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Messages - Paul1953

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1156
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 19, 2016, 09:52:43 AM »
Iva Specific bit... Fuel tank mod`s for compliance.  Photo below shows top of tank. Original "fuel- in" hole capped off, top left of photo, and re-located inlet stem welded in place.  Split side with bolt and nut to secure the flip top filler cap. (Top right section of tank profile cut away and capped off is not for compliance. This was for clearance of Manx "bonnet"). Bottom right of photo.. Small pipe welded onto a plate and welded to tank for "breather pipe.
Second photo... tank bottom. Two fuel outlets. One for drain off and the other fuel outlet to carb. Screwed connector for earth lead.
Third photo... Flip top filler cap gets around the wired separate cap issue. Screwed connector for drain off with open\shut valve. (This valve has to be accessible from the side of the vehicle to allow tank draining in an emergency). A quick note on gaskets etc. On older vehicles, pre 70`s, cork was used in fuel systems for sealing. I do not know if this material is still acceptable but will ask during the inspection. It may be that cork is usable if of the cork\neoprene mix. As a rule of thumb opt for a more modern material. Believe it or not there is a requirement to prevent petrol fumes from entering the tub area even though a buggy is open to the air. See later for  a mod needed to go someway to comply and is accepted during a inspection.


1157
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 19, 2016, 09:29:02 AM »
Guys.... Please .... if you see any of my posts whereby you have had a problem yourselves don`t hesitate to point out the error of my ways. I won`t feel insulted and throw a strop. Joined the forum for help.  I do now realise it`s a case of 1 step forward and 2 back  ;-)up

1158
Newbie Welcome Area / Re: Hello
« on: October 18, 2016, 02:17:15 PM »
Hi Folks.

My name is Dave H. from Bedfordshire..
Thought I'd introduce myself now after a few weeks getting to know my 2007 Sidewinder on a 68 chassis..
Looking forward to being part of the Bug community and promise not to ask too many daft questions..

Regards

Dave H.
Hi Dave and welcome. Cannot print what my wife said to me when the bright pink donor vehicle pulled up at my house and she realised I was 100% serious about another buggy build. What a relief when all the neighbours backed me up and they are showing so much interest  I cannot get rid of them. As for daft questions I am the one to ask them of - honest. Just take a look at my ongoing post in members buggies section and you will see if anybody can do anything backside first without even trying hard it is me.  ;D

1159
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 18, 2016, 02:08:26 PM »
Good tip with  the Gaffa tape, I used a cable tie which I just left in there
Hi Doon... Yep.. I was about to look for a cable tie but my 6 year old grandson was around and if I leave any about and am not watching him he loops them together making them useless. Try to keep him away from them cos I have this vision of him tightening one on his wrist as a bracelet ;D  Maybe not so funny eh. Still 6 years old helping his old granddad and so far he hasn`t lost any chunks or bits from his hands and such

1160
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 18, 2016, 01:57:50 PM »
I must've forgotten the SA bit. Yes, the later trans mount would be correct for 75 and South Africa kept with K&L fronts until the end of production there iirc. I think they were stronger on rough roads.
  Many thanks David  ;-)up  You have cleared up a worrying aspect for me. I wondered if this donor had been a 1975 shell married up to an earlier chassis. My views of DVLA relating to past changes, queries etc have not left me with any respect of the people manning the phones ability to give any meaningful help. Just the opposite. different views, lost paperwork and such. I think I will be safe asking one last question. I know that VW would sell you a chassis without a vin number as they classed a replacement chassis as a "spare part". You then could legitimately stamp in the original vin number. Do you know if any S African bugs were built without a vin number stamped into the tunnel top?

1161
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 18, 2016, 01:31:55 PM »
 Front "torsion bars. 1 from top bar, another in the bottom. Both identical. Each made up of two slats side by side top and also bottom. Single slats in between. See how they build up to make a hollow depression for the securing stud. Clean all the crap from in the beams. Put a torch up one end. Have a look up the other, and no don`t blind yerself ;D See the cross shaped hole in the centre the bars go through. Ok.. with your cleaned, greased bars get a 1" strip of gaffa tape. Wrap around 1 end of bars about 1" from the end. Tape will stick to itself. Torch down 1 end again. Look through from other end, note how the cross shaped hole is aligned and push and feed the bars gently up to the centre support hole & push through. The gaffa tape won`t go through but will slide back towards you. If you want the tape out of there just keep pushing the bars on through but not all the way through the hole. Go to the sticking out end and push back but all way through hole. The tape will be seen and you can pull it off the end. Push bars back to central position and fit and screw down the grub screw and tighten lock nut. (Needed to replace 2 of my grub screws due to rounded out hex. Noted that the repro ones are much more tapered so rounded off with a grinder so they fit snugly into bar depressions. You will need a cuppa of something now. ;-)(-;Don`t bother washing the greasy crap off your hands. It won`t hurt you honest. After 40 years of eating garage grime tea, bacon sarnie`s biscuits just don`t taste the same with clean hands. ;-)up 


1162
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 18, 2016, 01:10:27 PM »
While you've still got the paint out you may want to cut those jacking points off. They're useless on a buggy as you'll just lift the front up when you try to use them, plus they're ugly and they'll get in the way if you decide on side spats/pods. Jus' sayin'... ;-)up

How did you end up with a late style front trans mount on a K&L pan? :o
Hi Dave... Yep they are coming off. They came with the pans and I thought might as well have them on. Then realised pods may go on, probably mean will ;D and pods have brackets with them  to secure  in the pan hollow section, and I will need bracing for seat belts and the roll bar. (Have a problem also in that I have 6 year old grandson who is desperate to get this on the road. I cannot get a definitive answer to the legality of a child of his age\size wearing a harness. Am told this will all most certainly have to be 3 point retractable with reels that operate at any angle, Angles and heights critical. Angle of across shoulder diagonal. Lap belt must cross leg bone not hip joint area and each mounting must meet the 3 tonne criteria). Long way to go with this as we are talking road legality with a child on board and not just iva. Floorpan... A mystery. Donor imported from South Africa 1995. Registered correctly with DVLA etc and has a legitimate V5C.  However as the original was built at the Utenhage plant I cannot get any details from them or from VW museum at Wolfsburg. Chassis is swing\king\link pin so post 66? Shell id plate gives VIN number relating to 1975. I know that South African builds used anything available and often do not match normal expectation but this is unusual in the extreme unless it is a mix of more than 1 vehicle. Floorpans came from justkampers as supposedly correct for 1965 however when they arrived it looks like they were meant for left hand drive. cost a whopping 500 :'( Transmission mount ??? Your guess as good as mine. I can see no evidence of non original external welding or internal welds that are not original. It has another oddity also but need to be sure this will not drop me in it so to speak :P

1163
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 18, 2016, 10:23:06 AM »
Fully painted chassis. Bit on the glossy side maybe. This toned down well when the Dinitrol was applied and over-painted. I am not a fan of the old style rubbery underseal or Schultz. Dinitrol goes on a treat with air feed. Takes a while to cure but has a good strong adherence and is a tough resin. The swing plates still needed to come off here. Bought adjustable plates as a replacement but the doughnuts are of differing inner diameter and as far as I can determine only urethane versions available in the UK. Have had a trial fit with the urethane and adjustable plates and I think this was maybe the best part of 200 spent unnecessarily. My first dealings with urethane bushes and am not impressed. The ones I have are far too soft in my opinion and can be squashed easily in the hand. This, and maybe my ignorance in fitting, resulted in an issue that I will come back to and ask advice from you guys. I may be wrong here but I wonder now why I didn`t just plan on refitting original plates. Another bit of hard earned advice here, and again just my experience and opinion. Repeating myself but... Get your donor chassis and get the body before any cutting. I didn`t so spent a long time cutting, chopping and painting only to find I needed additional welding, which meant removing nice shiny paint. Hot grinding sparks all over the place which love to bond into painted surfaces. I wanted to get along as far as possible before ordering the body due to space issues,. In reality just caused myself more work in the long run. Won`t harp on about this again as the best of plans fall by the wayside when building from scratch I guess. Just don`t get wound up. At each setback take a break have a cuppa sleep on it you get there. Bit at a time is the way forward. ;-)




1164
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 17, 2016, 01:03:47 PM »
Another one on the bins. Didn`t realise that I depended on them so much. Beam refurbished. Still empty of torsion bar strips. Looks like I`m missing a shocker bolt as well.


1165
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 16, 2016, 06:51:25 PM »
Think there may be a clue to the body colour here 


1166
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 16, 2016, 06:41:48 PM »
 Cooling shroud undergoing refinish


1167
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 16, 2016, 06:37:09 PM »
Final alignment checks using laser level.


1168
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 16, 2016, 02:47:45 PM »
Here is the pan back together. A real milestone which will have you smiling and forgetting the trials and tribulations to get here. This is now where I made a major mistake which still chews me up. Having sprayed many cars in the past I should have known better. Again back to to 70`s when you could get proper Enamel Coach paint that could be painted directly onto cellulose paint without an issue. The red primer was put on to prevent rusting as this was early in the year and very damp. Talked myself out of using 2 pack epoxy as this needs to be used up in one go at an ideal temperature of 20oC and not then falling below 15oC for the first 24 hours. Opted to use the modern equivalent of coach paint.. "Synthetic Enamel". This uses chlorinated thinners and it still didn`t click. This type of thinner is very aggressive. Strangely this paint didn`t react with the cellulose and went on easily with a brilliant glossy finish and became very tough. However I found soon afterwards that it does not bond at all with cellulose based paints. It just forms a tough skin. Had I read the instructions on the web site I would have seen the warnings. Correct primer required. No exception. Then another surprise.  You cannot overspray synthetic enamel with cellulose or acrylic. Reacts madly instantly. Odd that it didn`t the other way round. So if you want a tough covering go 2 pack epoxy. (Note well not to be confused with 2K paints. This stuff needs a vented workspace and an clean air fed mask at the very least. Gives off cyanide so that should be a heads up).


1169
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 16, 2016, 02:01:05 PM »
All back together.


1170
Members Buggies / Re: BIRTH OF A BUGGY CONTINUED
« on: October 16, 2016, 01:45:37 PM »
Getting there. The clutch operating lever not yet removed as this is much easier bolted on the horns. getting the lever off the arm can be a real pain especially if someone has tried in the past and hammer the spline ends. make it easy and have a 3 leg puller, (small one), and a bit of patience because this is a job where three hands would make things a cinch. Centre the puller as squarely as possible on the shaft. Legs will be askew because of the shape of lever etc. One puller is half secure wind in slowly and the shaft will pull off. Have photo`s of the seals, washers and stuff showing where each piece should go. Some were missing on mine


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