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February 27, 2021, 05:50:58 AM

Predator Beach Buggy Build

This is a discussion for the topic Predator Beach Buggy Build on the board Members Buggies.

Author Topic: Predator Beach Buggy Build  (Read 105153 times)

this user is offline LUDICRUZ

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on: March 07, 2013, 05:34:31 PM
In 2004 i purchased a 1971 1600 beetle for £300 and my plans were to turn it into a cal look lowrider,
however i had no experience at all with, engines, bodywork, fabricating or any type of mechanical work...






My father however was a retired mechanic with over 50 years of experience and his job was to teach and
guide me through this journey. Within no time we separated the body from the chassis and started to strip
the paint off using a drill and plenty of wire brushes.





A week later and my first ever attempt at laying down a couple of coats of 2 pack primer.







And finally after a couple of coats of silver paint... 





Several months passed by as i deliberated on how to tackle the body, with no space in the garage – the
body was left out in the garden and unfortunately over the winter season several deep patches of rust
started to show through, it could have been salvaged, but i knew it had deteriorated bad enough that i
did not have the experience to bring it back to life.

Time flew by whilst looking for a donor body, i got married and jumped onto the property ladder.
In 2007 i attended Bug Jam and a couple of Beach Buggies got my attention on the Show and Shine morning.
This was a possible project worth looking at as i had a finished chassis.
I spent a couple of weeks surfing the net for different styles of buggies, and straightaway fell in love with
the Predator when i saw the following.










Summer of 2007 was spent desperately seeking where the Predator moulds were, who had them?... I was
informed that Mel had sold them on, but to whom.

I followed several leads from different forums and after several laps around the M25,  i ended up at
Replica Fibreglass in Brighton where i met the owner Stuart Bishop. He escorted me out of his workshop
and to the side yard where amongst a long pile of grass sat the Predator moulds. I was so excited that i
handed over a sample pot of orange paint to Stuart and asked, “can you make me one in this colour please”.

Three weeks later i was back in Brighton to collect this....











Back home and it was time to admire the finished look properly...











« Last Edit: April 02, 2020, 12:22:33 PM by LUDICRUZ »
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this user is offline LUDICRUZ

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Reply #1 on: March 07, 2013, 05:48:14 PM
It was now summer 2008, first on the agenda was to plan a roll cage...so off i went to BnQ and purchased
several lengths of 40mm plumbing pipe, a basket full of connectors and a couple of rolls of duck tape...back
to the garage and after a few late nights....













Next it was time for the chassis to be shortened, but i didn’t have a clue where to start or how to tackle
this operation. Through a forum i met a guy who could shorten the chassis and fabricate the roll cage, fab
i was in luck so both the chassis and tub were shipped to him to commence work.

Several weeks later i received my new shortened chassis and roll cage, however unfortunately due to
some miss communications neither turned out exactly how i had planned them to be. The guy was 
great person and such a helpful gentleman that we came to an agreement and parted on friendly terms.

As you can see the outer perimeter box section did not quite match the shape of the tub....








The middle bar of the roll cage was welded at the wrong angle, it was supposed to follow the contour
line of the tub....











The dilemma now was......do i give up and quit totally?.....or sell everything and start over.....and it was at
this point my father said “its about time you started to learn how to do things and get on with it”....with that
in mind it was time to put all the setbacks to one side and start learning some trades.....

The next few weekends were spent in the garage practicing how to weld with both the electric and Mig welders....
It was now early 2009 and i was ready to tackle the chassis... i went to a local metal merchant and bought a
couple of lengths of 25mm x 50mm mild steel box section...

Rather than cutting and welding angled sections i wanted to curve the outer box section to match the contour
of the tub, so i replicated the shape of the tub and drew it onto the table, rectangular sections was cut out
using a grinder allowing me to curve the sections and weld them up again...








A quick match up against the chassis to check for alignment...








I had the tub suspended off the garage ceiling using ratchet straps, this allowed me to lower
and raise the tub as and when i needed to....





Tub lowered to check for all is ok....





The curves match up well too....








Once i was happy, the section was welded together and the welds smoothed down, i then used the
first length to make a copy of the other side.





Both outer sections were then married up to the chassis and welded to the framehead.

At the rear, new sections were welded into place and all welds smoothed down...





Support for seat runners were also welded into place…





The same was then repeated on the other side….


« Last Edit: August 15, 2017, 10:30:07 PM by LUDICRUZ »
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this user is offline LUDICRUZ

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Reply #2 on: March 08, 2013, 10:10:46 AM
With the outer framework complete, it was time to work on the sections in between….





I didn't want to use a single thin sheet of steel to cover the floor…. making the chassis strong and sturdy
was more important even if it meant adding more weight.

So i purchased a few lengths of 1" L shaped steel angles, cut and shaped them to fit into each section like
a frame and welded them in.











Once all the framework had been set in, i turned the chassis over to tack weld it from the under side.








I then used cardboard to create templates for the floor, these were transferred on to 5mm steel sheet and
finally cut and sat into position.











Next was to round off the rear corners to match the curve of the tub….












« Last Edit: August 15, 2017, 10:34:48 PM by LUDICRUZ »
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this user is offline LUDICRUZ

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Reply #3 on: March 08, 2013, 10:16:47 AM
It was coming up to the summer 2009 when I saw Gordon Higgins’ Orange Sidewinder buggy up for sale
on ebay, it was featured in the October 2006 Volksworld issue. The main pictures on ebay had different
alloys, but amongst them was this picture….





I really liked the alloys, so took a chance and dropped Gordon an email…..
A week later I was the proud owner of these Porsche pattern Azev A alloys…

Fronts are 8J X 17 wrapped in Pirelli P7000 215/40/17
Rears are 10J X 18 wrapped in Michellin MXX3 285/35/18
All four wheels and tyres are in mint condition….





I’d picked up a second hand set of hydraulic pedals from bugjam that summer and next on the agenda
was to get them in…










Because I was running hydraulic pedals, I wanted to hide all the pipe work somehow so that the pedals
and the master cylinders look nice and neat….

I popped down to a company near me called Think Automotive, they sell all sorts of hoses and fittings for
the car industry…with their help I managed to put together a fitting that would run through the 2” box section…





This would allow me to run a braided hose to the calliper from the outer side of the box section and a
copper pipe from the inner side to the brake master cylinder…








If you look carefully at the previous two images you will see in each picture there are three nuts welded
to the floor and finished off in body filler, you may have already noticed them....


5mm steel plates will be bolted down on them....





The plates will sit flush in line with the top of the chassis frame leaving a gap of about 1/2 an inch underneath
to run all the pipes.












« Last Edit: July 12, 2017, 03:44:21 PM by LUDICRUZ »
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this user is offline Steve

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Reply #4 on: March 08, 2013, 10:31:22 AM
I still have Gordons feature in ultra vw someplace, he said he was a bit scared to drive it on the road at the time  ;D
Im sure its Frans on here now.

this thread is like Déjà vu for me  ;D

did you buy the matching flask on the left  ;D

« Last Edit: March 08, 2013, 10:37:28 AM by Steve »


this user is offline LUDICRUZ

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Reply #5 on: March 08, 2013, 01:57:37 PM
this thread is like Déjà vu for me  ;D



Don't know what you're talking about Steve   :-X :-X :-X :-X

The jar has orange paint in it that was left over from the job.
« Last Edit: July 12, 2017, 03:47:58 PM by LUDICRUZ »
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this user is offline LUDICRUZ

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Reply #6 on: March 08, 2013, 02:36:47 PM
It was early 2010 now and the floorpan was complete and ready for paint, but I had run out of funds and
my wife was pregnant with our first child and In April she gave birth to a beautiful baby boy, like always
priorities had to change and the buggy was put on hold….


A whole year had passed away and the pan sat outside under an enclosed tent as the garage space was
needed for other work…







In April 2011 it was time to get the pan back into the garage and start prepping it for paint…








Once it was ready, I dropped it off to Mark at County Coachworks who are based in Kingston. Mark and his
team are at the forefront in the business when it comes to Classis car restoration.

I decided i wanted the Peugeot 207 Shark Grey finish, A metallic Grey paint with white base pearl.

Mark applied an epoxy primer first, then the Aqua colour and finally finished off with a clear lacquer.

















I wanted the front framehead section to be a showpiece as this will be a visible area, so i had invested extra
time and effort in prepping this part, however Mark insisted in adding an extra touch of flair.

So he rubbed down and re-filled the section and smoothed it off to perfection.











Nice….very nice….








Two weeks later the chassis was back home….Mark had done me proud….











I had some ideas on how I wanted the front end to look like so I went and met up with a local chromer and
a media blaster to get some of the parts cleaned up and worked on….


I picked up a genuine 68 ball joint beam from ebay, had adjusters fitted in by Terry’s beetles services
Then it was dropped off to the media blasters along with a new set of dropped spindles and the steering box…
Removed the ball joints from the torsion arms using a welding torch…what a messy job….
Spent quite abit of time surfing for billet parts and bespoke one off machine parts….

Picked up a new set of rear adjustable spring plates – planning to get them chromed…





Oh and spent my birthday money on this beauty….
Black Mamba 4 speed shifter…










It was nearly August 2011 and I got some of my parts back from the media blaster…


The front beam was original and I wanted to give it some personal touches, I didn’t like the way the plates on
each tower were out of alignment as you can see below…





So out came the grinder and….







Then it was time to tackle all the welded areas on the tubes…





I didn’t want the welds to show, so I built up the areas with body filler and smoothed them off…..





The two middle uprights  -  Before




A few layers of filler and abit of sanding…








The same was done around the beam adjusters…











Once all the filling and sanding was done it was sent off for paint…
The chromer came through too and I managed to get these back….










I wanted to follow the theme of chromed parts around the buggy but I knew I couldn’t afford to pay for parts
to be polished and chromed, the only way I could do this was to learn how to polish…
So off I went to screwfix and purchased a cheap bench grinder and a polishing kit…have to admit its not an
easy job and very messy too…


But in three days I managed to get from this..




To this…..





And finally to this…..





One down, two more to go…
« Last Edit: August 15, 2017, 10:51:58 PM by LUDICRUZ »
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this user is offline LUDICRUZ

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Reply #7 on: March 08, 2013, 05:16:34 PM
A few weeks later I picked up the front beam, dropped spindles, steering box and the rear disc brake
brackets from the paint shop....Mark at County Coachworks has worked his magic again...hopefully i can
say this is a one off custom front beam...couldn't resist taking these pics and posting them on....all
items have been painted in the same finish as the chassis, unfortunately there wasn't enough sunshine
to show the pearl sparkles in the paint....
































A few days later I took delivery of these polished steering arms.. made by Project01....not too sure about
the tie rod ends though...i think they need a polish too..




Next it was time to run new Copper pipes down the tunnel for the hydraulic clutch and rear brakes.
The pipe for the clutch passed perfectly through the tube that normally takes the clutch cable.
Brake pipe was covered with a length of clear reinforced PVC hose to stop any rattling in the tunnel.








The polished master cylinders bolted into place and new pipes made up and plumbed in..




















The chrome plate cover tested for fitting…













 






It was coming upto Sept 2011 and the chromer had shut shop and disappeared on holiday without telling
anyone, unfortunately he had my trailing arms waiting to be chromed, so I could not progress any further
so I decided to sand and smooth down the pedals down as they were made of cast aluminium…


I didn’t realize how brittle they were and ended up snapping the clutch pedal just where the pivot bolt fits…
A fortnight later i got the torsion arms back from the chromer's after having them for eight weeks...what a
disappointment... They had not been polished properly and you could see pitting marks all over the chrome...


Unfortunately I did not get a chance to take any pics... Well we came to an agreement, the chromer would
remove all the chrome off the arms, I would then take them home - sand them down and polish them, then
return them back for chroming...


So I spent two weekends on them and managed to get the arms from this





To this….





And finally to this…..








Well things now started looking up, and I had been surfing on the net looking for a similar set of pedals
to replace the broken one, didn’t find them but struck gold when I picked these up for £80 on ebay….





My luck got even better the next morning when I bagged this brand new CNC Hydraulic gas pedal kit for
only £20,,,,





With all the front end parts back from the chromers, it was time to mock it all up using all the old nuts
and bolts. Once done I made I list of all the nuts, bolts and washers needed, originally plans were to get
all the old stuff cleaned up and zinc plated but then I came across Namrick Ltd who sell all types of
fasteners…so I sent a huge list off to them….




















Xmas 2011 was only a couple of weeks away, and whilst I was waiting for my new nuts and bolts, I decided
to tackle the inside of the tunnel… Although it was in good condition with few areas of rust, i wanted to make
sure it was protected well from corroding any further...so i bought a large tin of Waxoyl and a spraying kit...
and gave it a good pasting......cream cheese










Pedals were next on the agenda but there was a minor problem...the clutch and brake assembly were one
unit as you can see below, and these would not fit perfectly into the same holes drilled in the chassis for
the previous set. They were too wide and needed to narrowed by 1/2"....





Once cut to the right size i rounded off the corners of the base to make it look like they were two separate
units....these were then painted in the same finish as the chassis





Pedals were polished to a shine and colour coded grey to match the base units...all other parts of the assembly
were zinc plated along with other new nuts and bolts that were missing from the front end....




Both pedals were fitted and plumbed to the master cylinders.

The hydraulic gas pedal has also been plumbed through the tunnel and fitted in.

Very happy with the way the pedals have turned out......




















All remaining nuts and bolts have also been fitted...only thing left are the shocks....not sure whether to go
for coil overs or gaz adjustables....will look into this once the floor becomes a rolling chassis....going to take
some time off from the buggy for xmas and will start the rear end from mid january.....






« Last Edit: August 15, 2017, 11:30:51 PM by LUDICRUZ »
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this user is offline BugDream

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Reply #8 on: March 08, 2013, 05:51:09 PM
Brake pipe was covered with a length of clear reinforced PVC hose to stop any rattling in the tunnel.

Smart idea that  ;-)up
It all began in September 2008...

Slow progress...


this user is offline Fran_GP

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Reply #9 on: March 09, 2013, 06:48:42 PM
It was coming up to the summer 2009 when I saw Gordon Higgins’ Orange Sidewinder buggy up for sale
on ebay, it was featured in the October 2006 Volksworld issue. The main pictures on ebay had different
alloys, but amongst them was this picture….





I really liked the alloys, so took a chance and dropped Gordon an email…..
A week later I was the proud owner of these Porsche pattern Azev A alloys…
I always wondered what had happened to those alloys when I bought Gordon's buggy, now I know!  :) :) :)

Cheers

Fran  8) 8) 8)


this user is offline LUDICRUZ

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Reply #10 on: March 09, 2013, 10:08:39 PM
It was coming up to the summer 2009 when I saw Gordon Higgins’ Orange Sidewinder buggy up for sale
on ebay, it was featured in the October 2006 Volksworld issue. The main pictures on ebay had different
alloys, but amongst them was this picture….





I really liked the alloys, so took a chance and dropped Gordon an email…..
A week later I was the proud owner of these Porsche pattern Azev A alloys…
I always wondered what had happened to those alloys when I bought Gordon's buggy, now I know!  :) :) :)

Cheers

Fran  8) 8) 8)


Hey we both walked away with a good buy... 8) 8) 8)...and i have to say that buggy of yours is top class dude... ;-)up ;-)up ;-)up
« Last Edit: July 12, 2017, 07:29:03 PM by LUDICRUZ »
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this user is offline LUDICRUZ

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Reply #11 on: March 09, 2013, 10:34:46 PM
February 2012 and I was supposed to start the rear end but when I got into the garage and saw the front
end, something did not look right. It was all nice and shiny, painted finish and chrome parts and this…





The three copper pipes coming out of the master cylinders had started to look old and discoloured, they
needed a facelift, so I decided to give them a quick polish…





And got them chrome plated….








You may recall from earlier i had a plastic hydraulic line fed from the gas pedal, running through the
clutch and brake pedal and down the tunnel....





This has now been changed for a more flexible braided line that runs all the way through the tunnel
to the back of the pan…








A new fuel line was also passed through the tunnel….











At the rear i wanted to keep lines hidden as much as possible...so once i got the brake pipe to the
back of the tunnel, i attached a "T" piece to it inside the tunnel and ran two lines down the forks,
a fitting would exit out half way down the fork....











Fuel line exiting from the back…








Gas and Clutch lines exit from the left of the gearbox mount…





Handbrake lines exit from their usual places, little touch…pipes blended in with the rear forks…








Shortened gear link rod fitted in place and shifter bolted down….





Seats fitted to runners to check if runners run freely….











Gearbox stripped down, initial plans were to polish it, so I gave it a quick try…10 mins with the
dremel..











It was going to take a long time to do the whole thing so decided to paint it instead…Couple of
coats of zinc primer, two of the grey and clear top coat….Once done all the nuts were replace
with zinc plated ones…








While the rear axles were out of the gearbox they went straight into a press to have the bearing
housing removed and separating the retaining plates…








Whilst the weather was good both bearing housings were given a couple of coats of paint and
lacquer…








March 2012 and I had I list of items to polish…rear axle tubes, retaining plates and the adjustable
spring plates…this would keep me busy for a while. The gearbox side plates will be finished in black
paint…





A couple of months passed away waiting for the chromer again, but he finally came through and the
parts look stunning…








Right time to crack on with the rear end and first on the agenda was to press the axle tubes back
into the bearing housing and push the locking pins back in.

Then came the part i was dreading the most - fitting the spring plates. When i originally removed
the standard spring plates and torsion bars, i never marked anything even though my father did
tell me to do so at the time. So i spent half a day on Saturday surfing the net and reading up on
how to tackle this issue. However once i had read several threads and understood fully how to set
the angles, it seemed fairly straight forward and i managed to get both sides in parallel to each other
within an hour.











Spacers from Flatlands Engineering were used to fill the 5mm gap created by the second spring plate,
the torsion covers were also from Flatlands.

That left me just enough time to stick new gaskets to the retaining plates, fit them on to the gearbox
and attach the bearing housing ends onto the springplates.














June 2012 was kicking in, the first half of the year had gone so quickly, I really thought that I would
have had the rear end totally completed by now…When I fitted the red seats onto the pan, I wasn’t
too crazy about the manual runners, I knew we had a couple of Mercedes CLK seats lying around, both
with all the electric gear so I decided to take them apart and play around with the runners…





They were a bit too wide so I had to dismantle the whole subframe, cut them down to size and re-weld
them back up….











Once the tracks and motor were in position, i purchased a set of seat mounting wedges from Flatlands
and attached them onto the main subframe. This was done for both the driver's and passenger's side...
and now i have electric seats....














Empi rear disk brake kit bolted on with shortened handbrake cables, rear braided cable made up and
plumbed in temporarily…








As a temporary measure I used cable ties to hold the braided cable onto the axle tubes whilst I try and
get a fitting similar to the one below that I had seen being used on motorbike forks to hold the front cables…





Couldn’t resist a couple of pics of the chassis at this stage…








Seats mounted back onto the new runners for testing….





Got a bit excited and fitted the wheels on too, just to see how they looked….









« Last Edit: July 12, 2017, 08:25:10 PM by LUDICRUZ »
THE HARDER I WORK, THE LUCKIER I GET - HENRY FORD


this user is offline LUDICRUZ

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Reply #12 on: March 10, 2013, 12:18:45 AM
In August 2012 I had made plans to go and see Mark at Flatlands and had also made arrangements
with Pete (Fibrecraft) to pass by and collect a Predator bonnet, I had some ideas I wanted to work on
but did not want to take a chance with my original one and mess it up…

Plans was to make a quick 10mins pitstop at Pete’s, but ended up staying for an hour talking buggies,
shells and the amazing work pete creates at his place....he’s a top man with plenty of advice and
ideas...loved the bonnet idea and fuel tank cover Pete, i even ended up buying enough fibre glass,
resin and hardener to add an extra layer to my tub as i felt it was thin, plus a layer of fibre tissue...
this adds a very smooth layer onto the thicker fibre glass. Pete even managed to give me a quick ten
min lesson on how to lay the fibre glass....

So onwards to Flatlands to see Mark...in my opinion the man’s a Guru when it come to building
buggies, just could not believe how clean his workshops are...he had a couple builds there that he
was working on... so got a chance to see them, share some ideas and talked quite a bit about the
much dreaded SVA topic. Mark is registered as a car builder on a small scale and has submitted
several buggies in for SVA testing and all have passed through with flying colours. He has given
me some guidance and rules to work with and i have enough confidence to put mine through an
SVA now. It was great to get a bit of encouragement from him that i should get my buggy build
completed and get it into the Volksworld 2013 show....

I had a large wish list of parts i wanted, but for the time being i bought the following to keep the
build moving forward....

5.75“ headlamps with built in indicators





The latest LED rear light sets...
All four outer rings are clear LED 2 stage brake/stop lights
The two lights inside the far outer rings are clear LED indicators
The two lights inside the inner rings are – one clear LED Reverse and one Clear LED Fog lights.





Steering column support bracket, which is currently with the chromer…





Steering column outer tube in s/steel…





Amongst other things purchased were, fuel tank, battery holder, body fixings, side pod fixings...
I also got my hands on the following Magnolia dials made by smiths from Europa spares...





Seals direct sell some really cool stuff and i purchased this Expanded Neoprene 50mm x 10mm seal to
go between the chassis and tub, it’s also self adhesive on one side....





To keep with rest of the chassis finish, i wanted to get some chrome shocks, i surfed the internet for a
long time and came across a polished set from Protech at just just under £300 for a set of four but they
come with coils, then i found these last three standard chrome finished shocks from Cool Air, they are
no longer being manufactured or sold anywhere now...i purchased them but upon opening the boxes i
was disappointed with the quality of finish....





my brother was clearing the garage out, and I came across the cruise control unit…might fit it in….





Back in the garage and in October 2012 we finally took the chassis off the bench and sat it on the floor…








Managed to get a few more bits back from the chromer…. parts for the gearbox and some for the rear
spring plates…





Work on the buggy had come to a hold as I was spending a lot of time planning and designing what the
interior would look like, im hoping it will be a one off… I’ve made lots of sketches and mock ups with
cardboard but i want to keep this close to my chest until its almost all complete.... the Original red seats
i had purchased were sold off, as part of the new interior design, i wanted to go with high back seats...i
knew what i wanted and how much i wanted to pay.... and finally after two months of searching i got my
hands on these beauties....

A brand new pair of top of the range Corbeau Sportsline RRS Reclining seats....














You may recall from earlier i was trying to source some brackets similar to the ones below to clamp onto
the rear axle tubes to hold the brake pipes...








Whilst surfing on the net i came across a company a few miles from here called Small Order Springs, they
produce some great work from sheet Metal, laser cutting and prototype work. So i went in with a drawing
of a bracket i designed and to the measurements i wanted, within a couple of days i got my four brackets
back ready to be chromed.





The brackets were made as a two-piece part so that I could clamp them around the axle tubes.








Fitted very nicely around the tubes, braided cables run much smoothly now and look neater…














Next job was to fit the Hydraulic clutch slave cylinder on to the gearbox and plumb in the braided
hose…














Rear end is almost there now, just need axle boots and shocks…..





At the front chrome fasteners for the front adjusters screwed into position…





Now that the buggy was a rolling chassis and the old seats sold off, I couldn’t resist testing out the new
ones, so I took one down to the garage and to my luck the bolt holes were in exactly the same position
as the previous seats… once I got it bolted down and battery connected to the electrics, I gave it a quick
test run…. Very comfortable to sit on and the motor moved the runners perfectly and smoothly…..











I wanted to fit chrome shock and the ones I purchased from Cool Air were really poor quality so I ended
up returning them back, then I came across Gaz Adjustable Shocks, these looks great and there’s the
ability to adjust the stiffness of the ride, unfortunately they are Gold plated and have a blue rubber
condom as dust covers....Cool Air price £400 for a set of 4 delivered.

Gaz are based in Basildon, Essex, so i got in touch with them directly, and asked if they would Be willing
to make me a custom set to the ride height i want and in chrome plated finish rather than Gold plated,
oh and the Condom dust cover in either a clear or black finish, got a thumbs up, they will make me a set,
will take about four weeks….

i was fairly convinced that their product was best suited and the price was affordable too, but before diving
straight in i decided to read up on some reviews posted up on some of the discussion boards, whilst doing
so i came across a thread on the VZI forum, someone advertising the Protech Billet Aluminium Shocks for
Beetles and Buggies......I initially didn’t think much of them because I thought they came with coilovers only..

Hmmm Billet Aluminium.... this got me thinking again and it was only after contacting Colin aka "BROWN BUG"
on VZI, who owns www.royalcountyautosupply.co.uk, i found out that he had been following my build quite
closely.......

Colin ran me through the FABS of the Adjustable Protech Shocks and assured me that these were the ones
to go for, he even and offered me a set at a good price. Now I knew Mark at Flatlands had used a set on a
Beetle build he was working on, so i got on the phone to him and it was all thumbs up..........

But i didn't just want a made to measure custom set of Billet Aluminium shocks, i wanted them to be
different, something with a personal touch....So back on the phone to Colin, and i threw a couple of
ideas towards him on how i could personalize the shocks, not sure if i had quite convinced him at first....
i think he thought i was off the rails......so he asked me to think about it and at the same time he would
ask the manufacturers if they would be in agreement with my ideas.......

That evening i contacted Colin and emailed him the buggy axle weights and the exact measurements i
wanted the shocks to be and two weeks later, just before Xmas i received a package with all the exterior
parts....





Now it was time to get into the garden shed and add my own touch.........several hours later i emerged
covered in black dust
clenching two shiny tubes.......








Polished Billet Aluminium.....the front tubes look great compared to the rear original machined
parts.......So back into the shed to finish the rest of the parts off........









Once all were polished, I sent them back to Protech for final assembly….
January 2013 – two weeks in and finally they turned up…





After giving them a quick light polish to get rid of fingerprint and grease marks i attached the
manufacturer's stickers......











Added the dust covers on…








Early February 2013 – got into the garage and first job was to get the shocks bolted in…
Played around with the damper adjustable knob at different settings to see how soft / hard the bounce
would be... I guess the real test will take place once the buggy is completed and on the road...

Made some minor adjustments to the camber settings as both front wheels were fairly out...

Apologies I have no pics to show as the phone battery died on me.....

However I can finally declare the chassis to be 100% complete and rolling with fully working brakes,
handbrake, hydraulic clutch and the gears change very smoothly and swiftly.... Both seats are also
in with the electrics working perfectly....

Overall very happy with the outcome so far as all the parts have come together very nicely...

If I get the steering column fitted within the next couple of weeks, I could drive the chassis down
to volksworld ....  ;D ;D ;D
« Last Edit: July 12, 2017, 08:54:39 PM by LUDICRUZ »
THE HARDER I WORK, THE LUCKIER I GET - HENRY FORD


this user is offline LUDICRUZ

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Reply #13 on: March 11, 2013, 10:11:34 AM
Well folks thats everything up to date so far, over the weekend the body was lowered onto
the chassis and the front seats bolted down. Most of the day was spent working out the
right angle for the steering column and a bit of brainstorming on the interior design, dials
and switch layout....and possibly relocating both the handbrake and the gear stick.....

Will be attending the Volksworld Show on Saturday, and looking forward to meeting people
and picking up some ideas......
THE HARDER I WORK, THE LUCKIER I GET - HENRY FORD


this user is offline chris bulls head

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Reply #14 on: March 11, 2013, 10:16:54 AM
Think you will find we are all looking forward to meeting you and picking up some ideas  ;-)up