At last the petrol tank is sorted. I've no confidence that the sender will give an accurate reading, but as long as it gives me an idea I'm not going to worry too much.
I've probably over-engineered the tank support, but the tank is in so firmly I can push the buggy backwards and forwards just on the tank. Plenty of clearance for the steering gear underneath without resorting to a big hammer.

I made up some 'wonky T' brackets, the bottom edge goes against the main bolts holding the front axle with the short ends bolted through to the old body mounts.






25 x3 mm angle section across the front...






And finally, the tank in place,

Spend £50 on a Spyda "Gauge Matcher" and you will have a fully reliable, fully accurate fuel gauge reading no matter what the shape or size of your fuel tank. All details on my build thread.

Dougie, have you test fitted the bonnet with the tank and new supports fitted?
Just a bit concerned thet lifting the tank might cause clearance issues on the front corners of the tank/bonnet.

Quote from: Buggybaggy on September 03, 2024, 12:21:17 PM
Dougie, have you test fitted the bonnet with the tank and new supports fitted?
Just a bit concerned thet lifting the tank might cause clearance issues on the front corners of the tank/bonnet.

At every stage I test fitted the bonnet. It fits fine with plenty of clearance.

Early tanks do not have the ridged front and are what buggies were designed for but we all use post 66 tanks these days

   Getting somewhere now, fuel lines replaced front to back, lights fitted and wiring completed. I built the loom from scratch , wire by wire, as too much of a beetle loom would have gone in the bin. Everything works with brand new wire and connectors so hopefully no problems in the pipeline.
    The bonnet is now fixed in place using M6 x 30 self tapping hex head bolts. I'll put some normal bolts at the dashboard end once I've worked where the windscreen fixings will be exactly.
     

Looking great especially the rear end tyres and engine.

Just in time for Christmas and a few Santa runs out !

More progress....bonnet and everything that attaches to it, windscreen, wipers, washers etc are all sorted. Wipers are stainless Mini items using an adapter bush. This is a regular mod on Split Screen vans as the Mini parts have a much stronger spring than the VW. I also had to shorten and bend the arms to fit the 12" screen.

Always good to see progress being made

Looks like i'll be joining you!! Bought another and getting Rob to mould me an original GT front end. Old body is half off as got to try and save electrics fr the buyer and the build will commence.

Can i ask what you used or how you cut the speedo hole?

Quote from: Dougie on December 05, 2024, 11:02:22 AM
More progress....bonnet and everything that attaches to it, windscreen, wipers, washers etc are all sorted. Wipers are stainless Mini items using an adapter bush. This is a regular mod on Split Screen vans as the Mini parts have a much stronger spring than the VW. I also had to shorten and bend the arms to fit the 12" screen.

Looking good. A couple of questions for you before i get going on my build. What did you use to cut the dash and rear light holes please?
Also, just noticed you've put the screen on backwards to some as the groove sits forwards to attach a roof too.

I've got a 4 3/8mm / 110mm hole saw for speedo holes if you need to borrow it.

  Holes for the rear lights and speedo were cut with a 110mm hole saw. It wasn't that expensive from ebay. Luckily they were the same size. The windscreen is that way round because I thought the smooth side looked better on the outside and I have no intention of fitting a hood. Having looked online at images of buggies it seems about a 50/50 split on which way round it's meant to fit anyway.

Roll hoop is now finished. The main hoop was bent up using 38mm tube to my spec by a firm called Tube-bender, another ebay find. They also supplied the bracing tubes with the notches cut. It cost £200 including the delivery. I had to drill and tap for the seat belt mounts.

Neat, if you need a hood simmonds hoods have left me 3 stainless bars to sell that allow you to clip the hood to a reverse screen frame using the manx clamps.

Quote from: Manxdavid on February 10, 2025, 11:11:01 PM
I've got a 4 3/8mm / 110mm hole saw for speedo holes if you need to borrow it.

Thanks David, I also have one plus a 135mm for the rear lights i just wondered if Dougie used one or hand saw and filed them out.