Update on my IRS Buggy build (HW2)

adriaan pienaar · Posted: Fri Mar 26, 2010 9:51 am Post subject:

I started with the installation of the 914 rev counter in the dash today. These pics are a bit graphic, but there is no other way to do it since I am not prepared to buy a 115mm hole saw that I will only use once Confused

(Not even Volkspares use a hole saw for the turn key buggies they build for customers.)

Masking tape was put on the dash, the rev counter was measured, and a perfect circle the size of the rev counter was drawn (by compass, not by hand! Laughing

) on the masking tape. I then drilled small holes on the inside of the circle, all around

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

The small pieces of fibreglass inbetween the holes were then cut away, leaving a gaping hole in the dash with rather rugged edges

I then cleaned the rugged edges with the Dremel, till the surface was smooth (and the circle true) again. The gauge is a perfect fit! Cool

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Russ Wolfe · Posted: Fri Mar 26, 2010 9:57 am Post subject:

A "Rotozip" tool is wonderful for cutting circles like that. The come with a circle cutting attachment.
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adriaan pienaar · Posted: Wed Mar 31, 2010 8:06 am Post subject:

Slowly but surely things are starting to get together, and today I 'dry-fitted' the bonnet, roll cage and headlights on HW2. Cool

Unfortunately it started raining and I had to move it back into the garage before I could take more pics.. Sad

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tanner_122 · Posted: Sun Jun 06, 2010 8:40 pm Post subject:

any updates man?
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adriaan pienaar · Posted: Tue Jul 27, 2010 9:37 am Post subject:

Quick Update 27/07/2010

Today was pleasant and warm here in Jhb, and it almost felt like summer is on its way. I came home a little bit earlier than usual, and decided to start cutting the floorboards from the aluminium plate. This is the rough cut results, they still need to be trimmed slightly to fit inside the chassis:

The garage where HW2 is being stored was used by some builders who did work on the premises, and in spite of the fact that the buggy was covered, is was still a bit dusty, so HW2 got its first official WASH today, albeit with the body off the chassis Laughing

I trial-fitted the tail light housings, after spending about an hour to trim the edges of the metal, so that it fits the contours of the bodyshell perfectly. If all goes well, they will be chromed like those that were on HW1

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LouisB · Posted: Tue Jul 27, 2010 10:57 am Post subject:

Looking really good.

--louis
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adriaan pienaar · Posted: Thu Jul 29, 2010 6:28 am Post subject:

Went to fetch the roll cage yesterday on the roof of the Squareback, after I had some changes done to it... got a few funny looks from fellow road users Laughing

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adriaan pienaar · Posted: Sat Aug 14, 2010 8:46 am Post subject:

Update 14 August 2010

The aluminium floors are rivited in, and I am happy with the result Cool

- however I am not very fond of the 'chequered plate look', so the entire floor and transmission tunnel will be carpeted later.

As I put the body and roll cage back, I covered HW2 with a tarpaulin for the dust (there are still construction workers busy upstairs). I noticed a little orange Ladybird on the back of the cover - checking out the scene - wonder if it was the spirit of HW1? Wink

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MURZI · Posted: Sat Aug 14, 2010 11:23 am Post subject:

After seeing the wreck photos, all I have to say is that you are a brave man. not many would have got back in the saddle. looking good!!!
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Ruska B1 · Posted: Sat Aug 14, 2010 2:12 pm Post subject:

Looks good Adriaan.

Gert
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'68 Meyers Manx
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adriaan pienaar · Posted: Sat Nov 06, 2010 6:35 am Post subject:

A lot of time has past since my previous post, but in the meanwhile I've been busy with a few small things on HW2 - not really important enough to post here, but still neccessary to complete the project. At this stage I need to have the roll cage powder coated first, then I can carry on with the final assembly.

Got the front steel wheels back - not 100% happy with the work done on them, but they have to do for now. For now - a 'mock-up' pic I took this morning of HW2 to get an idea of what it will (hopefully) look like in the end..

After the pic was taken., I spent another 3 hours re-adjusting the rear torsion bars - as you can see in the pic the suspension was WAY too low in the back Laughing

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manxbuggy · Posted: Sat Nov 06, 2010 7:54 am Post subject:

LouisB · Posted: Sat Nov 06, 2010 8:54 am Post subject:

Looking good man. What size tubing did you use for your cage. I like the looks of it.

Thanks,

--louis
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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.

Gone Blue · Posted: Mon Nov 08, 2010 10:55 am Post subject:

Ditto on the steel smoothy wheels, they look just right on your buggy. I too also like the Sportstars. What size rims and tires are you showing here? Thanks, G.B.
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adriaan pienaar · Posted: Thu Dec 09, 2010 6:52 am Post subject:

Thursday, 9 December 2010 - FIRST TEST DRIVE!!

This afternoon (we are in a GMT+2 time zone) was the biggest highlight of the HW2 project so far - I took it for it's first test drive Cool

Please don't get me wrong - the buggy is still VERY FAR from being finished (yet another target date - Dec '10 holidays - not made Sad

), but I actually drove it for the first time today for a few kilometers (and about 2 plastic Coke bottles of petrol Laughing

) here in Kensington South, Johannesburg. For the first time HW2 has left the garage under its own power, and it was quite an adventure, I must add, trying to avoid the MetroCops with a vehicle with no identification plates or disc, no windscreen, super smooth rear tyres (temporay, btw), no wipers, no functioning lights, dodgy brakes and backfiring like the machine guns of a Mitsubishi Zero during the Pearl Harbour attack (OK, only till I sorted the timing out Wink

) Almost lost the front wheel (forgot to fasten the wheel nuts Embarassed

) but I guess that happens to all of us some time or other...

I am quite impressed with the buggy's pullaway, accomplished by the two Solex carbs but the brakes are still not right, might even have to change the (Golf) master cylinder.

Still have to have the roll cage powder coated, windscreen fitted, seats & rails sorted out, rear wheels painted, BF Goodrich's fitted, wiper motor sorted out, complete the wiring.... actually it is still a loooooong list Shocked

The chroming of the tail light housings and Ghia license plate cover also has to wait for a while.

Took these pics at Rhodes Park, got back home seconds before it started raining. Thanks once again to all for their support so far!

The only functional light at the moment - the reverse light! Laughing

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LouisB · Posted: Thu Dec 09, 2010 6:57 am Post subject:

looks sharp. I bet that was a blast to drive it for the first time.

--louis
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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.

adriaan pienaar · Posted: Thu Dec 09, 2010 6:59 am Post subject:

adriaan pienaar · Posted: Thu Dec 09, 2010 7:13 am Post subject:

manxbuggy · Posted: Thu Dec 09, 2010 7:49 am Post subject:

That’s a handsome buggy! Congratulations on reaching the ‘first drive’ milestone!

What exhaust system is that?

Rob

adriaan pienaar · Posted: Thu Dec 09, 2010 11:11 am Post subject:

Thanks, Rob Cool

The exhaust is a fairly common (in SA, at least) stainless steel 4-into-1 Buggy/Baja type with universal aftermarket VW J-pipes. I'm not very fond of the J-pipes passing underneath the cylinder heads, but I fitted slightly modified 36Hp heater box outers over them, and I am quite pleased with the effect in the end (the heater box outers also protect the pushrod tubes.)

I had the exhaust ceramic coated silver, it only appears white in the pic due to bad light in the overcast sky.
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