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V8 Bug Volksrod Project
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TheGreenVW
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PostPosted: Fri Jul 22, 2016 6:06 am    Post subject: V8 Bug Volksrod Project Reply with quote

This has been on hold for a while now....but finally going back together.


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The Video Build Series, to date, is here:

https://www.youtube.com/playlist?list=PL8xzCtTkH46aTgU1sOSh8VZOV52aD9irG

Latest chapter here:


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TheGreenVW
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PostPosted: Mon Aug 08, 2016 1:54 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Progress fabricating and installing the clutch pedal and master/slave cylinders and relocating the engine mounts.

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Rough Clutch Pedal will be shaped and trimmed to match brake pedal

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http://www.BenModified.com

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TheGreenVW
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PostPosted: Wed Aug 10, 2016 6:29 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

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andk5591 Premium Member
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PostPosted: Thu Aug 11, 2016 4:15 am    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Nice work. Applause
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TheGreenVW
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PostPosted: Sat Aug 13, 2016 8:08 am    Post subject: Re: V8 Bug Volksrod Project Reply with quote

andk5591 wrote:
Nice work. Applause


Thanks!


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TheGreenVW
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PostPosted: Sun Aug 14, 2016 2:15 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Since repositioning the engine, the customs headers no longer fit. I cut the flange off and inserted some filler tubing. The modified area will be wrapped in heat wrap.


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TheGreenVW
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PostPosted: Mon Aug 15, 2016 3:13 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Progress on the headers


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Machine Dr.
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PostPosted: Tue Aug 16, 2016 3:54 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

I am studying these pictures very closely and putting them to good use. Keep them coming!
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TheGreenVW
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PostPosted: Tue Aug 16, 2016 7:20 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Machine Dr. wrote:
I am studying these pictures very closely and putting them to good use. Keep them coming!


I'll do my best.

Leak tested the headers today, fixed a few pin holes. applied a coat of high temp paint and wrapped them in insulation.


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TheGreenVW
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PostPosted: Fri Aug 19, 2016 3:10 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Driveshaft is installed. Fits very well.

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Also got a set of headers for a very good price that I had ordered a while back. They do give me more clearance around the master cylinder, so no insulating wrap needed, but I really like the look of the roadster headers

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For comparison

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Last edited by TheGreenVW on Fri Aug 19, 2016 4:59 pm; edited 1 time in total
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eyetzr Premium Member
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PostPosted: Fri Aug 19, 2016 3:19 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Maybe a combination of both. Project is looking great.
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I think he meant "rare", as in "not well-done"
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TheGreenVW
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PostPosted: Wed Aug 24, 2016 4:37 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Finished drilling and air hammering off some of the left over metal from what has become the driveshaft tunnel


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Fitting the tunnel so that it does not interfere with the bench seat sliding motion

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Also cut out a large rust hole and welded in a new panel

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TheGreenVW
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PostPosted: Thu Aug 25, 2016 2:20 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Welded in the driveshaft tunnel today along with more rust repair


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TheGreenVW
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PostPosted: Thu Aug 25, 2016 8:15 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote


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TheGreenVW
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PostPosted: Sat Sep 03, 2016 5:54 am    Post subject: Re: V8 Bug Volksrod Project Reply with quote

I spent some time chasing the body mount threads with a tap and bolting it down.

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Still working on some rust repairs. At some point. the previous owner filled all the body cavities with expanding spray foam which held water and caused rust. This was main reason for having it sandblasted. but unfortunately, there is still some foam in hard to reach places. such as under the rear side glass. That said, instead of welding up the rust pin holes which may cause a fire or release of toxic gas, I decided to use something call Strong Steel Stik from LPS. I worked well and make a strong enough repair.

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The lower sections of the door were also filled with foam but stripped clean with the blasting. Passenger side wasn't too bad but the drivers door will need some new metal both inside and out.

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TheGreenVW
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PostPosted: Tue Sep 06, 2016 4:48 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Spent some time shaping and installing some sheet metal to replace the inner and outer lower door


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Inner door frame work

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I used a width of sheet metal and used a piece of threaded rod to get the correct rough shape

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Then used a piece of flat stock in the correct width to make the channel more square

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Welded in all in

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Just needs a skim coat of body filler

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TheGreenVW
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PostPosted: Wed Sep 07, 2016 7:18 pm    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Door is done.


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TheGreenVW
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PostPosted: Sun Sep 11, 2016 10:53 am    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Rust repairs on both doors are complete. Re-installed them this morning

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Prior to removing the doors, I drilled a small hole thru the hinges, the body and the backing plates to make re-assembly and alignment easier. It worked very well, I was able to re-install the doors by myself with the help of a floor jack and a couple of drill bits. I tightened them down and they shut properly on the first try!

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Machine Dr.
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PostPosted: Mon Sep 12, 2016 9:25 am    Post subject: Re: V8 Bug Volksrod Project Reply with quote

TheGreenVw wrote:
Prior to removing the doors, I drilled a small hole thru the hinges, the body and the backing plates to make re-assembly and alignment easier. It worked very well, I was able to re-install the doors by myself with the help of a floor jack and a couple of drill bits. I tightened them down and they shut properly on the first try!

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That is a great idea. I may have to try that.
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TheGreenVW
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PostPosted: Thu Nov 17, 2016 5:43 am    Post subject: Re: V8 Bug Volksrod Project Reply with quote

Currently replacing all the brake lines and the master cylinder


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