Build Diary

View of the workshop.

This page is intended to tell you what I've been doing (or not doing!), when I did it and how long it took.

Date

Beach Buggy Tasks Completed

Hours

People

Person Hours

  Total number of 'garage' hours spent to date: 226   249
  I've given up on trying to keep this section up to date. Sorry.      
25/02/2007 Trial fitted dual Dellorto carbs with new CB Performance manifolds, linkage and air filters to engine long block. 2 1 2
Winter 06/07 Little or no progress due to lack of funds and starting a new job :-(      
27/10/2006 Assembled clutch release mechanism on AM code gearbox. 1 1 1
25/10/2006 Installed Bosch 009 distributor, distributor drive shaft and fuel pump on engine long block. 2 1 2
24/10/2006 Removed differential from DC code, Type 3 gearbox and cut off the bell-housing to form the basis of an engine test rig. 6 1 6
23/10/2006 Ordered VW Mexico 1600 twin port engine long block from Street Style & Power.      
08/10/2006 Painted topside of differential and bell-housing and both differential side covers with 1st and 2nd coats of Hammerite smooth black. Gearbox painting is now completed. 5 1 5
01/10/2006 Degreased and painted topside of differential and bell-housing and both differential side covers with Hammerite primer. 2.5 1 2.5
26/09/2006 Painted underside of differential and bell-housing with 2nd coat of Hammerite smooth black. 1 1 1
25/09/2006 Painted underside of differential and bell-housing with 1st coat of Hammerite smooth black. 1 1 1
24/09/2006 Painted main gearbox housing with 2nd coat of Hammerite smooth black. Degreased and painted underside of differential and bell-housing with Hammerite primer. 2 1 2
22/09/2006 Painted main gearbox housing with 1st coat of Hammerite smooth black. 1 1 1
21/09/2006 Degreased and painted main gearbox housing with Hammerite primer. 1 1 1
19/09/2006 Painted gearbox gear carrier housing with 2nd coat of Hammerite smooth black. 1 1 1
18/09/2006 Painted gearbox gear carrier housing with 1st coat of Hammerite smooth black. 1 1 1
17/09/2006 Painted gearbox nosecone with 2nd coat of Hammerite smoth black. Degreased and painted gearbox gear carrier housing with Hammerite primer. 1 1 1
16/09/2006 Finished cleaning gearbox differential covers with a wire brush and Dremmel tool. Degreased with cellulose thinners and painted nose cone with a coat of Hammerite primer and smooth black. 5 1 5
03/09/2006 Cleaned up gearbox differential side covers with wire brush, rotary wire brush in a drill, Dremmel tool and an old screwdriver used as a scraper. 5 1 5
02/09/2006 Cleaned old gasket of AM code gearbox, cleaned the better of the two 'two bolt' nosecones, fitted it to the gearbox with a new gasket and torqued it up. Cleaned up the second side of the gearbox with rotary wire brushes in a drill. 5 1 5
30/08/2006 Major clearout of workshop. Chucked out crap, sorted out old and new parts, put big stuff up in garage roof and arranged smaller stuff on the new shelves. 2 1 2
29/08/2006 Bought more shelves and put them up on the other side of the workshop. 2 1 2
28/08/2006 Bought shelves from B&Q, put them up in workshop and tidied up tools and parts. 4 1 4
27/08/2006 Made bench top for second bench in workshop out of old kitchen work surface as chip board surface was deteriorating. 2 1 2
16/08/2006 Went to Merlin Motorsport at Castle Coombe race circuit and bought Smiths Telemetrix gauges and brake pipe flaring tool.      
13/05/2006 Went to Merlin Motorsport at Castle Coombe race circuit and bought Cobra Monaco S seats in black vinyl, with sliding mounts, Willans 3" 5-point stockcar race harnesses in black with shoulder pads and a Mountenay 14" 3-spoke alloy & black leather steering wheel.      
12/05/2006 Test fitted gear lever, hand brake lever and steering brakes to check clearances with dash board. 0.5 2 1
07/05/2006 Got dash board, bonnet and screen down from garage roof and test fitted on the buggy. 0.5 2 1
01/05/2006 Drained oil out of 2nd AM and DC code gearboxes and removed both gearbox nose-cones. Disposed of all drained oil and cleaned up. 2 1 2
29/04/2006 Assembled one rear drive shaft with CV joints, boots and washers. Drained oil out of AH and AM code gearboxes, removed both gearbox nose-cones and re-fitted AM code nose-cone (3 hole) to AH code gearbox using its original gasket. Began to remove remnants of failed gasket from AM code gearbox. 4 1 4
25/04/2006 Assembled one rear drive shaft with CV joints, boots and washers. 1 1 1
22/04/2006 Assembled one front spindle with drum, bearings, washer and lock-nut. Fitted completed rear trailing arm assembly to chassis. Test fitted all four wheels and dropped buggy off trestles onto the floor. Used jack and axle stands to fully raise and lower the suspension through it full range of movement to check wheel and tyre clearances. 5 1 5
17/04/2006 Painted one front and one rear brake drum with 3rd coat of POR-15 Chassiscoat Black. 1 1 1
16/04/2006 Painted one front and one rear brake drum with 2nd coat of POR-15 Chassiscoat Black. 1 1 1
15/04/2006 Painted one front and one rear brake drums with 2 coats of POR-15 Rust Preventative Paint and then 1 coat of POR-15 Chassiscoat Black. 2 1 2
14/04/2006 Assembled one rear stub axle, brake backing plate, bearing cover and brake drum. Prepared one front and one rear brake drums for painting by degreasing and etching using POR-15 Metal Ready. 5 1 5
13/04/2006 Took one 7x15'' rear wheel to tyre place to get 235/75R15 tyre fitted and balanced, as the other rear tyre hasn't arrived yet :-( It took 225g and required a static balance, as it couldn't be dynamically balanced. Apparently this is common on large aggressive 4x4 remoulds. Test fitted one rear wheel to the buggy to check clearance. Ordered a stack of parts from VW Heritage & SSP. Collected remaining parts from GSF Car Parts in Bristol. 0.5 1 0.5
12/04/2006 Ordered a stack of parts from GSF Car Parts in Bristol and collected most of them from their Bristol store.      
11/04/2006 Took 5.5x15'' front wheels to tyre place to get 205/70R15 tyres fitted and balanced. Had to try several tyre places before I found one that could balance 205mm PCD wheels, as most can't fit wheels with such a big 'hole' in the middle on their balancing machine :-( Test fitted one front wheel to the buggy to check clearance. 0.5 1 0.5
10/04/2006 Cleaned up the other 7x15'' steel directional wheel, to remove grime, road tar, red overspray and old balancing weights. Touched up small areas of paint damage on both 7x15'' wheels with Smooth White Hamerite. Trial fitted 7x15'' rim to rear of buggy to check clearances. 2 1 2
09/04/2006 Cleaned up one of the 7x15'' steel directional wheels, to remove grime, road tar, red overspray and old balancing weights. 1 1 1
08/04/2006 Drove to Wirral to collect a set of 4 second hand 'directional' white painted steel wheels; two 7x15'' and two 8x15'', both sizes with 3.5" backspacing.      
07/04/2006 Ordered tyres for buggy - 235/75R15 Bronco Grizzly Claws for rear and 205/70R15 Colway C-Trax ATs for the front. Also ordered O.E style silver painted steel 5.5x15'' wheels for front of buggy and 20 standard 'wide 5' wheel bolts.      
04/04/2006 Assembled one rear stub axle, brake backing plate, bearing cover and brake drum. Fitted completed assembly to chassis and measured maximum size of rear wheels and tyres. 3 1 3
03/04/2006 Painted exposed parts of rear stub axles and bearing covers with Smooth Black Hamerite. Cleaned, greased and assembled rear trailing arm bushes and bearings. 5 1 5
31/03/2006 Collected Type 1 rear trailing arms, steering arm, and steering box bracket, Type 181 steering knuckles and front beam supports and Type 3 dual spring plates from the powder coaters. Also collected Type 1 rear stub axles and bearing covers from blasters.      
30/03/2006 Visited 'Death Trap Dubs' club evening and collected Type 1 swing axle spring plates and torsion bars from Ray (Bug Barn).      
27/03/2006 Took Type 1 rear trailing arms, steering arm, and steering box bracket, Type 181 steering knuckles and front beam supports and Type 3 dual spring plates for powder coating. Also took Type 1 rear stub axles and bearing covers for blasting.      
26/03/2006 Cleaned up Type 1 rear trailing arms, steering arm, and steering box bracket, Type 181 steering knuckles and front beam supports and Type 3 dual spring plates, all to take for powder coating tomorrow. Also cleaned up Type 1 rear stub axles and bearing covers to take for blasting tomorrow. 5 1 5
20/03/2006 Stripped down Type 3 rear suspension assembly into its component parts and carried out basic cleaning to prepare them for blasting and powder coating. Started to strip down '62 king-pin front axle beam to recover parts to mount new steering box. 8 1 8
18/03/2006 Visited Bug Barn near Gloucester and bought a complete Type 3 rear suspension assembly (to get a set of dual spring plates) and a set of thermostat air control flaps for a 1600 twin port fan shroud.      
11/03/2006 Assembled rear suspension to measure wheel travel limits due to stock and heavy duty spring plates, shock absorbers and bump stops. 5 1 5
01/03/2006 Collected T181 trailing arms from MAD VW Workshop having had old ball joints pressed out. Took T181 parts to be powder coated but the bloke was on holiday, so brought them home again :-(      
26/02/2006 Assembled front suspension to measure horizontal and vertical front wheel clearances and wheel travel limits due to ball joints and shock absorbers. Began to assemble rear suspension. 5 1 5
25/02/2006 Stripped down '73 Type 181 front axle beam and took T181 trailing arms to MAD VW Workshop to have old ball joints pressed out. 2 1 2
19/02/2006 Collected '73 Type 181 complete front axle beam from Stafford.      
18/02/2006 Collected AM code gearbox from Swindon.      
17/02/2006 Collected stuff from powder coaters.      
16/02/2006 Painted inside of rear brake drums with 3rd coat of POR-15 Chassiscoat Black. 1 1 1
15/02/2006 Painted outside of rear brake drums with 3rd coat of POR-15 Chassiscoat Black. 1 1 1
14/02/2006 Painted rear brake drums with 2nd coat of POR-15 Chassiscoat Black. 1 1 1
13/02/2006 Painted rear brake drums with 2 coats of POR-15 Rust Preventative Paint and then 1 coat of POR-15 Chassiscoat Black. 3 1 3
12/02/2006 Prepared rear brake drums for painting by degreasing and etching using POR-15 Metal Ready. 3 1 3
10/02/2006 Took stuff to powder coaters. 0 0 0
22/01/2006 Sorted new nuts bolts and washers into storage containers. Sorted out a load of stuff to be sand-blasted and powder-coated (brake backing plates, rear spring plates, drive shafts and other bits and pieces). Trial assembled front suspension on both sides. Sorted out parts from donor car to be kept or scrapped. 4 1 4
21/01/2006 Assembled one front spindle with drum, bearings, washer and lock-nut. 2 1 2
08/01/2006 Started to assemble refurbished rear trailing arms. Tidied up and sorted out a pile of rusty junk to take to the dump. 3 1 3
07/01/2006 Cleaned up one side of 'AM' code 1303 gearbox with rotary wire brush. Stripped all exhaust, tinware and other bits off engine block. Stripped down four rear IRS drive shafts. 5 1 5
10/12/2005 Collected refurbished rear trailing arms from VolksMagic and bought steering brake and proportioning valve from Kingfisher Kustoms.      
28/11/2005 Cleaned up another CV joint. 1 1 1
27/11/2005 Cleaned up camber adjusters and washers and carried out trial assembly of front suspension. Disassembled and cleaned a rear drive shaft and CV joints. 4 1 4
17/11/2005 Took renovated front trailing arms to MAD VW Workshop to have new long travel ball joints pressed in.      
10/11/2005 Cleaned surface rust off front trailing arm grub screws and lock nuts and greased them. 0.5 1 0.5
09/11/2005 Removed flash rust from bare metal surfaces of front trailing arms and spindles. Polished bearing surfaces and greased them. 1 1 1
07/11/2005 Painted front trailing arms and spindles with 1 coat of POR-15 Chassiscoat Black. 1.5 1 1.5
06/11/2005 Painted front trailing arms and spindles with 2 coats of POR-15 Rust Preventative Paint and then 1 coat of POR-15 Chassiscoat Black. 5 1 5
05/11/2005 Degreased and prepared front trailing arms and spindles for painting. Used Gunk, then POR-15 Marine Clean to degrease them, then POR-15 Metal Ready to etch the surface before drying them thoroughly in the oven! 5 1 5
01/11/2005 Fitted rear gearbox mounting plate from 'EMPI 9507 Solid Steel Transaxle Strap Kit' - needed to grind out bolt holes to correct width for frame horns (about 0.5cm each side). Removed old rubber front gearbox mount and test fitted solid mounting plate from same kit. 1 1 1
31/10/2005 Cleaned up other steering knuckle to remove rust and old paint with rotary wire brush on a drill. Used POR-15 Metal Ready to remove rust from front drum brake backing plate bolts. 3 1 3
30/10/2005 Cleaned up bottom front railing arms and one steering knuckle to remove rust and old paint with rotary wire brush on a drill. Used POR-15 Metal Ready to remove rust from front brake backing plate bolts and washers. 2 1 2
29/10/2005 Cleaned up top front trailing arms to remove rust and old paint with rotary wire brush on a drill. 3 1 3
28/10/2005 Got ball joints pressed out of front trailing arms at MAD VW Workshop in Bristol.      
24/10/2005 Top coated front brake drum, inside and out, and rear brake internal components with POR-15 Chassis Coat Black. 1.5 1 1.5
23/10/2005 Used POR-15 Marine Clean and Metal Ready to prepare a front brake drum for painting. Painted front brake drum, inside and out, and rear brake internal components with POR-15 Rust Preventative Paint. 2 1 2
16/10/2005 Used POR-15 Metal Ready to remove rust from rear trailing arm pivot bolts and spacers and rear brake internal components (handbrake mechanism). It's amazing, soak them for a few hours and the rust just disappears! 1 1 1
09/10/2005 Started to clean up the front trailing arms. Continued cleaning up the gearbox. Cleaned up and test fitted the rear torsion bars. 1 1 1
01/10/2005 Doon kit and chassis delivered :-)      
24/09/2005 Went to a sale at 'MAD VW Workshop' in Bristol and bought two ball-joint front hub assemblies complete with trailing arms, a petrol tank and a 1600 twin-port inlet manifold all for GBP 30. Stripped the hub assemblies into component parts and chucked away the junk. Kept the trailing arms, stub axles and fittings, backing plates, adjusters, springs and 22mm wheel cylinders. 3 1 3
11/09/2005 Started to clean up exterior of gearbox to remove grease grime and corrosion. 3 1 3
01/09/2005 Visited VolksMagic to see my new VW Beetle chassis, whilst work is in progress and to discuss further detailed options with Lee. Also left my shift rod with Lee for shortening.      
20/08/2005 Visited VolksMagic to see my new VW Beetle chassis before work on it starts and to discuss the options for what modifications to make to it with Lee. Also left the stripped down rear trailing arms with Lee to be blasted, seam welded and painted.      
13/08/2005 Removed rear stub axle inner and outer bearings, circlips, spacers and oil seals. Rear trailing arms are now completely stripped down. 2 1 2
09/08/2005 Removed rear off-side outer oil seal and stub axle. 0.5 1 0.5
06/08/2005 Rearranged garage to move all buggy parts over next to workshop area. Removed remaining rubber bushes from rear trailing arms. Removed rear near-side outer oil seal and stub axle. 2 1 2
31/07/2005 Cleared out workshop area of garage, assembled new workbench, braced bench to walls, added laminated top and mounted bench vice. 3 1 3
29/07/2005 New 27mm socket arrived. Used it to remove final component from chassis - 'U' shaped rear gearbox carrier bracket. Chassis is now completely bare :-) 0.5 1 0.5
23/07/2005 Cut hammer-head off front of chassis with angle grinder. Removed shift rod from tunnel. Removed one rubber bush from rear off-side trailing arm - very difficult. 2 1 2
22/07/2005 New pipe wrench arrived. Finally removed off-side rear trailing arm!! Used lots of heat, penetrating oil, new pipe wrench and 600mm breaker bar on 17mm allen key socket. Took two of us 2 hours to free it up enough for it to come off. Removed off-side spring plate cover, spring plate and torsion bar. 2 2 4
21/07/2005 New rear torsion arm tool finally arrived :-) Removed near-side spring plate cover, spring plate and torsion bar using new tool. Really easy :-) 1 1 1
20/07/2005 Continued trying to remove off-side rear trailing arm. Cut away rubber bush so I could get a pipe wrench into the metal sleeve. Heated the whole thing up (filled garage and house with burning rubber smoke - nice!) and applied copious amounts of penetrating oil. Still couldn't stop sleeve turning. Broke the pipe wrench so had to give up! :-( 1 1 1
10/07/2005 Bought EMPI Hurst Shifter on eBay for GBP 36.00      
09/07/2005 Continued trying to remove off-side rear trailing arm. Removed near-side rear trailing arm; came off really easily. Figured out why off-side arm won't come off; metal sleeve inside rubber bush is seized to the pivot bolt so that the sleeve is rotating in the rubber, rather than the pivot bolt rotating in the sleeve. Put lots of penetrating oil on it and left it to soak. 2 1 2
03/07/2005 Began removing off-side rear trailing arm. Removed 3 x 19mm bolts holding trailing arm to spring plate. Withdrew central trailing arm pivot by about an inch but couldn't get it out - Extremely difficult! 2 1 2
02/07/2005 Visited British Volkswagen Festival to see Chad and Lee. Placed order for SWB Doon in Turquoise from the Standard colour range (after much debate about colours!) @ GBP 1395 + pair tail/brake lights @ GBP 35 + pair rear indicators @ GBP 35 + pair front indicators @ GBP 20 = Total of GBP 1485. Agreed to pay deposit of GBP 740 once Chad sends me bank details. Will agree additional cost for black flow-coat when Chad works it out. Lee will quote for chassis shortening next week (hopefully).      
16/06/2005 Visited VolksMagic to discuss chassis with Lee and to get him to quote for me. Ordered rear torsion arm tool from BigBoysToys.      
11/06/2005 Removed gear selector, hand brake, heater controls, gearbox, rear shocks, bump stops, rear wheels, rear drums, rear brakes and brake pipes, rear brake backing plates, hand brake cables. Lifted chassis onto trestles. 6 1 6
06/06/2005 Took all unwanted donor body parts to the scrappy in a van. 3 2 6
04/06/2005 Removed bitumen sound deadening material from front of tunnel, completed cutting off both floor pans and tidied/swept up. 1 1 1
03/06/2005 Booked transit van for Monday to dispose of all donor Beetle body parts.      
02/06/2005 Bought 600mm 1/2" drive breaker bar, both screw and 'pickle fork' type ball joint separators from 'JustOffBase' tools.      
26/05/2005 Removed bitumen sound deadening material from passenger's side floor pan. Cut 1/3 of passenger's side floor pan off (front part only). 1 1 1
24/05/2005 Removed bitumen sound deadening material from driver's side floor pan. Cut 2/3 of driver's side floor pan off (all except bit next to seat rail). 1 1 1
22/05/2005 Removed central brake line, front end brake lines, throttle cable, pedal assembly, clutch cable and master cylinder. Started to remove bitumen sound deadening material from rear of the tunnel. Put remaining drained petrol in Tina's car. 2 1 2
21/05/2005 Visited VolksMagic and Doon in Oldbury, West Midlands. Spent 2 or 3 hours there. Went for a ride in the Doon. Both Chad and Lee very helpful and friendly. Updated web site with photos of Doon and new layout.      
19/05/2005 Arranged to visit VolksMagic and Doon on Saturday.      
17/05/2005 Talked to VolksMagic about chassis shortening and Doon about their Buggy and the SVA test.      
16/05/2005 Joined Southern Dune Buggy Club.      
15/05/2005 Went to Bristol Volksfest. Joined the Southwest Buggy Club.      
14/05/2005 Bought 2 more plastic petrol cans. Put 2.5 gallons of drained petrol in Tina's car. Drained the rest of the petrol from the tank. Removed petrol tank. Removed steering column, front body, front suspension and steering box with tie rods. 5 2 10
13/05/2005 Removed petrol tank filler, fuel gauge sender, started to drain fuel tank from pipe at rear of car and found the location of the fuel tank outlet pipe at front of car :-) 1 1 1
10/05/2005 Removed speedo, wiper mechanism, disconnected steering column electrics, headlight switch, hazard lamp switch, removed all wiring and heater ducting from rear of dash. Removed petrol tank bolts but couldn't figure out where petrol pipe exits tank so couldn't remove it! 2 1 2
09/05/2005 Bought Gearbox Plug/A-Arm Tool, CV Joint Tool and 36mm Socket for wheel nuts from BigBoysToys.      
08/05/2005 Removed engine, rear body and heater channels (heater channels were completely shot to pieces and welded to the floor pan). 6 2 12
07/05/2005 Bought trolley jack, axle stands, Swarfega and penetrating spray oil. Removed front wings, running boards, rear wings, bonnet, engine lid, all windows, both doors, all interior trim, all seats (except drivers). Bought gloves, goggles and angle grinder cutting disks. Removed roof with angle grinder. Took a car load of bits to the dump. 6 2 12
06/06/2005 Removed front & rear bumpers, horn, headlights, indicators and started on front wings. 1.5 1 1.5
05/05/2005 Cleaned the crap out of the car, removed the carpets and bashed and poked it to assess its condition - very bad! Therefore, decided to strip it for the buggy immediately. 0.5 1 0.5
04/05/2005 Collected Beetle 1302S from Bracknell with trailer hired from Honeyfields in Bedminster, Bristol. First impression is that the car is really a bit too good to strip immediately as a buggy donor. I'll consider MOTing it and using it for a while.      
03/05/2005 Arranged hire of trailer for tomorrow.      
01/05/2005 Collected 1962 King/Link-pin front axle beam from Brixham.      
29/04/2005 Traveled to Southampton and Bracknell to look at two 1302S Beetles. Bought the one in Bracknell.      
28/04/2005 Bought 1962 King/Link-pin front axle beam on eBay.      
25/04/2005 Traveled to Worcester to look at a 1500 that was supposed to be a Semi-Auto but turned out not to be.      
- End -

Back to Rick's Buggy Project Home Page