Project Slowly Underway: Berrien 295

[Vanapplebomb]

Yeah, real good.

Mike...That engine looks familiar... was that a transplant from Black Ice?
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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[madmike]

well it's the 'cruise' motor from the white bug , plan was to slap it into Black Ice , But I never found decent wheelie Bars and a with an 80" wheel base & a 'show bar for a cage,, , I don't need the 'Pucker factor" at my age
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'Black Ice'Drag Buggy 'Turbo'
Rail Buggy 1915 turbo
76 Drag/Street bug 2180cc 'Turbo' 11:85 @113 mph"If I go any faster I'll burn up the Hamster" ,gets 28 mpg. also 10/09/22 11.90 @115 mph
"If I'm ever on Life Support,UNPLUG Me, Then Plug me back In see if that Works"

[madmike]

Hey dirk,I "drove"mine yesterday only took 15 days ,,,
i'm thinking it needs disc brakes on the rear or the wheel cylinders are frozen = slows down but doesn't stop worth a darn
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'Black Ice'Drag Buggy 'Turbo'
Rail Buggy 1915 turbo
76 Drag/Street bug 2180cc 'Turbo' 11:85 @113 mph"If I go any faster I'll burn up the Hamster" ,gets 28 mpg. also 10/09/22 11.90 @115 mph
"If I'm ever on Life Support,UNPLUG Me, Then Plug me back In see if that Works"

[Vanapplebomb]

Lucky... probably still won't be able to lift anything for another month... I am considering having some friends do some dirty work for me while I'm out of commission to keep things moving so I can take a fall trip up to the UP for a shake down in the fall.

edit:

By the way, Did you go to the Bug Run yesterday? I really was looking forward to the swap meet, but just couldn't swing it.
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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[madmike]

Hey Dirk, first time in years I missed the BugRun too
this fall ,,, sounds like a color tour
Free beer will bring friends around to ,,,help
I down with an abscess tooth
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'Black Ice'Drag Buggy 'Turbo'
Rail Buggy 1915 turbo
76 Drag/Street bug 2180cc 'Turbo' 11:85 @113 mph"If I go any faster I'll burn up the Hamster" ,gets 28 mpg. also 10/09/22 11.90 @115 mph
"If I'm ever on Life Support,UNPLUG Me, Then Plug me back In see if that Works"

[Vanapplebomb]

Hopefully the fall bug run won't be called off for rain.

I got around to a couple small things I could handle with one arm. I got a new spring retainer cup from Weddle and a new reverse light switch. The spring pushes on the cup and preloads the shifter into the 3/4 shift gate. Original reverse light switch was toast, so it was swapped out with a generic replacement from Hella.

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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[chappy89]

hey Van, first off i am loving the build, i just read through all 27 pages and your ingenuity and attention to detail is phenomenal. well done man.

second, i noticed a few pages back when you were doing stuff with your pedals you mentioned a plan on fabbing up a dead pedal. well i just thought i would throw this your way in case you haven't made up your mind on it yet.

This is how i did a dead pedal on my warrior

[Vanapplebomb]

That is a pretty clean way to put a foot rest on. Nice job. I'll probably end up doing something like that. Thanks for the kind words by the way. As far as enginuity goes, most of it is pretty straight forward stuff. Most of the ideas came from my buddies up north. Lots of hard riding in the upper pininsula of Michigan has defentntly tore up some buggies. Eventually after stuff starts going wrong you find ways to modify or tweak things so that they don't go wrong in the future.

Struggling to find things I can do with one arm while the other is still down and out. I started cutting up my IRS dual spring plates to make custom ones. The splined end was cut off to length to use with swing axle torsion bars. Next I'll have to remove the plates from the tube so I can get them welded to the splined end of the tube I cut off. Also found a solution for dust seals on the bearing housing on my custom Vanagon shift linkage. The seals on the wheel cylinders are just the right size. I got the cheapest wheel cylinder I could find, $11...certainly nothing I would EVER run on a vw, but that seamed worth it for the two dust boots on either end. Pics when I get around to it.
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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[Vanapplebomb]

Seals added to the bearing housing compleating my shift linkage. I changed the bushings to a larger flange so that it created a lip for the seal. Then I popped off the wheel cylinder dust boots, stretched them over the flange, then ran a fine bead of hot glue against the back edge of it. Heat shrink was slipped over and heated to shrink it. I made sure to apply enough heat to flow the hot glue I applied earlier. The hot glue under the shrink wrap works the same way waterproof electrical connectors work.

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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[pullstart]

quite nice. Where did you get heat shrink that large?
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4 seater Appletree buggy, road legal with 002 IRS, 3x3 Appletree kit, 6" over Dan's beam with 10" towers and Fox 2.0 shocks, '00 Subaru EJ25 with KEP stage 3 clutch and KEP adapter plate.

my build page: https://www.thesamba.com/vw/forum/viewtopic.php?t=662104&start=0

[Vanapplebomb]

Local industrial supply store. It's used for shrink wrapping heavy electrical cables. It's about 1-1/4"
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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[Vanapplebomb]

The midshift Vanagon transmission is ready to roll. I got a rebuilt Bosch starter from autozone. With a core to exchange, it worked out to about 90 bucks. Not so bad. The one thing I ran into is the factory starter bushing is 13.5mm od. The new bushing that came with the starter is 14mm od. Since the original factory starter bushing was still good I just reused it. Might still plug the vent and drill/tap the top of the case for a 1/8npt hose barb to vent through a hose and fuel filter to keep grit out.

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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[Vanapplebomb]

Testing the rebuilt Bosch starter. She kicks over, that's at least a good sign.


Link

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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[Vanapplebomb]

Modified the stock Vanagon mount by cutting off the flange that mounts to the rubber mount leaving just the plate behind. The plate will have to get welded to the torsion housing where the stock but nosecone mount is located.

I also ended up with a free vw bug hood. It's a bit banged up, but not bad. Figured it would make a cool nose for the front of the rail. Something more unique than the fiberglass noses available off the shelf. I figure some standoffs mounted to some 1-1/2" tube clamps will hold her on nicely. Still trying to decide how to paint it. Flat black, black and yellow, or a deep plum purple. I'm leaning black and yellow, but that might change. Shame it's orange...orange was my favorite stock bug color. Sad to paint over it, but it doesn't match anything.

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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[pullstart]

Nice black and yellow paint job, did you mask it first?


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4 seater Appletree buggy, road legal with 002 IRS, 3x3 Appletree kit, 6" over Dan's beam with 10" towers and Fox 2.0 shocks, '00 Subaru EJ25 with KEP stage 3 clutch and KEP adapter plate.

my build page: https://www.thesamba.com/vw/forum/viewtopic.php?t=662104&start=0

[cbeck]

I bet we left a dozen of those at the bottom of the big hill after big snow storms back in the 80s. Caved in and useless when we were done with them.

[Vanapplebomb]

[Vanapplebomb]

Stock throwout arm was trashed due to excessive wear on the forks, so I used an aftermarket HD 20mm crosshaft with solid brass bushings. A new throwout bearing was used over a new bearing sleeve as well.

I didn't have an extra clutch cable arm, so I picked up a new one from Appletreeauto. It's standard for an 091. After thinking about it for a while, I decided to extend it from the 73mm center to center and extend it to something more like the 75 and later irs bug at ~100mm. I dug a piece of scrap of 1/4" flat stock from the steel recycle bucket to splice in. Without cutting, this one came out to about 105mm, close enough for me.

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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021

[pullstart]

[Vanapplebomb]

I should know more tomorrow evening. I have to go back for some more X-rays. We will see what the word is then. I still can't lift anything with it, although I'm starting to be able to move it around somewhat, although motion is still really limited. It's expected to fully heal, but will take a while because there is no way to support the bone to stbalize it so it can heal up quickly...so it's just going to do what it's going to do, and hopefully grow back close to how it was before it broke.
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1800 Type 4 Berrien 295

http://www.thesamba.com/vw/forum/viewtopic.php?t=487021