Beetle - Schwimmer replica

[Mr Slug]

Hi, new guy here.

Just registered and figured I would share with you guys my project.

I have been trying to build a VW166 type vehicle, using a stock Beetle as a basis and donor. Been on the project in my spare time for about six months, I recon another six months left to completion.

But, as with all these projects, I could use a bit of help and maybe some assistance with parts.

The ride height is giving me some problems, and I figured maybe I could use Trekker/Thing reduction boxes, tubes and shafts. Maybe trekker/Thing spindles up front ? could I just use the spindles, or would I need the whole front beam.

These might sound like dumb questions, but be mindful that 6 months ago I had never even took a close look at a Veedubbaya, and this is practically a vertical learning curve for me.

Some pictures for your amusement.

[DannyK]

Looks great ! Nice fab work. Keep us posted with your progress.

[Glenn]

WOW... you got skills.

Keep the update coming.
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[JWDW]

you can use just the spindles and arms from a thing/treker/safari or just the spindle and flip the control arms around but you have to change the buall joints I believe, I have a set of them forsale just so you know.... nice work on the schwim but how much of that bug is under that nearly all fabbed up body? looks like a lot of one off panels. Did you have any OG parts on that or is it all from scratch?

[Chad1376]

Very impressive work!!! I'd love to see some of the in-between steps, like how you fabricated the entire rear bodywork, deck-lid, and cool dimples in middle of the seats. Do you plan on really Schwimming it when you're done?
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[kdf38]

Just use the tracks instead

[BlastMasterMannyFresh]

wow, impresive work bro, keep the pictures coming.

[Mr Slug]

Thank you for the very posative comments, and thank you Glenn for tidying up my post - I was not sure where to put it.

JWDW, thank you very much indeed - would you be kind enough to PM me the cost of those spindle parts ?

To answer a few of your questions.

Yes, this will be a swimming VW. There are, as yet, no 166 original parts, all of it is fabricated by myself by altering standard Beetle parts or useing sheet metal and fabrication at home - I hope to use all standard VW parts.

I don't have access to a real VW166, so have used a plastic model and whatever pictures I can get get off the Interweb, and books.

This is only a very rough working prototype, I hope to be able to make these to order in the future. If that happens, I would take the trouble to borrow a real one to copy.

The most tiresome, but perhaps important task is a reasonably accurate assessment of the shape and size. I have done a lot of internet research, and have several books and pictures of VW 166. The most useful item is the model.

To decide the shapes I bent wire to suit the model, then carefully drew around the wire on a piece of paper. then, by disecting multiple tangents that I drew on the curves, the centre of the radius can be found. Measureing back to the arc gives a figure and that can be calcalated up to full scale. It is a little tricky because many of the shapes have several centres, and different radius, however, It is one of the few things on the project that I do have formal training at. I am a bricklayer and it is the same method that bricklayers use to set out the formers under arched openings like doorways etc.

By useing pi, the lengths of the steel sections can be calcalated into a cutting list befor bending. It is of course also possible to calcalate out the surface areas of steel, and for that matter the volume within the vessel. I guess Mr Porsche had to do that to figure the displacement to weight ratio to confirm that it would all actually float. The way I figure it - if his did - mine will !.........as long as I am fairly accurate.

Some pictures of the process.

All very laborious, But neccersary. It is much easier and cheaper to alter or throw away a piece of card or ply then a sheet of steel.

Rear bulkhead / engine firewall.

[63ziggy]

more pics from start

great looking fab, would love to see step by step if available

[Mr Slug]

Chad, you asked about the seats.

As usual, starts with research - that generally means the interweb
and stealing pictures. This picture was copied from a VW166 hulk that is being restored in Germany.

Then the model is measured, and my collection of photographs studied. Next I measure the hull and figure out a size for the seat.

Next step is a wooden mockup - that can also double as a former.

Then, hired a pipe bender. (Actually this one is for electrical conduit)

Then off we go - bending, shapeing the pipework. Welding that together, and constantly checking the fit.
Making cardboard templates and eventually steel sheets to clad the frames. Punching holes, welding, grinding, you get the idea.

The pictures kinda explain the chronology of events.

Here is one of the pictures I work from, and a photograph of the model I scale up from. In the middle is my own beetle/166 creation.
A fair comparison I feel. What do you guys think ?

Finally, a coat of primer - phew !..........

[Mr Slug]

For those of you that requested more intermediate step pictures, here are a couple of the mudguards and rear cowling - as you can see, I just have some pretty unsophisticated tooling

[bigbulli]

Awesome fabrication!
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[Emeritusx]

Schweet....
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[tstracy39]

Very nice work. I can't work in steel myself because of arthritis in my wrists, everything I build has to be wood or fiberglass, so I always get kind of jealous when I see so many great parts turned out in steel. How will you be making the connection between the swing axles and body (or do I call it a hull) watertight? Just curious, keep up the good work.
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[cage66]

SERIOUSLY IMPRESSIVE

[1973 MELLOW YELLOW]

Hello Mr Slug

I've been following on VZi, great progress.

[Mr Slug]

[mike yapps]

HOLY COW!!! That is awesome! I like the tool you made to bevel the holes. I may have to use that idea.

[mnussbau]

There's no way that's the same car! Simply amazing work.
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Parts...

[kubelmann]

You obviously have a combination of skills and talents.... I see the boat making pattern skill from my boat building experience but them you cross over to amazing metal working. Unbelievable!!!! My hat is off to you. Most humbly, K-mann