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72BajaBen Rebuild Thread
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72BajaBen
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Joined: July 30, 2006
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PostPosted: Mon Dec 20, 2021 7:11 am    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

I have no idea how many miles are on this motor. It came from a 1996 mom wagon with an auto trans. So hopefully it was babied. But I have it on the stand and I have time to kill.

Here's what I plan on doing.

1 - Washing the motor
2 - Head Gaskets
3 - Timing Assembly
3b. - 36 tooth crank gear upgrade
4 - Water pump
5 - EGR Delete

So I started to tear the motor down.

Isnt it so cute...

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72BajaBen
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PostPosted: Fri Dec 24, 2021 2:33 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

Some progress made this week.

The body is back on for the time being. I've decided that I want a 3" body lift and I've also decided that the Empi body lift is garbage. So I will get some 2x3 sq tube and make my own.

I think its looking really good.

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There's quite a bit of trimming that's going to need to be done. But I don't want to do any of that until I have the lift done.

I also need to acquire a set of doors.

Motor has been cleaned. I'm waiting on gaskets to tear that down and freshen it up.

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Here is a side project I had going on this week too.

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66 Shorty
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PostPosted: Fri Dec 24, 2021 4:34 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

Really cool build! 😎
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72BajaBen
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PostPosted: Fri Dec 24, 2021 4:40 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

66 Shorty wrote:
Really cool build! 😎


Thanks!
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72BajaBen
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PostPosted: Wed Dec 29, 2021 8:44 am    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

I do have a question that I've been putting off...Until I got the body on.

So I bought the 3x3 kit from Pacific Customs. Pretty sure its the "Latest Rage" kit. Anyway, the arms are off. Neither wheel sits upright. The passenger side is the best of the 2. The driver side looks like I got t-boned and I need to replace parts. I tried both arms on both sides. And they both "fit" the passenger side the best. Both look the same on the drivers side. Now that the body is on it, it looks really bad.

Anyone have a recommendation on replacement arms? I'm sticking with VW, so no micros. I don't think it would matter tube or boxed...I think either would suit my purpose. I just want something that's made correctly so it will work right.

Any good companies or people out there that make quality arms?

Dune Buggy Warehouse sells a HD 3x3 set made in the USA. That's what I'm looking for. But I wanted to see what my other options are.

What's everyone's opinion on the bolt in bearing carriers?

Any benefit to 3x5 over 3x3? Since I'm using the 094 and I have to make a custom front mount I can move the engine and trans back 2" so the 19-1/4" axles will still work. I plan on cutting most of the rear package tray out so I can fit 2 seats in the rear (more comfortable leg room). Is it worth it for extra 2"?
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no1clyde
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PostPosted: Fri Dec 31, 2021 9:24 am    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

For arms check out this guy on Face Book, Nick Mailloux, he makes them.
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72BajaBen
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PostPosted: Fri Dec 31, 2021 9:55 am    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

no1clyde wrote:
For arms check out this guy on Face Book, Nick Mailloux, he makes them.


Thanks! I’m already a member of that group. No arms posted. But I’ll hit Nock up.
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dustymojave
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PostPosted: Sat Jan 01, 2022 9:02 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

I recommend Kartek arms. I know the guy who makes their arms HE also does welding for Robby Gordon. He knows what he's doing. I have a pair on the Chenowth out back. They're straight and fit as they should.
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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.
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66 Shorty
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PostPosted: Sun Jan 02, 2022 5:40 am    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

I bought arms from Nick at buggy barn. Very nice product made in the USA.

Whatever set of arms you go with I recommend putting notches in the bearing housings to make replacing bearings easier...


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dustymojave
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PostPosted: Sun Jan 02, 2022 11:26 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

I definitely agree with that. I feel EVERY bearing housing should have notches for driving bearings out. One's that I've dealt with that did not, really pissed me off.

Mill is nice, but not all will have one available to them. It CAN be done with a hand held grinder with a carbide burr.
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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.
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66 Shorty
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PostPosted: Mon Jan 03, 2022 6:07 am    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

Here's a video Nick made about camber issues with 3 x 3's (It's on FB, you probably have to log in to see it...)

https://www.facebook.com/1793020865/videos/374260157747923/
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72BajaBen
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PostPosted: Thu Jan 13, 2022 6:39 am    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

So I was able to get out to the garage and get some work done.

First of all...I got some new parts in.

Outfront motorsports Engine Adapter
KEP Stage 2 PP
Brand New clutch disk and throwout
Weddle 094 Shift Linkage
UA4C Speeduino ECU and wiring harness
EJ Gasket Kit
EJ Water Pump

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I put the UA4C together and loaded the base tune on it. It appears to be working. At least as far as I can test it on the bench.

All of the other part are going to get installed when I get to them.

Next I replaced head gaskets on the EJ. Man she was a bit crusty on the inside. Its obvious that its been sitting for a bit. But overall it looked pretty good. Now it looks even better.

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Cleaned up
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Going back together
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And that's all I have for now.
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Bad_chopper
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PostPosted: Sun Jan 23, 2022 7:45 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

one thing about that ej22 ill suggest, since i learned this myself not to long ago, and had to pull the engine to do it. That black plastic cover that is on the back of the engine that would be behind the clutch. get a replacement, there are on all subaru engines the replacement will be metal, they had the screws, the plate, and get an o ring for that plug that is on there as well. its a simple thing to do mine was starting to leak oil that is why i did it.
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72BajaBen
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PostPosted: Sun Jul 03, 2022 7:29 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

Ok...Back to work.

Body has come back off for final welding of the body lift. I want to cap the tubes to keep junk from getting in there. Wire wheel it all....wrap up some body work while its up in the air and easier to get to.
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Some prep work has to happen to the pan as well.
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I've also adjusted the front and rear arms so everything is square. She's looking pretty good. Pretty sure this is where I want to ride height to be. I have 14" under than pan.
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72BajaBen
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PostPosted: Sun Jul 03, 2022 7:29 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

So a smoking deal fell into my lap. I got a 75% buggy project for a screaming deal.

002 # Rib
Frame
2 Bins full of parts
Fiberglass Body kit
Spun Tank
Seats and belt
The list goes one.

Here are some Pics.
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And my plan is to run the good ole trusty T4 2.0L Bus motor. Which has been spruced up.
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The project needs a few things. But its one hell of a jump start.
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72BajaBen
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PostPosted: Sun Jul 03, 2022 7:30 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

So I got a fair bit done today and it went pretty good.

I got a pedal cluster for the 2 seater cleaned up and soaking in some EvapORust
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I took out the rotting door jam and hinge and replace the sheet metal all the way to the front.

Here is a before.
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and the process:
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72BajaBen
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PostPosted: Sun Jul 03, 2022 7:30 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

I dug out the old headers for the T4 and cleaned them up. I had to cut the old exhaust off. No big deal.
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And here is an updated pic of the T4.
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72BajaBen
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PostPosted: Sun Jul 03, 2022 7:52 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

I got the header all cleaned up. If you guys haven't tried Evapo-Rust yet...you have to get a bucket. Its magical.

I didn't take a before Pic...but here is the after. All of the rust just melts away. Then I spray it down with Ospho.
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I bought some rebuild parts and got the pedal cluster built. Still waiting on a boot and push rod. But its ready to go.cc
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I also re built the shifter. New springs, lock out plate and a dip in Evapo-Rust and its looking pretty good. Its just a stock shifter but it will work fine.
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This is something I have been working on for a few weeks while its been either too hot or raining too much to be outside. I scratch built a console/dash for the buggy.
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I'm not ashamed to admit it took me 4 tries to get it to work the way I wanted it and to fit everything.
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My plan is to weld it in the center of the windshield bar. I initially tried to plan it to have a radio in the dash...but there's no way it would fit. I'm running pretty much everything on a relay with thermal circuit breakers on the dash. Should work out pretty good I think.
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72BajaBen
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PostPosted: Tue Jul 05, 2022 6:59 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

I think all of the body patch work is done. For now. It doesn't look great...but its a woods car so I'm not really worried about it. I just wanted to get the rot off the body. Overall it wasn't too bad to begin with. Plus th 2mm of paint on this body make the patches look worse than they are.

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I also got the passenger lower door pillar cut out and a new one put in.

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And "new" doors put on.

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And lastly...I got some new seats for the 2 seat buggy

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72BajaBen
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PostPosted: Sun Jul 10, 2022 8:05 pm    Post subject: Re: 72BajaBen Rebuild Thread Reply with quote

I got the trans mounts built tonight. Lookin pretty solid.

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I also started pulling the window regulators out. They have to be replaced or rebuilt.
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