Project "Doom-Buggy" Early '60's Buggy...

[ChiefRocka]

I posted this in General, and decided to start another build thread. Picked this up in Northern CA. (Auburn).

Quick story .... Been sitting out in a field since the 80's (and it shows)

Filed points, new wires, carb and fuel pump rebuild and the stock 1500 fires and ran like a top. Tranny stuck in 3rd gear due to lack of lube and rusty guts.

Last week pulled engine (set-aside) and pulled transaxle (Type 1 with BUS reductions boxes for extra lift.

Tonight, my kids (5 and 9) and I got busy and removed (snapped off) all the rust pan bolts and removed the 'in good shape' body.

The pan was shortened using the "extreme hack-job" method.

Here's some pics when I picked it up:
-
-
-

-

-
-
-

[ChiefRocka]

Also today, I scored a complete one owner rolling '68 chassis/pan. Complete with good tranny, split brake system, pedal assembly, shifter, e-brake, etc.

Currently licensed thru 2011, and has both license plates. $300, not too bad.

So, my buggy will be considered a "68"

Now, I can 'professionaly' shorten this pan, and slap it under my buggy.

I'm also gonna cut off the nose of the '68 pan, and weld on the older style to except the older link-pin front beam. (for more travel)

Myself and my 9 yr old son lifted the body off ... the pan started to lift before the gasket let go ... man this thing is waaay light....

Wish I has a built 2 liter for this, it would fly !!

Unfortunatley, this stock '67 1500 will have to do ...

More pics soon !!

[cdowns]

looks like a good start for a fun little progect// post update pics as you go

[Frizzle Fry]

That should be fun!

[nomrlz]

these things are like the ultimate summer parts runner.
would love a manx to go along side the wifes VW Thing

[ChiefRocka]

My kids and I started the disassembly this past Friday night.

After test-running the stock '67 1500, I pulled it and the seized tranny out about a week ago.


-
Notice the bus reduction boxes to gain extra lift in the rear:
-

-
I'm assuming to locate the boxes, the previous owner did this with the spring plate. I think the idea is ok, but the popcorn welding is terrible:
-

-

-
Reminds me of the 'ol lady ....
-

-
Manufacture ID ?
-

-

-

-
Next, with help of J-bird ... we begin the removal (snapping) of the rusty body to pan bolts ...
-

-
Didn't know how light these bodies actually were ... although still needed some assistance:
-

-

[ChiefRocka]

-

-

-
Safely on ground ...
-

-
Next step is pan disassembly ...
-

-
J-bird, started on the front beam, We are going to save this older, link-pin beam, to replace the one coming on the replacement pan ...
-

-
My little girl gets into it too ...
-

-
"Can I cut something Daddy ?"
-

[ChiefRocka]

Here's some pics of the reasons why I'm replacing this pan, besides the rust...

Hack jobs ... torched steel, then ghetto welded ....
-
-

-

-

-
No, this isn't the accumulation of dirt ... these are welds !!
-

-
-

[ChiefRocka]

Yesterday ... while the wife ran the office, the kids and I drove to Oakland to a VW dismantler to pick up the nice, one-owner '68 pan ... complete with original '68 pink-slip, and both license plates ... Registered 2011 !! (Oh ya ... and a FUNCTIONING TRANNY !!!)
-
Located in a back industrial area, "ghetto" doesn't even come close ... Chris informed me "Do not let your kids pick up anything off the ground !!" I guess this is where all the crack-heads and paint huffers hang out ....
-
Anyway ... Loaded up and ready to go ...
-

-
Looks like he's ready...
-

-
Once home, we pulled it around back...."See honey, told you that mini-tractor would come in handy !" (she still gives me crap about that CL purchase)
-

-

-
Old pan outside:
-

-
Here's the '68 BallJoint front beam. Although, the BJ's were an improvement over the king/link pins....they lack in travel. Whether you want a slammed Bug, or a lifted off-road rig...the link-pins just swing up and down with no "maxing out". The front nose of the pan will have to be re-worked to except the earlier beam. The later tubes are spread farther than those of the earlier beam.
-

-

-
Now the fun begins...Removal of the sound-deadening tar glued to the pan. My son got a taste of this, just like I did some 25 yrs ago, when I did my first 'body-off' resto on a '58 Bug...I was like 14 or 15, man what a nitemare that was !!
-

-

-
It was getting late, but I managed to get in a quick pressure wash of the pan...
-

-

-
-

[ChiefRocka]

While in the ghetto, I also picked up a few other things I needed for the buggy.
-
First off is a cool, early-style (62') SpeedO and mechanical fuel guage. My buggy was lacking a dash-board, so some aluminum plate will take care of that.
-

-

-
Next, the fuel tank was half filled with a mixture of dirt and rust (??) It weighed about 25 lbs !! So a replacement was needed. This is the flat, 'inside-fill' style:
-

-

-
The buggy had wiper hole bossed modeled into the hood ... so a 12v wiper assembly was picked up:
-

-
In addition, I picked up two seat bottoms (tracks) ... and a hi-low beam switch. The one in the buggy fell apart into dust (Literally !!!)
-
It's Sunday now....'family day' so we are heading to Monterey to hang out at the beach, back soon !!
-
-

[wild one]

Very cool on many levels John, I sure hope I'm as lucky getting my two kids interested in "playing" with cars! Subscribed for sure - can't wait to see how this one turns out.

[ChiefRocka]

Originally Posted by wild one

Very cool on many levels John, I sure hope I'm as lucky getting my two kids interested in "playing" with cars! Subscribed for sure - can't wait to see how this one turns out.

Thanks brutha ... I always thought these buggys and the 'Things' were hella cool ...

I always wanted a slammed buggy or Thing, but this thing is gonna be built for the dunes, and around town summer driving.

Hopefully it gets done before the summer is over ... then again, did we even get a summer ??

As far as the kids go ... this was like the 1st weekend they got into this stuff. I am also building a treehouse for the kids, and after nailing one board, my son was like "can we go work on the buggy now?"

Hopefully it sticks !

[nuke1]

Cool, a guy at work is big into these buggies, has one restored and working on a second right now. Great little project

[ChiefRocka]

A few updates ... We got the pan stripped of it's front and rear suspension:
-
-

-
Link-pin set aside for now:
-

-

-
Getting ready to cut and shorten the pan ... First think it to remove the shift rod:
-

-
The clutch and throttle cable tubes must be measured for length/positions for future reinstall:
-

-

-

-
Then the rear cover is removed to gain access to the tube welds ... this will be reinstalled later ...
-

-

-
Located at the rear of the chassis, at the frame horns, the rear exit heater tubes are cut flush with the chassis, then later will be pulled out from the front ....
-

[ChiefRocka]

Before I continue on the chassis, I need to build a 'sliding' jig out of some 2" tubing. This will keep the chassis square, while I remove the 15.5", then allow me to slide it together, while keeping everything in check.

I could easily just cut, and lay on the ground, but I want it perfect !!

So, untill the steel can be purchased ... we moved on to some sanding.

I told my kids, if we work on it a little everyday, even for a few minutes ... It'll get done quick ....
-

-

-

[ChiefRocka]

BTW, the ice cold Heinekin is mine

Again, glad my kids are taking a liking to this project !!

Obviously we had the original yellow jell-coat, then cheap primer and red paint.

The paint blistered really bad, not sure if that was from a cheaper primer, or bad prep ??

Anyway .... back on it soon !!

[LEEVON]

That's gonna be fun. 67cheby here on the forum just finished one too, it came out real nice.

[FRENCHBLUE72]

Cant wait to see this buggy done and am so glad to see the kids getting involved..

[ChiefRocka]

Originally Posted by FRENCHBLUE72

Cant wait to see this buggy done and am so glad to see the kids getting involved..

Thanks man, I am too !!

I'm almost finished the LTD Hydro job at the shop (other thread) .... Then I can bring my welder home and get that pan shortened, and everything mocked up again.

Gonna be fun .... We just got hit with some HEAT ... wish it was done already.

Would be cool to cruise over to the 'Freeze' and get some ice-cream !!!

[ETsC10]

Chief, that's Really Neat!
When you and the kids get the bugger on the road,
you’re going to have sooo much fun!!

My friend Joe has one he calls his Doom Buggy too…
And I think the same painter worked on both yours and his
…here’s Joe and Dexter tootling around…



John, I had no idea this thread was even here!
Cool, cool, cool! Looks like you're doing great work
and you'll have a nifty ride when you're done!
Subscribed.

[ChiefRocka]

Thanks my man ....

Comments like these are what keep the projects going !!!!

Should be fun !!!

[fryer1979]

Cool little project you got there Chief. Being on the edge of the high desert up here, those things are pretty popular around my little town. They are a blast to drive. Enjoy

[joe231]

very cool!
the wife wants a buggy bad!
we got too much crap to do first though

[ChiefRocka]

Originally Posted by fryer1979

Cool little project you got there Chief. Being on the edge of the high desert up here, those things are pretty popular around my little town. They are a blast to drive. Enjoy

Thanks man ... should be fun !!

Originally Posted by joe231

very cool!
the wife wants a buggy bad!
we got too much crap to do first though

I had too much crap to add this one too ... the list keeps growing !!

As soon as the LTD hydro job is done, I can haul my welding gear home and start on the chassis shortening !!!

Thinking about the 'roller paint' for the buggy !

[ChiefRocka]

Not too much to update ... now that my son is back in school, he seems to have lost interest in sanding, get home tired with homework to do...

(Son, you dont even know tired !!!)

I tried to bribe him with $5 an hour .... then a few weeks later $10 an hour, still nothing !!

MAN.... What 9 yr old kid wouldn't want to use a power-sander for $10 an hour ?!?!?!?

Anyway, I pulled it outside, set it on some saw-horses and started on it 40 girt to get to the jel-coat, then I will go ove it again with finer paper before I start filling in some holes :
-
-
I started on the floor, but back starting hurting, so I decided I needed a more comfortable working height ... so off I went to purchase some cheap saw horses...
-

-

-
After sanding, I found some minor previous repairs, and other areas that need attention...
-

-

-

-

-
-
I chose to buy these cheap make-ur-own saw-horse deals ... they claim to use 1 1/2" x 3 1/2" pieces of lumber ... 2x4's .... .....
-

-
..... I had to bent the s#it out of them to get the 2x4 to pound into them .... Must be made for 'china' 2 by's !!!!