New Manx II Project

LouisB · Posted: Tue Jul 07, 2009 11:54 am Post subject: New Manx II Project

I thought I would post some pics of my new Manx II project. This shell has been floating around between different club members for about 10 years. I have been tempted to buy it a couple of times but always had other projects in the works. I was over at the PO's house a few weeks ago and mentioned I was planning on selling the set of repo gasburners I had decided not to use on Cal-look '66 project and he said he wanted them. So we worked up a trade and now I am the proud owner of an original Manx II shell. It's been sitting outside for many years under an oak tree and is pretty dirty but in over all good shape. Only a few areas will need some glass work. Plans are to use most parts cast off from other VW projects and build a late 60's early 70's style buggie that will see mostly street use. Anyway, on to the pics.

Right now it is sitting on the pan from my long term '66 cal-look project which you can see in the background. I have a '67 pan I plan to shorten for it in the next couple of weeks:

Image may have been reduced in size. Click image to view fullscreen.

Hood has had some repairs but is usable:

I dont know about these rear fenders. They are well made and grafted in but I may rework them to look more stock:

The only really bad area:

Dash won't need much work:

Proof its a real Meyer's Manx:

From the numbers it looks to be a later version of the Manx II made after Bruce left the company.

I will update this thread as the build progresses.

Thanks,

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

jspbtown · Samba Member Joined: January 27, 2004 Posts: 5157

louis,
Nice project. It looks like a solid start.

That hack in the back looks familiar!

I would think the fenders will require more work then that rear section.

LouisB · Posted: Tue Jul 07, 2009 1:25 pm Post subject:

Thanks for the comments. It seems every buggy I have ever seen has been hacked in that area. Too many people running bugsprays I guess.

For the rear fenders I am tempted to try and mold up a new lip using the fronts as a guide. The other option would be to look for a buggy that has been wrecked and graft in the rear fenders. Or I could just leave them alone and put humongous tires back there. (Probably not)

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

BL3Manx · Posted: Tue Jul 07, 2009 6:43 pm Post subject:

It shouldn't be too difficult to carefully remove with a file/surform plane, only and all the added on fiberglass and keep all the original. It will give you a good indication of the original top view of the fenders. The lip of the fender which extends down is pretty uniformly 2 1/4" until a point 4" ahead of the seat back top. At that point the lip begins to widen to blend into the rear apron. The lip didn't hang straight down. It extended outward at a 25 degree angle from vertical. You should be able to see at least the upper portion when you remove the added fiberglass.

If you think photos of original rear fenders could help you restore yours, I'm sure you'd get plenty if you ask.

LouisB · Posted: Tue Jul 07, 2009 6:51 pm Post subject:

Some close ups of those areas would be great. I think I can make up some molds and lay some new sections.

Thanks,

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

BL3Manx · Posted: Wed Jul 08, 2009 6:56 am Post subject:

You don't need to make a mold. After you remove the added fiberglass, attach a piece of thin plastic or plexiglass(fiberglass won't stick to it) along the original edge of the fender at the 25 degree angle of the original lip. Use small wood screws to attach it. Turn the body upside down and build up fiberglass against the back side of the plexiglass strip, so the lip is 2 1/4" long and 1/4" thick. After it hardens, remove the screws and plexiglass. Use body filler to fill holes and blend and shape the lip to match the original.

LouisB · Posted: Wed Jul 08, 2009 7:28 am Post subject:

Cool, thanks. I will give that a shot. Now I just need some cooler weather so I can go out and play with some fiberglass.

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

BL3Manx · Posted: Wed Jul 08, 2009 7:47 am Post subject:

You could start now by removing the added glass.

BTW, the thin sheet of plastic will also work for filling the hole they cut out for the air cleaner. Attach it across the hole and build up from the back. Maybe that's what you want to start with.

LouisB · Posted: Wed Jul 08, 2009 8:26 am Post subject:

Thats a good idea. There are a bunch of small holes that need to be filled as well. My first big project is going to be getting the pan in shape. I need to replace the frame head and then shorten it. Hope to get started on that this weekend.

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

jspbtown · Samba Member Joined: January 27, 2004 Posts: 5157

When I built up the damage in mine I took a piece of 2x6 and cut it to be width of the raised section (left to right on the inside of the section). I then took a 1x2 piece of scrap and attached it so it would sit right under what was left of the horizontal original lip. This provided a "shelf' that held the glass and provided a straight line.

After tapering the cut out back about 1.5-2.0" on the outside I placed some wax paper over the wood and clamped it to the back of the hump. I laid up the glass, and when done, I scuffed the back of the new glass up along with about 1.5-2.0" of the backside of the hump and laid down several more layers of glass.

Hopefully that makes sense. I wish I took pictures.

LouisB · Posted: Wed Jul 08, 2009 8:47 am Post subject:

I think I follow you. I am going out today and hunt down fiberglass supplies.

Thanks,

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

BL3Manx · Posted: Wed Jul 08, 2009 11:30 am Post subject:

It will definitely be easiest and you'll get the best results if you lay the wet fiberglass with the body upside down, just like when it was made.

Take your time removing the added on fiberglass. The more carefully you do it, the closer to original the results will be.

LouisB · Posted: Wed Jul 08, 2009 11:43 am Post subject:

Thanks for the tips guys. I went out to the West Marine store today and picked up some of their epoxy fiberglass resin and associated paraphernalia. I am already starting to itch just thinking about it. Very Happy

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

LouisB · Posted: Mon Sep 07, 2009 6:23 am Post subject:

I finally got a chance to do some work on the Max project. Here are some pics of my friend and I installing the new frame head. Next up will be shortening the pan.

Thanks,

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

bigtonkakid · Posted: Mon Sep 07, 2009 7:52 am Post subject:

With the ManxII why did you decide to go with the swing axle?
_________________
YES, I drove a hardtop Buggy!!!

LouisB · Posted: Mon Sep 07, 2009 8:09 am Post subject:

Because I had a SA pan & tranny w/ a title.

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

LouisB · Posted: Wed Oct 14, 2009 5:25 pm Post subject:

Finally some more progress on the Manx. First up are my rims that were widened to 15x6.5 by Jimmy at Rally America. If your looking for someone to do any wheel work I would highly recommend them. Great service, quick turn around and very competitive prices. http://www.rallyamerica.com/ I am going to have the fronts and rears powder coated white.

Tonight I also welded the replacement front frame head and Napoleon's hat on.

I hope to have the frame shortened this weekend.

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

LouisB · Posted: Sun Oct 18, 2009 1:55 pm Post subject:

Got the frame shortened this today. Took a lot of trimming and measuring but it came out nice IMHO. On to the pics:

My cutting the bottom the other night:

Cut lines marked. The one drawback I found to using this method is I will need to reweld the clutch tube bracket. Not a big deal:

I left a 5" or 6" lip on the bottom that I really think helped to line every thing up.

Last mockup with the body. I did this several times but I am paranoid so there you go.

I added these "V" cuts on each side to help everything line up.

Get it up on jack stands and make it all level.

How do you like that fit? Smile

Cleaning up the welds. And yes I need to clean up the garage but I would rather spend my time working on the car.

One area I am not happy about. But its the body that is warped not the pan. First time I placed the body on the pan after replacing the pan head I nearly had a heart attacking thinking I had welded it on crooked. Then I realized the fiberglass is warped. Not sure how to fix it yet.

Woo Hoo! IT FITS! I almost have a real buggy instead of just a fiberglass shell.

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.

manxdavid · Posted: Mon Oct 19, 2009 6:05 am Post subject:

Great work!!!

To body looks soooo much better with the rear fender flares removed. It shouldn't take too much fiberglass work to put back as it should be.

keep up the good work!!!

LouisB · Posted: Mon Oct 19, 2009 6:18 am Post subject:

Thanks. I may have a source that can pop some rear fender areas for me from an original Manx. Then I will just need to graft them on.

Thanks,

--louis
_________________
Louis Brooks
'67 Manx II

Old people at weddings always poke me and say "Your next." So, I started doing the same to them at funerals.


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