Mrcole's Build Page - My First Project

mrcole

I just purchased my first sand rail and I thought I would jump into introductions with a build page. I'm an electrical engineer working for a lithium power systems company ( Li-ion batteries for HEVs, PHEVs, EVs, Grid Energy Storage, etc) here in the heart of Indiana. I've been interested in sand rails for the past few years - just never took the plunge and bought one until now. I would say my knowledge on them is novice at best. I've spent a lot of time lurking in the forums and reading up online and with a few books. I've tinkered on a few before and can generally find my way around the parts.

I ended up buying a 1915CC with dual Dellorto carbs 44IDF, swing axle trans with (at least I was told) 3.88 close ratio gearing (low miles and rebuilt engine and trans that is street legal. The guy I bought it off of had a lot of the receipts and paperwork to back of his claims of what he had invested into it. I still feel like it was pretty beat up once I ended up getting it home (more on that later). When I got home and was about ready to back it off the trailer, bam, the clutch cable split open and started spraying hydraulic fluid everywhere when I depressed the clutch...great. I noticed the kingpin was in far worse shape than I had initially thought and ended up having to purchase a new one because the estimate to have it rebuilt was only a few $$ under the new price.

Anyways, I have it sitting in the garage and have begun to tear some things down. My plan is to tear it down completely for engine detailing, sandblasting frame, powder coating, etc. What do you guys think of my purchase - is it a diamond in the rough or junk? I ended up paying about $2400 for it (some trades were involved with that).
So far I've cleaned up a lot of the welds, welded on a new shifter box, have some new parts on the way, got my new kingpin in today and started making notes on what to do/fix next.

Does anyone know what type of frame I have? I heard someone who was looking at my rail murmur "venture frame"?

I'm not sure how "new" the kingpin front end is I bought. Looks like it was pulled or rebuilt and then dipped in this cruddy black paint. I'll have to end up sanding/cleaning it to repaint it eventually. The spindle area is very stiff. I can't even turn it with my hand. Is this normal on new kingpins (needs broke in)? There are two spots on the beam with little rubber bumper things over them; these weren't on my last kingpin - any idea on what they are used for?
It came with the snubber legs (place where you normally put on some bump-stops) already removed - is this normal? And now, pics!

As it sat before I bought it:

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

Now in my garage!

New shifter box welded in:

New kingin front end picked up:

So what do you guys think? Thanks!

ts39136 · Posted: Sun Jan 16, 2011 7:25 pm Post subject:

Looks like a fun project, I like the silver paint.

What size rear tires are those? Are they TSL's?

Welcome.
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My Build Page

mrcole · Posted: Mon Jan 17, 2011 5:00 pm Post subject:

Thanks for the welcome. They are super swampers, 32x9 from what I can see. While looking for sand rails, I usually ran into tires that were much wider than this.

Jowlz · Posted: Mon Jan 17, 2011 5:27 pm Post subject:

I'm also digging the swampers in that size.. What size (width) are the rear rims?

The paint on the beam looks like transportation coating. You will want to clean it off and repaint. The spindles should loosen up with use. Are the fittings on the beam you referred to the adjusters in the center of the beam?

I'm really amazed that it had plates on it when you got it. The spindle mount front rims and tires are both not DOT approved....

All in all it looks like a great project. You didn't do too badly on price. It will look great all painted and cleaned up!
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The honey-do list put my project on hold.......

mrcole · Posted: Mon Jan 17, 2011 6:53 pm Post subject:

From eyeing the rims (compared to the tire width) they look to be about 7 inches wide.

Yes, I'm talking about the adjusters...but what exactly do they adjust (probably a dumb question)?

As far as street legal, I was concerned as well with the spindles among a few other things, but I guess it came from a small Indiana town where everyone knows everyone, including the law enforcement type so my theory is it got approved this way or was changed later down the road.

I picked up an engine stand yoke for VW engines off ebay and grabbed a 1000lb engine stand from harbor freight so I think I'm set to pull the engine. I want to have things off and welds cleaned up in about two weeks to get it all off to the sandblaster/powder coater.

I bought some larger racing seats with headrests as the rail came with the uncomfortable (well, at least I think they are) fiber glass bucket seats. A problem though...I set the seat inside the rail and plopped down just to realize my head hits the top crossbar section. It looks like my only options here are to use the fiberglass bucket seats or have the top of the rail cut off and reworked. Has any ever ran into this issue before?

tanner_122 · Posted: Mon Jan 17, 2011 7:34 pm Post subject:

mrcole · Posted: Mon Jan 17, 2011 8:31 pm Post subject:

Thanks,

I was looking at trying to lower them but there just isn't any room to do that. I was actually thinking of raising where the bucket seats are as it seems one well placed rock/tree/mound/etc on the underside would feel like a horse kick in the a$$.

jsturtlebuggy · Posted: Mon Jan 17, 2011 8:40 pm Post subject:

It is a Hi-Jumper/Prowler's Sand Sprite II.
The nylon tubing use in hyd. clutch system does not like sun. Will crack and break.
Have fun with it.
_________________
Joseph
Fair Oaks/Orangevale, CA
Elrod Motorsports
Motion Tire Motorsports
Having fun with Dune Buggies since 1970
Into Volkswagens since 1960

mrcole · Posted: Mon Jan 17, 2011 9:12 pm Post subject:

Jowlz · Posted: Tue Jan 18, 2011 1:49 pm Post subject:

The spindle mounts are ok for sand use. Being up north like I am there is probably more dirt/mud/rocks than sand. I replaced the spindle mounts on my rail with standard rims. I still used tractor tires and am fairly happy with that set up. On my blue rail I have no front brakes, only a steering brake set up. Let's just say it gets interesting with no front brakes. My father in law used front brakes on his rail. It is much much better stopping than my rail. I can't imagine running on the road without front brakes.

One other thought is that the PO registered it, so he could pull it out to off-road areas with a tow bar.....
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The honey-do list put my project on hold.......

jsturtlebuggy · Posted: Tue Jan 18, 2011 4:38 pm Post subject:

I had the same Hi-Jumper frame for use in the sand. And yes the cage is low. Being mine was for sand use only I mounted the fiberglass buckets so bottom of them was below frame rails. It was quite the feeling when you went over a razor back and felt the sand under your bum.
I have seen some who bent pieces of tubing to fit under the seats with it welded in place, and attach aluminum panels for floorpan/skidplate.
They did build a taller cage chassis.
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Joseph
Fair Oaks/Orangevale, CA
Elrod Motorsports
Motion Tire Motorsports
Having fun with Dune Buggies since 1970
Into Volkswagens since 1960

supervert · Posted: Tue Jan 18, 2011 6:47 pm Post subject:

mrcole, not to be nosey, where are you located at in Indiana? I live/work in the Bloomington/Ellettsville area (approx 50 miles south of Indy). I know a few people who can probably help with your questions as well. Your project looks good, keep plugging away at it, my build took me about 1-1/2 years. Good luck!

mrcole · Posted: Tue Jan 18, 2011 9:41 pm Post subject:

supervert · Posted: Thu Jan 20, 2011 10:12 pm Post subject:

Well, greetings from a fellow Hoosier! I definitely know Colby and the guys at Buggyworks. They know what they're talking about and are good guys, they just look kind of funny! Laughing

If you want to see pix of my car, ask Colby to show you the screensaver of the black and blue convertible baja, it's mine. Anyway, I know a couple of local guys that could prob help with any questions you might have, ask away, we're here to help!

Jeff Rihm, aka "supervert"

GreeneHoosier · Posted: Fri Jan 21, 2011 5:27 am Post subject:

More Hoosiers!!
Cool, we seem to be a bit rare on here.
Good to see some more VW based off-roaders in the area.
Love the rail, I need another one. You will enjoy it.
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1974 Super Beetle
40 Years VW enthusiast!

quadrazer · Posted: Sun Jan 23, 2011 10:29 am Post subject:

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

Nice first project. Welcome aboard.

mrcole · Posted: Sat Feb 12, 2011 2:07 pm Post subject:

So the black crud on the new kingpin I bought is proving more than difficult to remove. Are there any issues with just taking it to a sandblaster to have the whole thing sandblasted? I know there are openings where the adjusters are and exposed bushings - will these be ok if covered?

Thanks.

Putting together my engine stand now to drop the engine. Using a 1000lb harbor freight engine stand with a vw adapter I'll bolt on. Pics to come.

58Dub · Posted: Sat Feb 12, 2011 2:20 pm Post subject:

are you asking about sandblasting the beam? Yes you can do it...but I would disassemble it so it can the cleaned properly....that sand/media gets everywhere
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58 Beetle (now just a pile of parts in the corner)
60 Beetle (2221 turbo under construction)
70 Beetle Baja project

riceman · Posted: Sun Feb 13, 2011 6:28 am Post subject: Im a newbie also.

Mr Cole, I'm a newbie also, next door in Ohio. Went to Silver lake last year with a buddy that has been asking me for 10 yrs.... Came home bought a rail.. Here is a pic of my first rail project (hopefully the link from Facebook works). I bought it last August and have done quite abit of work to it. The buggy has a fresh 1600 DP that runs great, with a bus three rib. The first thing I replaced was the shifter. I put a new nylon bushing in the back of the shifter boxas wel and installed a scat short throw shifer. What a difference over the stock one. Next was a rack and pinion, again another worthy improvement over the stock box, but mine was worn very bad. I am in the midst of installing an aluminum front beam with spindle mounts and fox shocks. The pic is white board used to mock up the Aluminum panels that we are currently fabricating. Again this will primarily be a sand toy. My question for some of you veterans is in regard to the bus engines. I buy most of my parts from Larrys off road in Dayton, Ohio and Appletree Automotive in MI near the dunes. I have noticed that there are not many parts mentioned on line or in their catalogs for bus engines. I know my stocker will be reliable, but if I wanted to go to one of the larger c.c. Bus or Porche engines, is there a huge difference in it compared to the 1600? Will it bolt up, Do the engine parts interchange as far as headers, sand seal pulleys, tins, intakes, etc? Sorry for writing the book. I was a little worried to get on here with my limited knowledge, but after 6 months of reading and researching I am still not clear, so I thought I would ask the experts.

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