Burro Buggy 2.0 build

[cbeck]

Made it out of scrap lexan.
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My cut in half and rebuild thread
www.thesamba.com/vw/forum/viewtopic.php?t=647779

[heywebonya]

Updates are small upgrades that do not make large changes in appearance.

1. Finished brakes and bleed them (one of my bubble flares leaked!) Finished.

2. Pulled wires for buggy.

3. Added tail light mounts.

and mounted lights

Next step(s)

a. fill transaxle flluid (~ 1/2 qt low)
b. install engine
c. finish wiring
d. install fuel tank
e. cover front cowl with 0.065" Aluminum skin
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If I knew what I was doing; I wouldn't be building a buggy!

[heywebonya]

Installed the engine and fuel cell!

I like how it fits, but the 12 gallon fuel cell looks HUGE!

I think there is enough air flow around the engine.

I planned to have the fan intake open and it turned out nice.

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If I knew what I was doing; I wouldn't be building a buggy!

[heywebonya]

Finally made some progress on the front end. Kind of a chicken and egg issue with wiring, front pedals, and headlights - couldn't decide on the order to move forward.

1. Made a firewall from an old desk and tried my hand at bead rolling. Turned out pretty good. As a bonus, I was able to use my plasma cutter too.

A quick coat of paint:

Then I made a front cover out of an old fiberglass truck cap.

Coat of paint

Finally installed headlights and screwed the "hood" in place.

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If I knew what I was doing; I wouldn't be building a buggy!

[dennismcd707]

It's cool to watch you guys put your sleds together. It gives me hope. And as usual, I'm impressed with your fabrication skills. Nice work.
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1971 Super Beetle, 1776, dual Weber's, roller crank, big valve modified racing heads, close ratio trans, lowered suspension, 4 wheel disc brakes, car has over 368,000 actual miles. (RIP 1970 Beetle/Baja, 1986 GTI, 1999 Jetta, 2002 Jetta)

[tobiism]

that nose cover is really clever. And I'm digging on that old school select-a-drop front end adjuster!
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"There has never been a genius without a hint of madness."
-Albert Einstein

[Vanapplebomb]

Good work man! I like your creativity with materials, particularly on the hood.
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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[heywebonya]

Thanks for the comments, I always thought an old fiberglass topper would make a great buggy lid. I was surprised how they are built using cardboard spacers for strength.

Next step - finish wiring
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If I knew what I was doing; I wouldn't be building a buggy!

[heywebonya]

95% complete and on wheels!

To do list:
1. Adjust shifter (cannot get into 1st)
2. Adjust clutch (does not disengage)
3. Replace brake switch (always on)
4. Add front wheel panels (keep front wheels from killing me)
Misc to do:
Paint wheels white
Add hubcaps
Add windsheild

Pictures!

I really like the side view - looks fast when parked!

Front corner - looks good

Front end - notice the beam is bent - the bottom tube was never welded! I think the added weigh made it spread!

Fuel cell and battery box

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If I knew what I was doing; I wouldn't be building a buggy!

[dennismcd707]

Lookin' good Jeff! I'm envious of your buggy's status. So close to being done. It sure looks like it's gonna be a fun sled!
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1971 Super Beetle, 1776, dual Weber's, roller crank, big valve modified racing heads, close ratio trans, lowered suspension, 4 wheel disc brakes, car has over 368,000 actual miles. (RIP 1970 Beetle/Baja, 1986 GTI, 1999 Jetta, 2002 Jetta)

[pullstart]

Looks fun! That offer for Yankee Springs still stands!
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4 seater Appletree buggy, road legal with 002 IRS, 3x3 Appletree kit, 6" over Dan's beam with 10" towers and Fox 2.0 shocks, '00 Subaru EJ25 with KEP stage 3 clutch and KEP adapter plate.

my build page: https://www.thesamba.com/vw/forum/viewtopic.php?t=662104&start=0

[heywebonya]

Added some 0.063" Aluminum filler panels to the front corner. - Kind of dicey looking at the front tire waiting for a rock to fly up.

Cut the panels with plasma cutter and straight edges.

Bent a lip with bead roller.

Installed with 3/4" self tapping screws.

Inside view

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If I knew what I was doing; I wouldn't be building a buggy!

[pullstart]

If you plan to ride in the dunes, side panels might be useful as well. Before I put on the sides for my buggy, it wasn’t uncommon to get a lap full of sand in a turn!
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4 seater Appletree buggy, road legal with 002 IRS, 3x3 Appletree kit, 6" over Dan's beam with 10" towers and Fox 2.0 shocks, '00 Subaru EJ25 with KEP stage 3 clutch and KEP adapter plate.

my build page: https://www.thesamba.com/vw/forum/viewtopic.php?t=662104&start=0

[heywebonya]

PullStart - good point, it is a balance of ease of entry versus shielding.
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If I knew what I was doing; I wouldn't be building a buggy!

[pullstart]

Maybe fashion some half doors?
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4 seater Appletree buggy, road legal with 002 IRS, 3x3 Appletree kit, 6" over Dan's beam with 10" towers and Fox 2.0 shocks, '00 Subaru EJ25 with KEP stage 3 clutch and KEP adapter plate.

my build page: https://www.thesamba.com/vw/forum/viewtopic.php?t=662104&start=0

[heywebonya]

Cleaned up the filler panels (to remove marker). I am thinking of removing ~ 1" triangle from the top corner to eliminate the snag potential.

Took an old bazooka exhaust and grafted in onto a stinger to eliminate the potential of water filling the exhaust and also quiet the exhaust a little bit too.

Added mirrors - just cheap Jeep mirrors. Cut down the arms to 5 1/2" long and welded on some mounts. Shortened them to look normal and eliminate them getting snagged.

I need to add some shocks to the front end - super bouncy and too soft. I have welded in some adjuster on a new beam.
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If I knew what I was doing; I wouldn't be building a buggy!

[heywebonya]

Done, now what? I have completed my "Burro Buggy" type based on a VW pan.

Have a great day!
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If I knew what I was doing; I wouldn't be building a buggy!

[dustymojave]

Now what?

USE IT!
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Richard
Offroading VW based cars since 1965
Tech Inspection 1963 - 2012 SCCA/SCORE/HDRA/MORE/MDR +
Retired from building Bajas, Fiberglass Buggies and Rails in the Mojave Desert. Also Sprints & Midgets, Dry Lakes, Road Race cars. All types New and Vintage
SoCalBajas Member
Kicked Cancer's A$$...1st and 2nd round...Fight ain't over yet.

[dennismcd707]

I was just looking at my buggy the other day and I felt a bit overwhelmed with the amount of work that I still need to do on it.

Then I see your finished product. That thing looks awesome!

You've lit a fire and inspired me. (buggy porn)

Great job! Let's hear tales of what it's like when you're out squirtin' dirt with it.
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1971 Super Beetle, 1776, dual Weber's, roller crank, big valve modified racing heads, close ratio trans, lowered suspension, 4 wheel disc brakes, car has over 368,000 actual miles. (RIP 1970 Beetle/Baja, 1986 GTI, 1999 Jetta, 2002 Jetta)

[no1clyde]

Looks like it is for sale.

https://www.thesamba.com/vw/classifieds/detail.php?id=2257741

Ed