My Baja project

chubby53 · Posted: Thu Nov 05, 2009 4:13 am Post subject: My Baja project

here is the first couple pics i've taken of my baja project. i in the first stages of the build. I used an older pan so i have the option of link pin down the road if i want. probably use a ball joint for now though. I already welded in irs gussets, relocated the heater cable and ebrake cable tubes in the frame horns, now i'm in the process of putting late model tunnel part the holds the ebrake and heater lever, also the shifter location is further back which i like better than the early model so i'm using that also. i would of used the irs pan i had, but the tunnel was severly rusted in some major spots so i chose to go this route. so far so good.

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watch out for my thumb!

I guess this body don't fit so well, lol

just though i would share my stuff. i'll keep posting more pics as it continues. hope you all like it.

90xjlimited4x4 · Posted: Thu Nov 05, 2009 6:06 pm Post subject:

if you used a link pin pan only a link pin beam will fit the frame head> that is without modification or a trick you have up your sleeve!
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my baja

so-calvwdude · Posted: Thu Nov 05, 2009 6:09 pm Post subject:

I spot a traxxas revo.
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chubby53 · Posted: Thu Nov 05, 2009 6:26 pm Post subject:

If you cut off the two lower tabs on the link pin frame head and drill two new holes for the bolts a ball joint will fit, the lower tube is just a little bit lower. and use thru bolts with nuts on the backside. done it before. works great. i'll show some pics later.

and yes there are actually two revos, just got into them this spring. love them. lots of fun.

chubby53 · Posted: Tue Nov 10, 2009 6:35 pm Post subject:

finished my tunnel today. pics are kinda blurry. also put in a couple pics of what i was talking about with the ball joint on a link pin pan. still need to clean it up and fill in the holes.

this is my old baja. seen better days.

chubby53 · Posted: Fri Nov 13, 2009 10:54 am Post subject:

I picked up a 3 inch body lift a couple yrs ago(no bolts or spacers) just wondering if i could order bolts from a parts house or just a fastner shop? I'm going to stop by a fastener shop today and see what they have and for how much. the spacers i figure i'll just fab up out of some pipe.

chubby53 · Posted: Fri Nov 13, 2009 12:33 pm Post subject:

found some bolts at the fastener shop. cost about 22 bucks. nickle and dimes suck!!

carlos_magnum · Samba Member Joined: April 21, 2009 Posts: 591

I think this would be a long baja build thread. I'm looking forward to see the progress. Cool

chubby53 · Posted: Mon Nov 16, 2009 3:32 pm Post subject:

man it seems like i'm never going to be done cutting/welding/grinding. this is alot more work than i thought. Oh well hopefully it all comes out well. I'm about half way done fabbing up my body lift. i'll post some pics soon. i'm building it out of .095 steel. when i install it on the pan should i weld it to the torsion housing? or do you think it matters? I plan on tieing my cage and side nerf bars into it. don't know if i should just bolt the nerf bars to it or weld to it? what do you all think?

chubby53 · Posted: Mon Nov 16, 2009 7:18 pm Post subject:

O.K. so here are some pics. the first is where i welded up the holes on my frame head. Now i can bolt up either a ball joint or link pin front end.

and here is some pictures of my lift that i'm fabbing up. it's only about half way done so far. I'm trying to keep everything the same shape as the pan the best i can. this is the piece that goes over the hockystick. i didn't like the cheesy one that came with the lift.

here is a few different shots(angles) of what i've gotten done so far.

what do you think? I'm pretty happy since i don't have a whole lot of welding/fabbing exp. i'm learning a lot though.

I do have some questions. the piece that fits over the front tunnel that came with my lift is different dimensions than the rest of the lift. it is 5/8 inch shorter than the rest of the lift. what gives? could i have gotten screwed when i bought the lift? i want to fab that piece also but unsure on what to do? should i keep it 3 inches like the rest of the lift? or make it 2-3/8 like what it is now. Here a couple pics.
this is the original piece that goes above front tunnel 2-3/8"

this is the original body lift 3"

this is the two pieces stacked, you can see the difference. it's huge.

BigRich · Posted: Mon Nov 16, 2009 8:17 pm Post subject:

Your measuring it wrong. You have to measure vertically as it would sit on the pan. Remember that section you have your ruler on is at an angle. So your ruler will not be 90 degrees to it when you measure. Dont know what the angle is but guessing 30 ish degrees. ?get the picture?
If you measure the section at the top of the curve (center), it should measure out ok.

chubby53 · Posted: Mon Nov 16, 2009 8:34 pm Post subject:

good call. that makes sense. thanks. I'll have to check the rear piece. i may have to redue it.

chubby53 · Posted: Wed Nov 18, 2009 12:52 pm Post subject:

last night i almost got the passenger side of my lift done then ran out of gas for my welder. Crying or Very sad

So i stated cutting out the pieces i need to fab the front piece over the tunnel. lots of fun. going to get more gas today. got lots of stuff to do, hopefully i'll be out there by 6 to start working on it again. I wish i had a drill press for all the holes i have to drill in it. just have to use the good ole dewalt

chubby53 · Posted: Thu Nov 19, 2009 8:01 pm Post subject:

so i got my lift pretty much done. just got a couple small welds, clean it all up, drill holes, then tack it all together(make it one piece) and then test fit. cross your fingers. here is some more pics.

this is the old lift... me no likey

see how the piece above the hockey stick is all cheap.

and along the sides of the pan, has crappy welds and it's not shaped like the pan.

here is the one i built

took some time but it was worth it.

if you look closely you can see that i followed the pan shapes the best i could. I should be able to weld it all together when i'm done, and then weld a cage or whatever i need to to it. Hopefully i'll get some time friday to work on it. if not it will sit till monday. Crying or Very sad

when i go to put it all together i was wondering if i just got a lot of urethane or silicon and gooped that all over the pan, lift, and body if that would seal good, of if i should do two belly pan gaskets and silcone or urathane or something? any opinions?

chubby53 · Posted: Tue Nov 24, 2009 11:25 pm Post subject:

well i got my lift all done. holes drilled and all welded together. on the test fit the front piece over the tunnel had a gap, so i'll have to fix that, otherwise fit pretty good for a newbie fabber. replaced the rear right pan section and patched up some small holes today. hoping to be putting the body on in a week or two. got some work to do to the body before i can match them up. sucks having very little $$. I'm just going to have to primer and paint the pan and whatever else with rattle can. Oh well.

thesatelliteguy · Posted: Wed Nov 25, 2009 1:01 am Post subject:

nice body lift. I wanted to make my own because i saw the ones you buy arnt boxed but C shaped. Not strong enough for my liking. I like what your doing. Keep it up.
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chubby53 · Posted: Wed Nov 25, 2009 10:53 am Post subject:

thanks, it's a pain in the ass to build, but i think it will be worth it in the long run, plus i can weld whatever to it.

baja72 · Posted: Wed Nov 25, 2009 4:04 pm Post subject:

Not to bad. Keep up the good work!
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chubby53 · Posted: Sat Nov 28, 2009 10:45 pm Post subject:

so i bolted up the lift against the pan and only have two spots that have a questionable gap. easy fix though. still got to bolt the body on as a first real try to see my gaps there. hopefully not too bad. sucks being on a budget though, not really a budget as to electricity and house or baja??? Hmmm. baja! well maybe i need electricity and a house to work on it. anywho... I do have a question for all you gurus out there.

if i just rattlecan(primer and paint) the pan for know and decide to bedliner/ undercoat it later, i've read alot of good posts about the herculiner? can you roll that stuff on upside down or will i need to seperate the body and pan later to do it? if so maybe when that time comes I'll replace the pan sections completely to make it all new. let me know. thanks.

havn't been able to work on it since wed. it's killing me. it's only 100 ft away and i can't touch it. kind a like having an open bar full of desperate hotties and your the only guy, but your married and she's with you. lol

chubby53 · Posted: Wed Dec 02, 2009 3:34 am Post subject:

so back again with more updates.
found some cheap rust converter, primer and paint( all rattlecan). It's not what i would like to do, but don't have money to do what i would like to do right now. I think i'm just going to have to do what i can do semi prevent any more rust and stuff to make a weekend warrior/daily driver for now then down the road hopefully I'll have the money to somewhat redo my project to what i want (long travel bad ass daily driver mud and dune machine) can only do what i can do for now.

So here is some more pics...
this is the body i'm going to use. It's a 64, has 66(i think) doors on it but i got a coupke 64 doors i'm going to put on it.

front and rear firewalls look pretty good.

it does has a good amount of surface rust though, break out the sanding disk... this is the inside roof front to back

here are a couple more trouble spots. I'll do what i can.

and this is before and after starting to cut up/part out my old baja. After cutting the roof off, kinda makes me want to save the body and pan and eventually make an offroad/dune baja. obviously it would be a long time coming, but then i could have my dd/ weekend warrior and a full on dune runner.

So tommorrow I'm going to try to hopefully get the suspension bolted up and temp fit the body/lift/and pan and make whatever adjustments i need to make it all fit right. then once that is all done i will remove pan and work on all the rust on the body.
This sucks cause i'm starting to get impatient. I just want it to be done, but i also want to take my time and do it as right as i can so down the road when i want to do more i don't run into problems i could have avoided.

I do have a couple questions... I posted another topic reguarding those if anybody has any anwsers. here it is.
http://www.thesamba.com/vw/forum/viewtopic.php?p=4231692#4231692
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http://www.thesamba.com/vw/forum/viewtopic.php?t=385100


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