completely welding the beam and gusseting the shock towers too.
Gonna beef up the tie rods, steering shaft and shim the pitman arm.
A roll cage is coming, which will be tied to the beam and frame horns.
Thinking about a full size spare in the front, so I think I'm going to build a gas tank for the rear like I had in my last car. Maybe pull out the stock tank and make a storage box/battery tray to move the Optima up front.
Then skid plates and side bars when the cage is in.
Here's some shots of the 20 gallon tank I used to have:
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DirtGhost Samba Member
Joined: September 19, 2007 Posts: 547 Location: Greensboro,NC
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Posted: Thu Jan 14, 2010 3:52 am Post subject: |
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Long ranger I used to have one of those in my Baja. People would look at me strange when I went to fill it up. People around here are not into VW's like I am . _________________ Orange Boxx Design and Fabrication |
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tundrawolf Samba Member
Joined: February 24, 2009 Posts: 1384 Location: RIP Mishomi my friend. I will always love you.
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Posted: Thu Jan 14, 2010 10:22 am Post subject: |
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Wow, what a great job! Let me tell you, I was dead-set on a cut up Baja, but now this opens up the options to a stock Beetle. I like the stock beetle look, and this gives me a lot of hope for something that is offroad-capable. I do hillclimbs, tricks trails, no real high-speed stuff. I love those tires, too. A 20 gallon fuel tank is a great idea! There's no hope for a rear seat with that tank though, is there? |
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AZ-BUG Samba Member
Joined: January 27, 2008 Posts: 477 Location: AZ
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Posted: Thu Jan 14, 2010 10:25 am Post subject: |
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sxuxrxf wrote: |
I'm already thinking of more changes.
I've got new ball joints that I'll be clearancing in hopes of more travel - every little bit helps. |
I like the planned upgrades... will be interested in the skid plates, next on the list for mine.
I probably need to replace ball joints pretty soon. Can you provide more details on what you are doing? Brand of BJ, how you are clearancing, pics, etc?
Thanks! |
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sxuxrxf Samba Member
Joined: May 18, 2005 Posts: 1338 Location: Oceanside, CA
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Posted: Fri Jan 15, 2010 2:52 pm Post subject: |
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My current ball joints are "Made in Turkey" and have blue wire holding the boots on. The new ones are German with silver wire.
As I've read, the potential for travel has to do with gettting the right joints, the right color wire, and all the planets in alignment at the time of purchase.
I've read that some have a plastic sleeve inside that prevents metal to metal contact and by removing it, you get more travel.
I will be removing some material from the ends to allow more movement of the stud. Here's where it gets tricky, as I understand, not enough removed yeilds no improvement and too much will weaken it. Both of us have hook stops, so that should help.
I just read last night that 57baja has 10" of travel with a type 3 set-up. Didn't know there was a difference, so I'll have to hit him up. That's almost double my 5-1/4" - 5-1/2". _________________ (ignore the X's ) |
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AZ-BUG Samba Member
Joined: January 27, 2008 Posts: 477 Location: AZ
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Posted: Sat Jan 16, 2010 9:44 pm Post subject: |
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Thanks for the info. My brother checked out different type of balljoints available in Mexico several years ago and found a huge difference in travel.
He bought some "German" ones (probably cheapo chinese labeled as German), some "Nakata" brand, and then some at the VW dealership.
From left to right... cheapo "German", Nakata, VW dealer.
He compared the travel on all 3, from front to back: VW dealer, Nakata, cheapo.
as you can see, a bunch more travel from the VW dealer balljoints. Would be interesting to see difference between what is available here in the US.
I hope your German ones are really German and not like the ones above... thought this might help. These went into a Class 9.
BTW, please share on the T3... I've always wondered what could be done with one of those front suspensions. |
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Lotrat Samba Member
Joined: December 08, 2007 Posts: 2528 Location: Vista, CA
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Posted: Sat Jan 16, 2010 10:04 pm Post subject: |
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Define "German"
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