Page 1 of 8

The bug project...

Posted: Wed Apr 25, 2007 1:29 pm
by Merlin
's up all?

Seeing as how the first batch of my parts arrived at my mate in the US today, I've decided it's a good time to start a thread about my slowly-progressing bug project...

I'll keep it up to date with info, pics, and plans as it moves along.

What's been done so far...

We've got my German-import (LHD) '67 sunroof bug, which has had it's 1600 replacement engine sold.

I purchased a rather rare '68-only US-only double-springplate IRS bug earlier this year, for much more money than what it was worth.

This bug will soon appear on your table as cutlery...

The IRS is being meshed into the b/j front-end.

The badly-cracked pan and papers were donated to a friend as future payment, and the suspension is stashed at his place.

By the way, you can buy some of the parts from this bug. ;) Offered :mrgreen:

A new engine has been put into the works, and after having the block heat-painted, it wil be built.

1796cc 76mm Stroker crank, 1mm cut, balanced, Pertronix electronic ignition, etc.

To this I'm adding new custom cal-look tinware, with upgraded fan and oil cooler, twin 40mm Kadron carbs, detailed intake manifolds, custom fittings, all detailed, with Ti retainers, and super tin.

The gearbox, a custom Brazilia 'box, will be getting a custom ratio 4th gear, which will be welded to 3rd. Hardened keys will be used, a super-diff fitted, and billet side plates fitted. It will then be detailed.

Synthetic oil will be used, as before, in case you're curious. Runs better. :)

New CV joints, with uprated 22mm driveshafts will be fitted.

All nuts and bolts will be changed to hex-nut, and will either be s/steel or Cadmium plated - decision to be made.

The pan will be cleaned up, rust-proofed, and sprayed with a protective matt paint - black.

Urethane reinforced bushes will be used throughout, and CB Rhino mounts used for the tranny, steering coupler, and IRS arms.

Porsche IRS arms and possibly 944 discs are pending, which will replace the current 4-disc system.

4-stud will be changed to 5-stud.

The front beam retains it's stock length, and uses two Avis adjusters. The rear will again drop 1 spline.

Gas shocks, and dampener are being fitted.

3/4 sway bars with uprated clamps front and back.

CSP Torque bar and engine brace are being fitted.

That's the story in short. :)

I'm overbuilding my bug so that down the line, I can fit an uprated engine without worry. This is going to be my toy, so I want it perfect.

Most of this kit is on it's way, the rest is being organized. :)

Cheers, N.

Posted: Wed Apr 25, 2007 1:40 pm
by Blitzkrieg
what a sweet project!I'm especially interested in your IRS..so when you busy doing the Porsche suspension thing, please snap a few pictures....
and what is a brazilia gearbox?

Posted: Wed Apr 25, 2007 2:12 pm
by Merlin
Will do. :)

A Brazilia was a F'ugly sedan-type vehicle built in Brazil.

It's a confusing term, because the Brazilians know it as that, while the US/EU get a bit confused.

In ZA, we had a one-year-only hybrid sold in '76.

This WE called the Brazilia. It was a Fleetline arse mated with a Bay' nose...and yes, it was really F'ugly.

My bug will be using a ZA Brazilia 'box with some nice existing custom engineering. :)

I'll take pics for all and sundry soon.

N.

Posted: Thu Apr 26, 2007 12:26 pm
by Blitzkrieg
can't wait for the pics............

Posted: Thu Apr 26, 2007 7:33 pm
by IMPI
Overbuilding Merlin?
Brazilia boxes as you call them had an od Diff using a crownwheel from a passat half the size of the beetle diff.....
Other than that I like

Posted: Thu Apr 26, 2007 8:55 pm
by Merlin
Hey Impi,

My idea is to build a very strong chassis-setup, with the idea of chucking in a larger engine down the line when I can afford it.

A lot of the kit, and mods I'm doing are quite in excess of what's needed for the current setup, hence overbuilding. :)

When I purchased my IRS donor, we had no idea it was not the stock 'box. It was confirmed by my builder.

It's had some very nice mods engineered on it, but I don't quite understand the tech...my mate's explained it twice. I'll ask him to do it again - and take pics for you. :D

He confirmed that I could still fit my new CV joints as usual, etc.

I've ordered a super-diff for the 'box, and will chat to you on TUE about it. Your input would be greatly valued.

If I have issues with the 'box, I'll have to, somehow, somewhere, source a different box. :|

Cheers, N. :)

Posted: Fri Apr 27, 2007 6:32 am
by Watercool
I can always slip one of my 901 Porsche 5 speed boxes in the shipment for you :)

Posted: Fri Apr 27, 2007 8:07 am
by Merlin
Hehe Henry,

I *may* have found one here...waiting for confirmation.

...and the way I'm sitting now, I'm not quite sure how I'm going to be able to eat soon :mrgreen:

We'll talk. :D

N. ;)

Posted: Tue May 15, 2007 9:45 am
by Merlin
Weeeeeeeeeee!

The first two sets of parts for my toy have arrived in the US...due to be shipped here soon. :D
Dog House Kit (Black) - No Air Ducts
Dual Port Cylinder Covers - Black (1 set)
Super Tin - Black (set of 2)
Total Cal-Look Model - Black
Engine Breast Plate - Black
Turbo Fan Mount
IRS Super Diff 1969
3rd and 4th Gear Keys - Hardened
IRS - Super Duty Side Cover, fits '69-later
Transmission Gasket Set, T-1 '61-'79 - Also fits T-2 '61-'67 & T-3 '64-'73
RHINO Engine Mount Kit, Complete - front & rear (3 pieces)
Heavy Duty Engine Mount - T-1 IRS 69-on (chrome)
Caster Shims
Rhino Steering Box Coupler
3/4" VW Sedan & Karmann Ghia
3/4" VW Sedan, Lowered - Ball Joint Front '66-later
Front Sway Bar Clamp Kit - 66-on
Steering Dampener - Sedan
IRS Urethane Control Arm Bushings with Steel Sleeve
Weld On IRS Control Arm Brackets
NEW DRIVE AXLE WITH C.V. JOINTS, TYPE 1 1969-1979 2
AC413110 AXLE BEAM BUSHINGS, URETHANE FOR BALL JOINT FRONT ENDS, SET 4 1
AC510001 REAR SPRING PLATE GROMMETS KNOBBY 1 7/8 ID, PAIR 1
AC510002 REAR SPRING PLATE GROMMETS ROUND 1 7/8 ID, PAIR
Some of the stuff...

Image

Image

Image

Image

Rather chuffed I am.

One more order from the US soon, a part from CT, and then the actual work starts...

N.

Posted: Tue May 15, 2007 11:00 am
by Blitzkrieg
YOU LUCKY PUPPY!!!

Posted: Tue May 15, 2007 11:22 am
by Merlin
Poor puppy. ;)

Posted: Tue May 15, 2007 12:14 pm
by Blitzkrieg
It goes with the territory Merlin, don't despair...

Posted: Tue May 15, 2007 12:54 pm
by Tony Z
Toys toys toys
can I also play???

Posted: Tue May 15, 2007 1:28 pm
by Merlin
Get y' freekin' own! :mrgreen:

Posted: Thu May 17, 2007 10:06 am
by flatfourfan
I was about to start bitching with the no posting of pictures...............good save nic.