Thought I had best start a thread on here about the rebuild of my LWB mk1 Rat. I've had it 7 years now, and time has come for it to get some proper attention... These first few posts will be copied from another forum, so bear with me.
So, the time has come for my buggy to get some attention.
It's a FibreFab RAT long wheel base body on a 1959 VW Beetle pan. Currently looking something like this...
(http://www.jelfs.eu/buggyRebuild/images/481357_10151611384703465_1661875549_n.jpg)
(http://www.jelfs.eu/buggyRebuild/images/999549_10200766008485862_1449259644_n.jpg)
Now the plan is to swap the body on to a later pan, and in the process change from RHD to LHD, and from UK registration to Dutch. So, in comes the donor...
(http://www.jelfs.eu/buggyRebuild/images/IMGP0095.jpg)
Which is a 1974 Semiautomatic beetle thats been off the road as a stalled project since 2007. They key thing is semi-auto, means IRS instead of swing axle rear end, and ball-joint rather than link-pin front suspension.
Plan is to do the minimum to get it legal and on the road, so as well as swapping the body to the new chassis, I will need to do things like fit seat belts (and fab the mounts to fit them...). Once it is legal and I have more time it will get a few more bits done, like a body lift, disc brakes all around, upgraded suspension and a bigger engine.
Realistically I have have a few weeks whilst another car is away having some work done by someone else, once that comes back the buggy has to be out of the garage again.
Let the fun begin!
So, first job: get the body off the pan. Pull the bolts out, and use the winch in the roof of the garage to support the front end, engine hoist to support the rear.
(http://www.jelfs.eu/buggyRebuild/images/IMGP0106.jpg)
and up we go...
(http://www.jelfs.eu/buggyRebuild/images/IMGP0108.jpg)
then a couple of bits of 2x2, chop up a cheap removal dolly, and we have a frame to out the body on and push it out the way.
(http://www.jelfs.eu/buggyRebuild/images/IMGP0109.jpg)
Now I am glad I don't want the body, some of the welding is, well, interesting.
(http://www.jelfs.eu/buggyRebuild/images/IMGP0115.jpg)
So, with the body off and out the way, first job was to get the chassis on stands and strip the suspension off, checking the brakes over on the way. Bit of work needed to the front brakes, its had new cylinders, shoes etc fitted but the cylinders have been left with neither pipe nor blanking plug fitted to the inlet, so they have since corroded rather nicely.
One stripped chassis...
(http://www.jelfs.eu/buggyRebuild/images/IMGP0118.jpg)
Given the state of the welding on the body I thought I would have a look at what has been done to the chassis. Hmm, lots of seam sealer...
(http://www.jelfs.eu/buggyRebuild/images/IMGP0117.jpg)
And hiding underneath? some rather crap tack welds, nice and porous with little penetration... joy!
(http://www.jelfs.eu/buggyRebuild/images/IMGP0121.jpg)
So, current jo is now to strip all the sealant off the joint between the pan halves and the spine of the chassis, on both left and right pans, on top and underneath... What a fun job... Then I can reweld it all, reseal it, and get the thing painted ready for the rebuild to start.
So, where was I... Oh yes, crap welds. In the end the welding was so bad, and the amount of sealant gobbed everywhere meant that I couldn't get the joint clean. So pulled the pans off completely and welded new ones in.
(http://www.jelfs.eu/buggyRebuild/images/IMGP0128.jpg)
And when I say pulled the pans off, it was so bad I could pull half of them off with bare hands, didn't even need to use a hammer.
So a couple of days later, lots of welding and grinding, and we have a chassis with two new pan halves.
At this stage a nice big box arrived with my body lift kit :D I have always struggled with clearance between the front wings and the large tyres I want to run, so I thought a 3" lift would help. Nice bolt on kit, at least that was the idea. Offered up on the new pans and, hmmm...
(http://www.jelfs.eu/buggyRebuild/images/IMGP0130.jpg)
So that went back in the box, and was returned to the supplier for them to investigate.
Next job, strip the body off the old chassis, and the chassis down to a bare pan for storage.
(http://www.jelfs.eu/buggyRebuild/images/IMGP0133.jpg)
(http://www.jelfs.eu/buggyRebuild/images/IMGP0140.jpg)
and glad I did, the old pan has got rather crunchy in places.
(http://www.jelfs.eu/buggyRebuild/images/IMGP0143.jpg)
This was the end of april, and a short brake was taken whilst I travelled over to the UK to run a 100 mile ultramarathon along the Thames.
I got back in the garage this weekend just gone, and turned my attention to adding some strength back into the cheap and nasty floorpans. So, a couple of metres of 30x30x3mm box section, some slicing, bending and welding:
(http://www.jelfs.eu/buggyRebuild/images/IMGP0145.jpg)
and you end up with a nice reinforcing beam to go on the underside of the pan (chassis has been flipped over here)
(http://www.jelfs.eu/buggyRebuild/images/2017-05-07%2019.13.50-1.jpg)
Tonight I shall get the other side done I hope.
I also managed to get the supplier to finally agree to refund me on the lift kit, apparently they are all just as bad and the suggestion to cut it up and reweld it to fit was not what I had in mind. So, time to make my own I think.
Hurry up, IBW is only a few weeks away
Dave
As much as I would love to have it done that quickly, can't see it happening! Got to finish the chassis / body lift. rebuild all the brakes and suspension, refit everything, rewire, new seats, sort out some form of seatbelts as its never had any in my ownership, modify the roll hoop, etc etc... Oh and there is talk of a repaint as well just to add to the list :D Plus I have to get it through the inspection with the RDW (Dutch equivalent of VOSA / DVLA) for the change from beetle to buggy...
Excellent another RAT :D :D :D
Be keeping and eye on this ;-)up
Quote from: davydoff on May 08, 2017, 06:26:20 PM
Excellent another RAT :D :D :D
Be keeping and eye on this ;-)up
Have another one for good measure.
(https://scontent-frx5-1.xx.fbcdn.net/v/t1.0-9/59424_428283917412_2075729_n.jpg?oh=14c926544921e5beb0ab0677b1f1e18f&oe=59BE121A)
The black one belongs to my father, he built it in the late 70s I think, possibly early 80s, certainly before '82, and it's never left his possession and never will. Hence me buying my own :D
Not a lot to report for this evenings garage session, got the other reinforcing bar made, just need to drill the holes through it tomorrow.
(http://www.jelfs.eu/buggyRebuild/images/2017-05-08%2021.45.30.jpg)
Other than that, spent a fair chunk of money on brake and suspension parts (all stock for the moment) which will hopefully arrive in the morning.
Good work, some weeks not much changes othrs the bug moves on in big steps , when you look back after a few months it is surprising how many things you have ticked off the to do list ,.👍
Yeah, I have a list of jobs on a whiteboard , it's nice to tick things off no matter how small.
I hope to get the steel for the body lift this week, depending on work it might have to wait until Saturday morning.
So, slow progress is being made.
Second reinforcing beam was finished up and drilled out:
Whilst I've been at work, Raemond (my OH) has been busy cleaning up parts for me, Brake backing plates and stub axles were cleaned up and given a lick of paint
(http://www.jelfs.eu/buggyRebuild/images/18406315_10154361777592413_1325163582_o.jpg)
(http://www.jelfs.eu/buggyRebuild/images/2017-05-12%2006.29.59.jpg)
Raemond also started on cleaning up the beam and she got a coat of paint on that last night,
(http://www.jelfs.eu/buggyRebuild/images/2017-05-12%2006.29.46.jpg)
I have done some work myself also :D Spent way too long getting the track rods apart, one rod end did not want to come free, but the rods are now all cleaned up and painted. Started on cleaning up the torsion arms as well. I need to get one ball joint changed, which I hope will be done this afternoon. Last few bits to be painted this evening and hopefully tomorrow I can start putting the beam back together.
Oh, and I took a punt on some rectangular(ish) headlamps from ebay.de, I think they will be more in keeping with the front-end shape than the current round ones, plus LHD.
(http://www.jelfs.eu/buggyRebuild/images/s-l1600.jpg)
Front brakes have all been rebuilt, I do hate those bloody springs and keepers :D
(http://www.jelfs.eu/buggyRebuild/images/IMGP0150.jpg)
Bit of red paint, because well, it's the only brake paint I had to hand.
(http://www.jelfs.eu/buggyRebuild/images/IMGP0152.jpg)
Just got to get the upper ball joints changed and then the beam can go back together.
Got the new body lift kit in as well, fits as well as the EMPI kit did ;)
(http://www.jelfs.eu/buggyRebuild/images/IMGP0153.jpg)
So, time to cut, weld, grind, rinse and repeat.
(http://www.jelfs.eu/buggyRebuild/images/IMGP0154.jpg)
That was the end of saturday. Sunday was taken up by helping out on a trail race.
50mm box? That is a decent body lift.
60mm x 80mm, 3mm wall. I was going to use 50 x 80, but the place I get the steel from had the bigger stuff in cheap, so, that's what I will use :D Plan is to make the section over the Napoleons hat out of 3mm plate, and probably the same across the rear cross member.
As it's a LWB, I think adding extra strength back into it is no bad thing. I was hoping to keep the weight under 750kg total, but will have to see.
A day at the beach, and a rather large bill from the vets have made for slow progress of late, but making progress at least. And well a day dossing about in the sun was needed (the large vets bill really wasn't...)
(http://www.jelfs.eu/buggyRebuild/images/2017-05-20%2021.37.20.jpg)
Getting those curves right kicked my arse, but I think they are good enough for this buggy :D
In between welding / waiting for stuff to cool I made a start on rebuilding the pedal set. Needed some serious heat to get the clutch pedal off the lever, but I won in the end! Should be pack in one piece today, but hopefully it will all move now :D
(http://www.jelfs.eu/buggyRebuild/images/2017-05-20%2021.36.41.jpg)
Still need to change the upper ball joints so I can get the beam back together. I agreed a price to buy a second hand garage press, but the seller went quiet as soon as I tried to arrange a time to pick it up...
Coming along nicely, one thing to watch with the lift kit is the ramp sections and curves use a different height as you measure the box height at right angles to the pan surface and on the ramp area it needs to be the vertical height.
Plan is to make the front / rear sections out of flat sheet instead of box section. The body I have is a bit twisted and distorted around the front firewall section anyway, it never actually touched the napoleons hat across the top on the old chassis, so I will make the lift fill the gap, rather than the body fit the lift :D
Finally managed to get the body back on the pan, with the side rails of the lift kit in place and everything bolted down, but somehow didn't get a picture of that...
So now the next fun job begins, filling in the gaps front and rear. In theory that should be easy, but the body is old, twisted and distorted. (though I doubt it would have fit any better when new...)
An offcut of the side rails shows the issue, the gap at the top of the napoleons hat should be the same as the side rails, but its not, by a long way.
(http://www.jelfs.eu/buggyRebuild/images/2017-05-21%2019.04.15.jpg)
And looking down on it you can see the other issue
(http://www.jelfs.eu/buggyRebuild/images/2017-05-21%2019.04.24.jpg)
Yup, the whole front section is bowed out. One option is to cut out the fibreglass firewall and remake it, but I don't fancy that.
So it's time for some CAD and thin sheet metal prototypes
(http://www.jelfs.eu/buggyRebuild/images/2017-05-21%2020.36.41.jpg)
and that's as far as I got. At that point my beer was empty, and dinner was calling. I did manage to get the pedals all put back together and waiting to be bolted back into the car in what I hope is the not too distant future. And yes, I have gone for the chav-tastic aftermarket aluminium pedal covers. Having drivne the buggy in the wet and had the fun of my feet sliding on the pedals, I thought an extra bit of grip would be nice. They may yet come off and get painted mind.
(http://www.jelfs.eu/buggyRebuild/images/2017-05-21%2019.55.02.jpg)
So whilst everyone has been out enjoying the sun and heading off to IBW, I've been making slow progress, but progress non the least.
front section of the lift kit was made from two pieces of 3mm plate to form the front and back, with 2mm plate bent to form the top and bottom, all fully seam welded together.
(http://www.jelfs.eu/buggyRebuild/images/2017-05-23%2018.44.02-1.jpg)
For the rear section I needed some 75(ish)x60mm box, so cut up some of the 80x60, and rewelded so that it had the correct 80mm vertical height when installed in the car on an angle.
(http://www.jelfs.eu/buggyRebuild/images/2017-05-27%2020.21.12.jpg)
Lots of grinding and welding later, we have an 80x60x3mm body lift :D
(http://www.jelfs.eu/buggyRebuild/images/2017-05-30%2017.36.25.jpg)
(http://www.jelfs.eu/buggyRebuild/images/2017-05-30%2017.36.38.jpg)
Between this and the 30x30x3mm reinforcing under the floors, there is a lot of strength gone back into the floor - and unfortunately a lot of weight... Think in total the lift kit is about 45 kg, and the reinforcing another 10 kg. Be interesting to see what the car comes in at when I get it on the weighbridge.
It was decided that seen as the weather was rather nice a trip to the beach was needed and it just so happened that with a slight (hour long) diversion, I had some new seats :D
(http://www.jelfs.eu/buggyRebuild/images/2017-05-27%2019.17.22.jpg)
Okay, so they need recovering, but for the price I won't complain. Either my OH will have a crack at recovering them, or I will use them as a test for the upholsterer in my village before needing the big car doing.
With the body back on, and the steering column roughly shoved in, I could set about making some seat mounts. Luckily the sliders on the old seats bolted up to the new seats just fine.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-05%2020.52.04.jpg)
(http://www.jelfs.eu/buggyRebuild/images/2017-06-05%2021.00.50-1.jpg)
And thats where I am at. Few other small jobs done without pictures - ball joints up front have been replaced and new bushes fitted to the rear trailing arms.
next up - making dash / bonnet / steering column support structure...
So with both seats fitted, I ripped all the stuff out the old dash and fitted it up with a quick notch to go around where the steering column now sits (for the moment).
(http://www.jelfs.eu/buggyRebuild/images/2017-06-08%2023.26.59-1.jpg)
One thing I never liked about the buggy was how far out from the dash the steering wheel sat. I'm trying to make space for both rear seats and some kind of storage, so space is at a premium.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-08%2023.27.12.jpg)
So, out comes the column, and the inner shaft is stripped from the housing. The inner shaft is hollow to allow for the horn electrics to pass through it. A couple of holes drilled in the shaft, and some careful marking. The plan was to remove 50mm from the overall length, so a bit of 50mm masking tape as a guide, and two small marks 100mm apart to help with lining up later.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-09%2019.16.25.jpg)
No going back now!
(http://www.jelfs.eu/buggyRebuild/images/2017-06-09%2019.24.42.jpg)
A rummage through the scrap pile finds a bit of 16mm tube, 8"ish section was cut off, given a quick clean. The ends of the cut steering shaft were given a nice big bevel...
(http://www.jelfs.eu/buggyRebuild/images/2017-06-09%2019.39.20-1.jpg)
Clamp it down to a bit of box section to keep everything lined up and out with the hot metal stick, plug welding through the holes drilled earlier, and a nice fillet to fill the V between the ends of the shaft.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-09%2020.28.38.jpg)
A quick clean up with a flap disk and a double check to make sure I got it right and the marks that were 100mm apart an hour ago are now 50mm apart.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-09%2020.44.58.jpg)
A quick trim of the outer tube, shove it all back together, and back in the car. Looking a bit better.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-09%2020.58.11.jpg)
Small things, but makes it slightly easier to get in and out.
;-)up
That's exactly the way I did mine, except I used a solid tight fitting bar and cut a tube section from a second steering column.
Its a nice safe and secure way, if there is such a thing, to have a solid steering column thats exactly the right length from the outset.
Peter
I used tube rather than a solid bar to go inside mainly as I want to be able to run the horn feed down the column as done originally, but also because I had some 2mm wall 16mm tube in stock :D It was a tight enough fit that I had to give it a gentle sand to get it to fit, even then it needed some persuasion with a mallet to go all the way in. I don't think it's going anywhere.
Been a bit lax in keeping this thread up-to-date, so a quick post dump from my thread on another forum...
So, whilst waiting on suppliers to get back to me about a replacement dash, thought I would crack on with another job...
(http://[url=http://i.imgur.com/MyqvsqV.jpg%5Dhttp://i.imgur.com/MyqvsqV.jpg%5B/url%5D)
(http://www.jelfs.eu/buggyRebuild/images/2017-06-14%2021.00.18.jpg)
Now, previously it never had back seats, and well, I never wanted them either. But, a) not having them seemed a bit odd and the luggage box I had previously a bit bulky, and b) I think it is better to put them in now and get it registered as a 4-seat car. I can always remove them later. So, various bits of box, and a frame is starting to take shape.
I find it very usefull to have some form of enclosed kinda safe storage, so my back seats will be forward slightly. This does mean it will be a 2+2 more than a true 4 seat car, adults in the back might not be the most comfortable :D
I am hoping that I have understood the Dutch rules correctly, and being a 1974 car it doesn't need seatbelts on the rear seats. I don't really intend to carry passengers, so from a safety factor I am not too worried, it would just be easier not to have to fabricate structural mounts.
Managed to get the majority of the back seat framework welded up, but ran out of welding gas with only a small amount left to go. Typical...
(http://www.jelfs.eu/buggyRebuild/images/2017-06-20%2021.21.43.jpg)
So, got distracted and started cutting up some half inch ply to make the base and back out of.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-20%2021.22.02.jpg)
right, so, small update.
Finished cutting the wood for the rear seat, all the welding was finished and reinforcing plates made for under the rear wings where it bolts through the fibreglass.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-21%2018.55.54.jpg)
And I still have a small but usefull storage area behind the seats (though some space will be eaten up by the battery. Does make it a little more practical at least.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-21%2018.56.37.jpg)
Been lots of thinking going on with regards to dash and screen and the like. It seems that all the people who can supply me a dash, can't supply me one in the right size. Same with the screen... Bonnet is 41" wide, screen is 41.5" wide between the legs. The original dash was clamped between the two, making up the extra 1/2". 2 different companies can supply me a dash, but they are designed to go inside of the bonnet, rather than outside of it...
So, I have a plan, but I need to experiment and see. First, I need some fiberglass resin, the stuff I had in stock was rather solid...
So, whilst I had a few minutes to kill I thought I would turn to the front end. Now I never liked the round headlamps, they just don't fit the shape of the wings at all.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-26%2020.37.05.jpg)
So, lets see if we can make these new ones fit...
(http://www.jelfs.eu/buggyRebuild/images/2017-06-26%2020.33.52.jpg)
Now, the issue here is that the adjusters stick forwards, so they are almost level with the front of the glass.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-26%2020.34.37.jpg)
It would mean either having the adjusters sitcking out in front of the wings (ugly), the glass flat level with the wings (not ideal) or having to try and make some bezels (likely a PITA). So, out with a knife, and pull them apart.
(http://www.jelfs.eu/buggyRebuild/images/2017-06-26%2020.35.04.jpg)
The plan is to re-rivet the brackets for the adjusters onto the reflecter but pointing the other way around. Turn the plastic mount plate backwards, and make a frame to hold it all in place up under the wing...
(http://www.jelfs.eu/buggyRebuild/images/2017-06-26%2020.36.38.jpg)
Much better. I will need to get another pair, a) as one of these has lost a bit more of the silver than I would like, and b) because I need some more of the adjuster brackets. They use different ones top and bottom and the top one will be hard to re-use.
Now if the body was nice and square and strong, I think I could get away with screwing them directly to the fiberglass. Unf, if you look at the front end on shot you can see that the one wing (on the left of the picture) doesn't sit level, its twisting up and out. So a steel frame is going to end up going underneath to pull it all into shape I think...
Not a lot of progress to show, but new toys arrived at least...
(http://www.jelfs.eu/buggyRebuild/images/2017-07-04%2018.01.16.jpg)
Now - where do all these wires go?
(http://www.jelfs.eu/buggyRebuild/images/2017-07-04%2018.01.55.jpg)
Small amount of progress made in between other jobs / hobbies...
First thing was to add a bush to the bottom of the steering column, never liked the way the shaft just wobbles around in the outer tube. I didn't take as many pictures as I ought to have done but still, out with some plastic I had laying around...
(http://jelfs.eu/buggyRebuild/images/2017-07-10%2020.10.00.jpg)
and with a hole saw cut it down to roughly the right size. Then the fun beings :D An 8mm bolt through the hole in the centre with a nut to clamp it tight. Chuck the bolt up in the pillar drill and we have a hobo lathe. With a combination of different files the outer diameter can be taken down fit inside of the steering column tube, leaving a lip on the bottom to hold it all in place. The centre drilled out and it split in two, we are left with a 2-piece bushing
(http://jelfs.eu/buggyRebuild/images/2017-07-10%2020.10.20.jpg)
Which gets fitted in here
(http://jelfs.eu/buggyRebuild/images/2017-07-10%2020.11.24.jpg)
It should hold its self in place, but when I strip the column for paint I might add a couple of drops of glue to hold it firmly.
I've also made a start on a brace for the dashboard, but need to pick up some more flat steel bar to make the braces back to the body, so on hold until tomorrow night now...
(http://jelfs.eu/buggyRebuild/images/2017-07-10%2021.41.20.jpg)
Not my best work ever, but the bulk of the dash support is done for, just got to make a bracket to support the steering column. Had to notch the bottom tube to clear the wiper motor, so welded an extra piece of angle iron to the back to reinforce it.
(http://jelfs.eu/buggyRebuild/images/2017-07-11%2022.10.16.jpg)
Am I talking to myself in here? Anyway...
So, finished off the dash brace by adding a support for the steering column. Needs a tidy up and paint, but think it will do...
(http://jelfs.eu/buggyRebuild/images/2017-07-12%2021.37.45.jpg)
certainly better than what it replaced!
(http://jelfs.eu/buggyRebuild/images/2017-07-12%2021.37.57-1.jpg)
With that in place, time to start on the actual dash. Now if there is a job I dislike, it's woodwork. A lot less forgiving than metal.
(http://jelfs.eu/buggyRebuild/images/2017-07-15%2018.32.43.jpg)
This was then covered in some of Ikeas finest fleece. (Once the dogs had stopped using it for a bed of course...)
(http://jelfs.eu/buggyRebuild/images/2017-07-15%2019.36.54.jpg)
It's had the first coat of fibreglass resin on the outside, but a lot more to go yet. No photos though, far too sticky to be messing with a camera at the same time. Original Plan was just to use this as a buck for a mould to make one out of 'glass, but at this rate it may end just being covered in vinyl and fitted...
But not too messy to.play with a smart phone! ;D
Most of them are away at NEWS thus weekend. Jobs coming on nicely ;-)up
Sam, great job you are doing . As Zipbuggy says most are at NEWS. Us northern lads are still here to tell you you're doing a great job
;-)up
Paul
Cheers guys, nice to know someone is reading ;)
After the first coat of resin inside and out, some extra half-round profile wood was added to the edge
(http://jelfs.eu/buggyRebuild/images/2017-07-16%2015.35.57.jpg)
Unf the resin had warped the frame
(http://jelfs.eu/buggyRebuild/images/2017-07-16%2015.36.18.jpg)
So a piece of steel box was screwed into the back and that has pulled it back into line (ish). Close enough at least.
I've added another layer of resin to the front and will leave that to cure overnight. Tomorrow I shall give it a quick sand back and see how it looks. I'm not sure it will need it, but I might give it a layer or two of glass fibre on the inside. Not like it's got to take any load.
(http://jelfs.eu/buggyRebuild/images/2017-07-16%2020.23.25.jpg)
Plan is to cover it in vinyl, but think that can wait till later, need to see if I can find some 2-way stretch material. Place I would normally go closed down yesterday, doh!
Warping and suppliers closing you are not having much luck but all part of the learning curve.
To be honest I'm not surprised it warped, the wood was crap quality fast grown pine, but best I could get at the time. As for the fabric store closing down, i knew they wen't into administration a few months back, so wasn't out of the blue, i just hadn't been paying attention.
Time for an update. After the last update I got distracted with another project I have been wanting to do for a while, namely getting a decent air compressor. I had been keeping an eye out on marktplaats for some time, and a decent spec machine turned up at a good price, only issue being it was too big for my car, and over an hours drive away :D But, 10 bar / 145 psi max pressure, 200 litre tank, and 400 lpm / 14 cfm. 3 phase, 4 hp.
Now I didn't want it in the garage with me whilst I am working, but in the shed behind the garage. This way the noise will annoy the neighbours and not me ;) Knock on effect of this was that I needed to run a 3phase connection out to the shed, and an air line back in. If you are going to do it, do it right, and the air line ended up being run in 25mm pvc pipe (rated to 12.5 bar), with 3 quick connect outlets spaced down the side of the garage, and a connection run out to the enclosed carport out the front.
Between installing all the pipework and borrowing a trailer to go and pick up the compressor that took about 3 evenings and most of last saturday. Worth it for new toys though
(http://www.jelfs.eu/buggyRebuild/images/2017-07-23%2016.16.28.jpg)
And back to the buggy, time to try and get this new screen to fit...
Now the condensed version of trying to make this screen fit, missing out the large amounts of swearing and despondency...
Now the first problem, the bottom seal is not a great fit...
(http://www.jelfs.eu/buggyRebuild/images/2017-07-25%2021.38.12.jpg)
I tried fitting it and just bending the rear lip out, but the angle was so extreme that the seal was pulling off the frame, and not touching the bonnet and the front. Not a good luck. So, out with the knife.
(http://www.jelfs.eu/buggyRebuild/images/2017-07-25%2021.38.52.jpg)
This at least gets the seal pointing in roughly the right direction. Unf I did end up having to remake part of the dashboard as it wasn't going to work. Was fine with the old screen, but not this one, oh well...
But it fits!
(http://www.jelfs.eu/buggyRebuild/images/2017-07-26%2019.15.35-1.jpg)
kinda... bit of a gap under the seal, but I think a bit of mastic when I come to fit it for the last time, and it will do.
(http://www.jelfs.eu/buggyRebuild/images/2017-07-26%2019.15.53-1.jpg)
Once the dash is wrapped I think it should look alright. Just got to find some decent vinyl from somewhere, ideally 2-way stretch to help with fitting the curves.
(http://www.jelfs.eu/buggyRebuild/images/2017-07-26%2020.22.12.jpg)
So with the screen fitted, and the dash built, time to turn my attention to the bodywork... The biggest issue here, other than the masses of cracks, the roller paint job, and the general abuse of multiple owners over the years, is the fact that the panels that the headlights sit in aren't actually flat to the front of the car.
(http://www.jelfs.eu/buggyRebuild/images/2017-07-26%2020.22.46-1.jpg)
You can see how I had to put a load of spacers behind the light units to get them pointed in roughly the right direction.
(http://www.jelfs.eu/buggyRebuild/images/2017-07-26%2020.23.00.jpg)
Problem is I have never really liked the way the front end looks with the round lights. So, do I go for the easy life, and just change the glass over for LHD and say sod it, or do I start digging into the front end and try to pull it all back into line and fit the modified wartburg lights I started on previously.
One of the deciding factors will be when I can get it in for the roll cage to be fitted. If I am going to have weeks to wait for that I might as well have a go at the lights. Other than the painting and rewiring, the lights and cage are the two big things that will stop me getting it registered and on the road... Speed of getting it on the road, verses those ugly lights...
(http://www.jelfs.eu/buggyRebuild/images/2017-07-26%2020.22.27.jpg)