'69 Baja - Dark Earth Version

[Dark Earth]

When I first bought the Baja, I was just gonna install a "Thing" front end with torsion adjusters and start driving it. Well, I got the beam installed

Using magnets, I mocked up the parts to show what it might look like when I'm finished.

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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~

[veeweeman]

[quote="Dark Earth"]

[Dark Earth]

[pullstart]

Paint is a wonderful tool if you understand it... I've designed many a different things with that program, then sent to CAD for scaling...
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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

[Dark Earth]

[Dark Earth]

I bought a 4" C-clamp

I bought a 7/8" OD x 1/2" ID x 2" spacer and a 1/2" transfer punch.

I bought a 5/8" ID spacer.

I trimmed the 5/8" ID spacer to 1 1/2" in length and welded it to a piece of 1/2"-13 all thread cut to 21" in length.

Using a magnet to hold the 7/8" spacer, I set the hooks in place to locate where the spacer goes.

I marked around the spacer with a sharpie, removed the magnet, and clamped the spacer in place using the mark for reference.

The ball joints are in a bind making it difficult to turn the spindle with the steering arm. I tightened the nut on the all-thread until the ball joints came out of the bind, making it noticeably easier to turn the spindle with the steering arm, which was at 2 5/16" from the top of the nut to the top of the all-thread. I tightened the nut down to 2 1/2" and checked the alignment of the lower hook. This is where I'll tack the lower hook later. The measurement from the center of the lower shock stud to under the upper shock mount was 18".

I tightened the nut down until the ball joints went into a bind again. This happened at 8 1/4" of all thread above the nut. I backed the nut off 1/4" to 8". The measurement from the center of the lower shock stud to under the upper shock mount was 12 1/2". That will give me 5 1/2" of travel between hook stops.

The hooks lined up no matter which position the trailing arms were in which means they are perfectly round.

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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~

[veeweeman]

Where the heck did you get a Thing front end from?...its not like you can go down to the Dollar store and pick one up. ...you must have connections, right?

VeeWeeman

[Dark Earth]

[dustymojave]

[Dark Earth]

[Dark Earth]

After cycling the suspension through the upper and lower limits and checking the alignment of the hooks, I'm satisfied that the spacer is in the right spot.

Using a straight pick ...

... I scribed a line around the spacer and removed the C-clamp

I lined the spacer up with the scribed mark ...

... and tapped the transfer punch with a hammer.

Now I have a center punch mark to start the drilling process.
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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~

[veeweeman]

Hey dark earth...I'm going to guess that you must be a Virgo? ...your attention to detail is evident about your work ethic and trying to get it done perfectly not to mention all the photo time you have on your hands. ... ...otherwise very nice detailed build topic here.

VeeWeeman

[Dark Earth]

[Dark Earth]

I began the drilling process starting with a 1/16" pilot hole working my way up to 1/2" a step at a time. I used the spacer ( to make sure the hooks still lined up ) and transfer punch ( sticking through the hole I just drilled in the outside of the beam ) to make a punch mark on the inside of the beam.

I drilled the hole on the inside of the beam ( through the hole I just drilled in the outside of the beam ) to 1/2", in steps, as well. I used the spacer and transfer punch to scribe a mark on the inner side of the beam.

I bought a 3/16" - 7/8" step drill bit.

I opened the hole up to 7/8" using the step drill bit. I didn't quite make it all the way through the inner side of the beam. My drill doesn't fit on the inner side either

I used a die grinder, with a burr bit, to open the inner hole to 7/8". I set the rod in place flush with the beam.

With the rod flush on the inner side of the beam, the hook is also flush with the outer end of the rod.

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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~

[Dark Earth]

I bought some 7/8" 8620 alloy steel round stock. I cut two pieces 3 1/2" long. The rods that came with the kit were the same steel only 3" long.

I cut the longer rods so I'd have more than enough room on the inside and outside.

I'll tack the rod in place and tack the hooks flush with the inner surface the seal rides on ( Once I get a fresh bottle of 75% Argon 25% CO2 )

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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~

[veeweeman]

Not to critique your work but I think you should put a 45 degree bevel on those arm stops. ..you will get much better penetration on both sides of your weld...welding is basically melting metal together, as you know. ..but a bevel will keep those from breaking off if choose not to bevel.

Another paid add by "my two cents".

Sorry dark earth but with your attention to detail, I just had to say something. ..it your great photography that gave you away.

VeeWeeman

[Dark Earth]

[Dark Earth]

I tightened the nut on the all-thread to 8", tacked the rod in place, and tacked the hook in place.

I loosened the nut back down to 2 1/2" and tacked the lower hook in place.

The hooks will never hit each other.

Now I need to take the trailing arms off. I don't want to put too much heat around the trailing arm needle bearings. Welding the inner side of the hooks, where the seals seat, will be easier as well. But first I'm gonna do the other side.
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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~

[Dark Earth]

I bought a ball joint separator.

The way it works is pretty straightforward. The upper end slips under the ball joint boot, and the lower end pushes against the ball joint stud as you tighten the bolt on the separator.

(I set this up just to get a photo. I'm not ready to take this side apart. I haven't even loosened the nuts on the ball joints yet. I did the drivers side already, but didn't get a photo . On the drivers side, I loosened the nuts until they were flush with the bottom of the studs to protect the threads.)

On the driver side, I loosened the nuts and grub screws and pulled the upper trailing arm right off. The lower trailing arm still had a little tension on it, with the hook against the rod, although I backed the adjusters all the way off. I tapped the lower trailing arm with a hammer, using a 2x4 to protect it, and it came right off.

Now I'll be able to weld the inside and outside of the trailing arm hooks.
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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~

[Dark Earth]

I welded a series of tacks on the outside.

I bought a burr bit.

I backgouged the outside tacks.

I welded a series of tacks on the inside.

I backgouged the inside tacks.

I welded a series of tacks on the outside.

I sanded the inside fairly smooth.

Just three more arms to go
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My Build: '69 Baja - Dark Earth Version

~I'm almost done. I just lack finishing up.~