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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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Posted: Fri Dec 03, 2021 8:06 am Post subject: 72BajaBen Rebuild Thread |
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Well after many years of overseas deployments, 2 houses and 2 more kids...its finally time. The poor ole baja has been sitting for about 11 years and she is getting a complete ground up rebuild.
I debated long and hard between a long travel beam setup and A-arms. I eventually decided to go with the Nichols Fab A-Arm kit. Im also going 3x3 in the rear. At this stage in the game Im also going to be upgrading the 3-rib to a 094 side shift 6 rib and the 2L bus motor to a 2.2 Ecotec. But dont worry...I already have plans for the 3-rib and T4.
So here is the current progress. Its been about 4 weeks since I brought the baja into the shop.
Here is what she looked like when I bought it back in 2006 in Long Beach California.
And after thrashing on it for years, then sitting for the last 11...This is what she looked like when I pulled her into the shop.
I started by cutting off the rotting body. Im keeping it for now to harvest some sheet metal from it to patch up the "new" body.
As you can see...the pans were in really rough shape. They were already falling apart when I bought it...but didnt have the pace or means to fix them. So expanded metal was the option at the time.
Now the body is off and the pans are coming out.
Dropped a new pan 1/2 in there. I bought these pans half's about 10 years ago.
Now its on to stripping the entire frame to coat it in Ospho. Overall the frame is in really good shape.
Here is my oldest son...who is now 20.
Ospho going on all the raw suspension parts and the bare frame.
Finished building out my 2x72 belt grinder. Love this thing.
Pans are welded in.
Pan head is coming off.
Some rot on the tunnel and the old shifter, brake lever holes and the old master hole welded up.
And now I'm capping off the tunnel so the new bulkhead can go on. I used some 3/8" steel plate and it went on pretty nice.
And this brings me to last night. We started stripping all of the paint and rust off the pans. The plan is to coat the entire thing, top and bottom with Raptor bed liner.
Let me know what you guys think. _________________ Semper Fidelis
Build thread - https://www.thesamba.com/vw/forum/viewtopic.php?p=9762332 |
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Maddward Samba Member
Joined: July 18, 2010 Posts: 206 Location: Orange County, CA
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Posted: Fri Dec 03, 2021 9:24 am Post subject: Re: 72BajaBen Rebuild Thread |
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You’re moving pretty fast! Looking great!
I'll be following this build for sure _________________ 1959 Baja Bug, A-arm J30 Honda
https://www.thesamba.com/vw/forum/viewtopic.php?t=701787&highlight=
Last edited by Maddward on Sat Dec 04, 2021 8:56 am; edited 1 time in total |
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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Posted: Sat Dec 04, 2021 8:06 am Post subject: Re: 72BajaBen Rebuild Thread |
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Not much progress last night. My plan was to prep and prime the pans for the bed liner...but that didnt go as planned.
Ive heard nothing but good things about the Raptor Bed Liner kits. But I have to say that the U-Pol Raptor Epoxy Primer SUCKS. The nozzle clogged like every 30 seconds and 1 can didnt even cover the entire bottom of the pans.
So today I plan on prepping and priming the pans to apply the bed liner. I think I need the temps to be at least in the 70's to apply it...so I might have to wait a few days before I can get that done.
I went with tan to make sure I cover everything with the bed liner when its sprayed on. _________________ Semper Fidelis
Build thread - https://www.thesamba.com/vw/forum/viewtopic.php?p=9762332 |
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sailtexas186548 Samba Member
Joined: December 01, 2014 Posts: 423 Location: Kemah, Tx
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Posted: Sat Dec 04, 2021 10:15 pm Post subject: Re: 72BajaBen Rebuild Thread |
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Awesome! He is selling a ton of those j arm kits people seem to really like them _________________ it's more fun loud and dirty |
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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Posted: Sun Dec 05, 2021 4:25 pm Post subject: Re: 72BajaBen Rebuild Thread |
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Dare I say Christmas came early for the baja rebuild?
I was over at my buddys house and he had a Subaru EJ22 laying around that he wasn't going to use. So I guess the baja is not getting an Ecotec after all. After giving it very little thought...Im going with the EJ22. Pretty close to the same HP and torque and I think it weighs less and its for sure a smaller package.
I need to source an alternator, wiring harness, an ECU (maybe a stock ECU..or microsquirt). Not sure what I'm going to do about the computer yet. Any suggestions?
I think all the other accessories are there. I think an oil pan with a lower profile might be needed.
Of course it uses metric bell housing bolts...so I cant put it on the engine stand tonight.
I also picked up the 094 today. Which is looking in really good shape.
I also got 6 "lightly" used Fox Air Shocks. I know there is a lot of opinion out there on the C/O vs air shock topic. Its what I have right now and the price is right. If they dont work out, then I know where I need to go from here.
I got 2 - 10" stroke for the front. Looks like 2 - 14" and 2 - 16" stroke for the rear. One of the 16" shocks needs to be rebuilt. Which is no big deal.
Next on the agenda is to prep the rest of the pans and bed line it. While the bed liner is curing and doing its thing Im going to get the motor and trans cleaned up. _________________ Semper Fidelis
Build thread - https://www.thesamba.com/vw/forum/viewtopic.php?p=9762332 |
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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Posted: Mon Dec 06, 2021 8:50 pm Post subject: Re: 72BajaBen Rebuild Thread |
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So I got the topside primer-ed. Its looking pretty good. Im going to give it at least 24 hours before I do anything else.
So while that was drying I refurbed a vice I got on Sunday from a buddy. It was already in really good shape. It doesn't look like it was ever used. Some light surface rust. I just cleaned it up and painted it.
I got the engine on the stand. It looks like I have the complete engine side of the harness on the motor. Which is great. A few wiring diagrams and I can get the ECU wired up. Im probably going to go with a microsquirt. For future proofing.
I think 95% of what the MS needs is already on the motor. It looks like I'm only missing the alternator and bracket.
Me and the boy (my oldest son) couldn't help ourselves.
It looks so good!!! _________________ Semper Fidelis
Build thread - https://www.thesamba.com/vw/forum/viewtopic.php?p=9762332 |
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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Posted: Thu Dec 09, 2021 9:30 am Post subject: Re: 72BajaBen Rebuild Thread |
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Update time - Raptor Bedliner
So if im being totally honest, doing this next bit had me nervous. I was worried about how the finish would come out and either being stuck with it or having a lot of work in removing it. Since the U-POL Epoxy Primer didn't go on so well.
But...just wait for it.
So I got all the parts I didnt want to paint yet masked off.
My kit came with 4 bottles of bed liner, I used a total of 3, 1 on the top and 2 on the bottom with 2 coats.
Here I sprayed the top before my helper came out.
Close up of the top cot texture. I sprayed it at 40psi about 10-12" away.
Now the boy came out and wanted to try it.
We did 2 coats on the bottom using 2 full jars of bed liner.
First coat
2nd coat
Texture after 2 coats
And then I ripped of all the masking
I think it turned awesome. Its way better than I expected. after about 12 hours the coating feels nice and hard. I'm going to let it sit for 5-7 days to fully cure before I do anymore work to it.
I have another project I need to work on and Im going to clean up the engine nd transaxle because they are pretty gross. _________________ Semper Fidelis
Build thread - https://www.thesamba.com/vw/forum/viewtopic.php?p=9762332 |
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Maddward Samba Member
Joined: July 18, 2010 Posts: 206 Location: Orange County, CA
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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Posted: Sun Dec 12, 2021 8:01 am Post subject: Re: 72BajaBen Rebuild Thread |
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So while the bed liner cures I had another project I needed work on. Ive been putting it off for a few months since it was kinda buried in the back corner of my shop.
So here is my Shapeoko 3 CNC Router. Im upgrading the Z axis and spiondle.
I forgot to take a pic of what I started with.
But here is the machine torn apart.
Electronics box
Here is the new 1.5kW (~2hp) spindle. Its going to be a HUGE upgrade from the like 1/3 hp router.
Here the machine is all assembled again.
And my new desk. LOL
Today I need to solder the spindle connector and run a 220v line over to the machine. I'm waiting on a VGA to HDMI cable coming Monday before I can fire it up.
I also couldn't help myself. I assembled the front suspension. Shock tower is welded on.
Trans has also been cleaned up.
Not too bad for 1 days milling around the shop. _________________ Semper Fidelis
Build thread - https://www.thesamba.com/vw/forum/viewtopic.php?p=9762332 |
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67rustavenger Samba Member
Joined: February 24, 2015 Posts: 9665 Location: Oregon
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Posted: Sun Dec 12, 2021 11:18 am Post subject: Re: 72BajaBen Rebuild Thread |
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Forgive my ignorance.
Is there any other support for the front suspension? It seems to me, that the single 2x4 box steel welded to the 3/8" bulk head is a weak point.
Sorry for the dumb question. I'm a street car guy. But always curious on what folks are building. _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo! |
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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Posted: Sun Dec 12, 2021 11:33 am Post subject: Re: 72BajaBen Rebuild Thread |
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67rustavenger wrote: |
Forgive my ignorance.
Is there any other support for the front suspension? It seems to me, that the single 2x4 box steel welded to the 3/8" bulk head is a weak point.
Sorry for the dumb question. I'm a street car guy. But always curious on what folks are building. |
Yes, it gets tied back into the roll cage. I dont think it would hold up just like it is. _________________ Semper Fidelis
Build thread - https://www.thesamba.com/vw/forum/viewtopic.php?p=9762332 |
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67rustavenger Samba Member
Joined: February 24, 2015 Posts: 9665 Location: Oregon
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Posted: Sun Dec 12, 2021 11:47 am Post subject: Re: 72BajaBen Rebuild Thread |
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Gotcha! Thank you.
It really is a nice suspension system.
I would have loved to have that on my 69 baja, I had to give up in 2005. That car was rough off road with the standard BJ front end. _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo! |
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Bad_chopper Samba Member
Joined: August 15, 2012 Posts: 295 Location: Portland, or
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Posted: Sun Dec 12, 2021 12:28 pm Post subject: Re: 72BajaBen Rebuild Thread |
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I have been wanting to buy that A arm kit as well. my only issue is the exact width. have you got your ride height figured out yet? and if so do you know what the over all width is? like from say outer edge of spindle to outer edge of spindle? my limitations on width is my toy hauler. _________________ my build page http://www.thesamba.com/vw/forum/viewtopic.php?t=536267 |
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Bad_chopper Samba Member
Joined: August 15, 2012 Posts: 295 Location: Portland, or
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Posted: Sun Dec 12, 2021 12:29 pm Post subject: Re: 72BajaBen Rebuild Thread |
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I have been wanting to buy that A arm kit as well. my only issue is the exact width. have you got your ride height figured out yet? and if so do you know what the over all width is? like from say outer edge of spindle to outer edge of spindle? my limitations on width is my toy hauler. _________________ my build page http://www.thesamba.com/vw/forum/viewtopic.php?t=536267 |
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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Posted: Sun Dec 12, 2021 12:39 pm Post subject: Re: 72BajaBen Rebuild Thread |
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Bad_chopper wrote: |
I have been wanting to buy that A arm kit as well. my only issue is the exact width. have you got your ride height figured out yet? and if so do you know what the over all width is? like from say outer edge of spindle to outer edge of spindle? my limitations on width is my toy hauler. |
As it sits right now its 61" wide...tip of the spindle to spindle. The kit is supposed to put the hubs at the same width as 3x3 arms. ~ 72-74" over all.
My 3x3 arms are 54" bearing face to face...so that seems pretty close once you include the stub axles.
Check back...within the next 2 weeks its going to be a roller and I can measure it for you again. Just hit me up again. _________________ Semper Fidelis
Build thread - https://www.thesamba.com/vw/forum/viewtopic.php?p=9762332 |
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Bad_chopper Samba Member
Joined: August 15, 2012 Posts: 295 Location: Portland, or
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Posted: Sun Dec 12, 2021 12:45 pm Post subject: Re: 72BajaBen Rebuild Thread |
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72BajaBen wrote: |
Bad_chopper wrote: |
I have been wanting to buy that A arm kit as well. my only issue is the exact width. have you got your ride height figured out yet? and if so do you know what the over all width is? like from say outer edge of spindle to outer edge of spindle? my limitations on width is my toy hauler. |
As it sits right now its 61" wide...tip of the spindle to spindle. The kit is supposed to put the hubs at the same width as 3x3 arms. ~ 72-74" over all.
My 3x3 arms are 54" bearing face to face...so that seems pretty close once you include the stub axles.
Check back...within the next 2 weeks its going to be a roller and I can measure it for you again. Just hit me up again. |
cool, when i called about them, i was told the 72 to 74 as well, if they are 72 im good if they are 73 im almost hitting 74 i hit. this looks like a pretty awsome build, i just did a lot of work on mine last year. my rear is done, but the front sucks, still ball joint.
check my build out looks like we are pretty much doing the same thing. i am a 97 ej22 but it is now on a stand alone ecm no longer using the subaru ecm.
thanks for the quick reply by the way _________________ my build page http://www.thesamba.com/vw/forum/viewtopic.php?t=536267 |
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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Posted: Sun Dec 12, 2021 12:50 pm Post subject: Re: 72BajaBen Rebuild Thread |
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I ordered this kit with BJ stubs on it. I already had the BJ disk brake kit on the car. I can always buy or make Link or Combo spindles if I upgrade to that in the future.
I also plan on running a 7x15 tire in the front so its going to be skinny compared to the 10.5s on the 3x3 arms. _________________ Semper Fidelis
Build thread - https://www.thesamba.com/vw/forum/viewtopic.php?p=9762332 |
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72BajaBen Samba Member
Joined: July 30, 2006 Posts: 888 Location: Tampa Florida
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Posted: Sun Dec 12, 2021 2:00 pm Post subject: Re: 72BajaBen Rebuild Thread |
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Bad_chopper wrote: |
check my build out looks like we are pretty much doing the same thing. i am a 97 ej22 but it is now on a stand alone ecm no longer using the subaru ecm.
thanks for the quick reply by the way |
Nice looking build. How do you like the raptor liner on he inside. I think Im going to do it.
What ECM did you use? Ive been reading through the Microsquirt docs. _________________ Semper Fidelis
Build thread - https://www.thesamba.com/vw/forum/viewtopic.php?p=9762332 |
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