1969 Baja Bug - TX Build

[sailtexas186548]

Coil mounted:

Oil filter mounted and sender installed:

Battery mount installed:

Terminal access from above:

Bumper on, all new 3/8” and 1/2” G8 hardware, a 2.5” full width angle for the inside backing plate, oil lines installed, time to start wiring.

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it's more fun loud and dirty

[sailtexas186548]

Added an oil temp switch for the warning light, 235*F is when it comes on.

Cylinder Head temp guages in finally, I think the dash came out pretty cool!

All of the battery cables, wires, grounds, etc are done and just need to be terminated at the dash. I build boats also, so I always end up using left over marine grade wires/cables/etc, this build is no different. I had enough wire colors to actually make a proper color coded harness which is cool, basically following the Chevy colors. Here are some assorted progress pics, I will loom it all up once it tests out

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it's more fun loud and dirty

[sailtexas186548]

Finished the wiring, tested everything and have three issues to work though.

1.) The new turn signal switch I installed is shorting to ground when switched “on” for both the right and left sides… I was just going to use it as a switch for turn signals to give +12v to the circuit… not looking forward to pulling the column apart again… maybe I can make it work with a three prong flasher relay controlled with the ground? I’m not really sure how those work but I’m guessing this is just wishful thinking…

2.) The headlights I’m using are drawing 21-22 amps, so I need to run a dedicated wire from the battery and a relay, that’s a lot to put though the switch lol it was gettting hot fast

3.) The low fuel light module isnt working, I think I have it on the wrong ohm range I will have to check what sender I put in :p

Alternator “not charging” light works! The first sign of life!

Cylinder head temps:

Turn signals installed:

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it's more fun loud and dirty

[ORANGECRUSHer]

Im not sure those headlights are big enough. Lol i kid because im a light guy. Never have too much.

As for the turn relay, are you using OE or aftermarket? Ive tried to stay with the vw stuff before but that's really kinda silly. I used an electronic two prong flasher on my woodsbuggy last winter using a stock switch on the steering column. I always use relays for actual power going to a load, even the turn signals. But i couldn't tell you right off hand how i wired it without my notebook. It's just too easy to look that stuff up on goggle to commit to memory.
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Brian H.
I may not know everything,but I will try to help if I can
OrangeCrushER Berrien Warrior 2.4L Quad4
LAZY MARY 1970 Baja 1835cc

[ORANGECRUSHer]

Keep up the good work. Your motivating me to get started on my baja restoration. I hope it looks as good.
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Brian H.
I may not know everything,but I will try to help if I can
OrangeCrushER Berrien Warrior 2.4L Quad4
LAZY MARY 1970 Baja 1835cc

[sailtexas186548]

They are pretty bright! They are pre-production versions from my friends lighting company so the price was right, i would have preferred 7" but they have grown on me.

I have a two pin aftermarket flasher unit, and a turn signal switch from Jbugs. i think the turn signal switch is the issue, grounding out in the column because they aren't the best quality and i may have left out some insulators or something . I will open it up and modify as required!

I only use relays when I have to, for big loads like fans and pumps. Definitely going to use one for these headlights at 21A draw
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it's more fun loud and dirty

[sailtexas186548]

Fuel!

Cranking oil pressure of 35+ lbs

Cam break in done, 1700-2100 rpm for 20 minutes.

Had a valve cover leak, and one oil pump stud is weeping, otherwise no leaks! The jetting is bad, way way way rich and I’m not certain but it seems like my timing/spark is a bit erratic. Need to check out the distributor, condenser, and maybe fouled plug from being so rich. Coil got pretty hot so I need to Chase that down also

Lights!

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it's more fun loud and dirty

[ORANGECRUSHer]

What tire size are you running in front? Sorry if u already mentioned it but I run a narrower slightly smaller all season in front and 29" wrangler in back but i like your stance. I'm wondering how much more steering effort comes with those larger fronts. One of the reasons i contemplated a lift was going to a full size steering wheel.
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Brian H.
I may not know everything,but I will try to help if I can
OrangeCrushER Berrien Warrior 2.4L Quad4
LAZY MARY 1970 Baja 1835cc

[sailtexas186548]

I’ll have to look at the tire size, I robbed them off another Baja I bought six months ago for parts.

The points in the distributor were trashed, got a new set installed

Also picked up Some jets, changed to 50 idles, 200 air, 115 mains and it is better, need to get a wideband on it and really dial it in

I thrashed on this thing all last week to make “Bug off 2022” so these pics are from last Thursday night. I zip Tied the wires up for now, I will loom them once it’s all working right for a while

Hood on:

Oil change from breakin to vr1, 10w-30. I have 45+psi oil pressure at cold idle, 22 psi at hot idle, and about 35-45psi any time it’s much above idle. No shavings or glitter, just some moly lube and fines from the cylinders and rings wearing in.

I learned that you still have to index the rear torsion bars close to how you want final ride height, and tweak the height with the adjuster, there isn’t much adjustment It’s more of a fine tuning tool.

Also set the front steering stops, I had to weld a nut to one because it was too short to keep the wheel out of the fender.

Loading up on a utv rack I bought from alpine designs. I had to winch it up, driving it was not really possible to do safely with the gearing and tire size I have. Also the pan just barely scrapes (like a high centering) when loading so if if you look into a rack like this your car better be all the way up on the limiters. My Manx can’t make up the ramps.

Made it to the “bug off” and had a great time running the off-road course. I had some fun sorting out the ignition (I had a 0.6 ohm coil on there, which melted… I ordered a 3.0 ohm but didn’t check it in my rush to get this thing done lol), my digital timing light was being erratic - only increasing my confusion!, and then I discovered this fuel tank has some varnish in it that was slowly dissolving in the new gas and clogging the fuel filter, so it would idle fine but under higher fuel demand it was breaking up. Once that was sorted it ran pretty dang good and I was able to make a few runs at the off-road course. I didn’t win but I posted a respectable time and the car performed well.

It still needs a few things sorted out, some suspension tuning, windshield, etc. but it’s running and driving almost 8 years later!!! It had been a lot of work but it was certainly worth it
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it's more fun loud and dirty

[ORANGECRUSHer]

That one pic makes your engine look like it went subterranean!

I'm curious how well the head temp gages worked. Was that useful information to have?
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Brian H.
I may not know everything,but I will try to help if I can
OrangeCrushER Berrien Warrior 2.4L Quad4
LAZY MARY 1970 Baja 1835cc

[sailtexas186548]

Ha yeah so it turns out black spray paint makes old shocks look good, but it doesn’t make them perform well! Overall it is way too soft to send it in the bumps. The old bump stops also disintegrated after taking a few big hits so that made the suspension travel even higher

The head temps are nice to have. I have oil temp warning light (235F), oil pressure gauge, and head temps. The heads stayed under 200F whenever I looked, their real Purpose is to show when they are getting really hot or when one is hotter than the other. They seem to work really well and are easy to see
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it's more fun loud and dirty

[The Phil]

What are you using for headlights? Are they DOT approved?
I'm after something like those to replace my stocks and mount to bumper as well.
Where can I find them?
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"In case I don't see you, good afternoon , good evening, and goodnight."

My '66 Baja Build Page http://www.thesamba.com/vw/forum/viewtopic.php?t=456365

Free from the evils of facebook Dec 2012. No other Social Media.

[sailtexas186548]

[The Phil]

[quote="sailtexas186548"]

[ORANGECRUSHer]

I'm not sure if you've noticed, but there's a lot of decaying corpses in your neighborhood. Perhaps it is time to relocate?
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Brian H.
I may not know everything,but I will try to help if I can
OrangeCrushER Berrien Warrior 2.4L Quad4
LAZY MARY 1970 Baja 1835cc

[sailtexas186548]

Finally fixed the turn signals, popped the windshield in and wired up the wipers. I am just a reverse light and license plate light away from passing my safety inspection so I can get plates.

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it's more fun loud and dirty

[ORANGECRUSHer]

I was just noticing your gas tank location. How does the front end feel being so light?
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Brian H.
I may not know everything,but I will try to help if I can
OrangeCrushER Berrien Warrior 2.4L Quad4
LAZY MARY 1970 Baja 1835cc

[sailtexas186548]

feels normal to me, but my other VW is an Ecotec Manx with front mounted fuel tank, so in comparison this is slightly heavier up front.

I dont have issues with understeer unless I'm in the dirt and going fast, but the cutting brakes more than compensate for that
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it's more fun loud and dirty

[sailtexas186548]

Messed with the jetting some today, moved up from 50 to 55 idles and from 115 mains to 135, kept the 200 airs, and turned the accel pump way up so it squirts instantly when the throttle moves. Drives almost perfect, still a couple weird moments but overall it’s pretty good. I may try some smaller mains again since i went up 20 in one step.
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it's more fun loud and dirty

[sailtexas186548]

Inspected/plated, it doesn’t need anything else so it’s “done” but I’m sure I’ll throw a few more things on like an interior light, a small radio, and a skid plate. I have an 002 and an 091 transaxle that might make their way into this thing, depends on how the type one holds up.

There is still some funky old varnish in this tank so I’m clogging the fuel filter filter pretty regularly, once I burn this tank of fuel I’ll be able to really clean it and get the jetting right, it’s hard to make intelligent changes when the fuel supply is inconsistent.

Now some pictures!

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it's more fun loud and dirty