The Buggy build begins

[jspbtown]

I finally got the Bradley GT out of the shop and wheeled the Buggy (which has been sitting in my attached garage for 2 years) down to the shop. Separated the body using my $49.00 Ebay hoist and got it up onto the dolly. Got all the mounting hardware off and ripped out all the wiring. Body work starts tonight. But I think I made some good progress for one evening after work. Much more pics to follow.

[scarybuggy]

Wow, talk about a project! But, I've seen what you can do, and that should be a walk in the park! Can't wait to watch your progress. Have fun!
_________________
Jay

'67 Manx Clone

[Genom]

Looks like you're off to a good start already...the tension on the belt for your invisible generator seems just fine.

One of the good things about starting out with such a project is that anything you do from this point on, is an improvement. This buggy should turn out awesome judging by how well the Bradley came out.

[MURZI]

I rub my hands in anticipation. :hehe:
_________________
62 vert
2276
Tim’s welded heads
45 Dells
A1 sidewinder
Fk44 cam

[darkdune]

very interested to see the progress

take lots of pics

[jspbtown]

Let it be known that sanding red paint off in 95 degree weather is NOT one of my favorite things! I got most of the outside of the body sanded and all the spots needing glass work have been ground out. Need to sand the inside now. Hopefully will be doing some glass work this weekend.

[dunebuggydrifter]

It looks like a fun project. Reminded me of what mine use to look like. Have fun and post pictures.

[JiI]

I love the pans! Those are mint condition in Illinois and go for some serious $$$$$!!!!
JiI

[jspbtown]

Body is sanded, holes are glassed, and pans are out.

Plan is to get the motor and tranny out today as well as the front end dis-assembled. I will give the new fiberglass a couple of days to cure well and start shaping. Lots of small holes to fill. It will be basically a hole free body when I am done.

Ordered some 1x2 steel tube for the outter frame rails and some .125 diamondplate for the floors. It wasn't as unreasonable as I thought. The rear sections of the pan (where it goes back upwards) is gone so I think I will be cutting them out and replacing them with tube and diamond plate.

The center tunnel looks real solid. I strippd off all of the insulation and sanded it to nice solid steel. It is a 1961 chassis ( I think: vin # 4085217), so I fab'd up a small plate and welded the older knob style heater control hole up. I am going to skim it with some two part putty to make it nice and smooth. With the diamondplate floors there will be no carpet so this tunnel will either be black, silver, or body color.

Pics are coming.

[labigboy256]

get on it and keep us posted with your progress....i'm just getting started on my first manx wish me luck!!!

[jspbtown]

OK...some new pics. BUT there are some ground rules for viewing:

1. NO flaming me for the pig pen of a shop!
2. NO flaming me for poor tool maintainence...I just got back from
vacation and it was pics or clean up time!
3. NO flaming me for being a shop slob!

OK.....if you abide by those simple rules...here are some pics.

Some before and after shots of some rear damage. The plan is to use a VW license plate hood (any ideas which year look best?):

Here is the center tunnel. I am smoothing it out for either some black hammer finish or body color. Pans are 1/8" polished diamondplate:

Here is the Hawkeyes buggies cage. Since my welds aren't all that pretty I am smoothing them with Rage Gold:

Here are my 1/2 finished front spindles/brake assemblies:

Here is a front end shot. Beam has new adjusters. Everything is all cleaned up..except for Rage dust!:

Here is a dash pic. It will be re-painted black hammertone. I know...I know...easier to just buy a new one from the manx store!:

Here is the tranny. New boots & new input seal. Rear brakes will be done when re-installed:

And lastly, just a couple of pics of the damage I was dealing with:

Hope to get to paint soon. Lots of stuff to do, but just so little time.

[Elwood]

Looking good, I gotta do about as much work as you gotta not including the stretch. Looks great.

Heres a question, How did you get the trans so clean. I pressure washed and scrubbed for seemingly ever and still couldn't get all the crap off of it.

[jspbtown]

Simple Green, scrapers, and dental picks to get the tranny clean. It was a nightmare!

[hotair65]

is the hawkeyes buggie cage a pre-made unit? by pre-made is it pre bent that has to be welded? there are quite a few pict of that style cage and it is what i am looking for but dont have any experience bending tubes.

[jspbtown]

Yup, pre-bent and fish mouthed. Needs welding and the rear pipes need to be cut for length. Not that hard. I have NO experience in metal fabrication and mine came out OK.

[hotair65]

sweet. just checked out the website and there really isnt much info. what was the cost if you dont mind?

[jspbtown]

Yikes...I bought it over ayear ago and I am thinking it may have been around $200 with shipping?? Can't gaurentee that tho...the old mind is slipping with age.

[hotair65]

thats very reasonable. i will have to get in touch with them.

[jspbtown]

Have made some progress on the build. Diamondplate floors are in. Made a few diamond plate trim pieces with the left overs. I have installed the steering box, new link pins and shims, steering damper, front spindles, brakes, the tranny, one rear brake (the other will be tomorrow), clutch cable, pedal cluster, master cylinder, some brake lines, tranny mounts, painted the center tunnel, primed the repaired dash, herculinered the chassis, ran a new fuel line, installed a new shifter bushing, stripped the tail light housings and license plate light, and finished fitting the side pods.

I had forgotten how tedious it is wire wheeling each and every nut, bolt, washer, and fitting!

Waiting for some wheel seals & tie rods. I have the primer and am hoping to get the body primed next weekend. Maybe some pics tonight.

[ArthurBrazil]

pics pics pics!
Definitly going to be a really cool build.