Cut-Weld-Drive Forums

Cut-Weld-Drive Forums (
-   The Cutting Board (
-   -   Fernons Chop (

jkien65 April 22nd, 2008 10:00 AM

Fernons Chop

I posted this here because I wanted to comment.
I just read this guys project thread. That chop looks relatively "easy", for lack of a better word. Much simpler that some of the others I have seen done.

I also had a couple of questions. The blue lines drawn from the quarter windows to down between the decklid and rear wheel well, was that material cut ou and the roof just layed down to take up that gap? And did you have to lean the windshield back to make up for the roof gap? This looked like a nice way to chop the top with out alot of patch panels and filler.

Rumblewagen April 22nd, 2008 10:11 AM

Re: Fernons Chop
Hmm, I like the way that looks. He may have to clearance the engine lid for the alternator but I kinda think thats cool looking too.

Props to Fernon :thumbsup:

V8SuperBeetle April 22nd, 2008 10:14 AM

Re: Fernons Chop
Just finished reading it as well and it does seem a simple way to go. Nice work!

fernon April 22nd, 2008 12:08 PM

Re: Fernons Chop
First off, thank you for the comments, I was actually going to post on the cutting board to get some feedback. I know, I know, everyone has an opinion and opinions are like assholes, everyone has one - but without assholes we would all be full of shit, so with that said lets start answering some questions.

The first question that I would like to answer is "what's this we shit kemo sabe" lets face it I am just a glorified designer with a vision and a VW my Brother-in-Law is the Evil Metal Genius behind the cuts.

The two blue lines that are on the back half of the car are guide lines for the chop, we decided that it would be easier to cut the roof only once and make all other cuts on the body since it is a little more stable. The bottom blue line is approxametly where we wanted to end up.

The main thing that we wanted to do is to chop a bug with the least amount of cuts to retain the original shape and not have a huge wedge to it. The entire roof was moved forward 2" to meet with the A-pillers and then they were both cut and leaned in to the roof thus eliminating the need to lean the windshield back. The roof top actually sets inside the body in the rear that is why we had to cut the rear fender wells to shape the body back in to the roof line.

I will post more photos of the chop and more explanations of what we did, I will try to upload the photos and info as soon as possible. - Funny it seems to take longer explaining how to chop it than actually chopping it.

Again thanks for the feedback and don't hesitate to ask a question that is what this forum is for.

Remember there are no Stupid Questions... only Stupid Answers...

lehmikangas April 22nd, 2008 12:37 PM

Re: Fernons Chop
That is pretty much the way I was once going to do it, but never got to it. I even draw the lines already, but then got into another project.

There are a few good articles on, like this Cappella chop

Unkl Ian April 22nd, 2008 12:43 PM

Re: Fernons Chop
Good looking car.

jkien65 April 22nd, 2008 12:51 PM

Re: Fernons Chop
Does anyone think it would be super difficult to weld in an Oval clip doing this sort of chop? I have one lined up for a really good price, but if its to difficult, I might just skip it. Ah, who am I kidding. I never shy away from hard work. And i figure for my first chop, this way might not be to bad.

fernon April 22nd, 2008 02:03 PM

Re: Fernons Chop
Yes, it is imposible to do an oval insert on this kind of chop that is why you should abandon the idea and sell me the oval clip. (LOL)

OK, actuallty the main benefit to doing this kind of chop is that the back glass is untouched therefore letting you actually use glass for the back instead of Plexi, also by using an earlier beetle the front glass is flat so you can easily get glass cut for the windshield, along with the sides.

Eventually the final build will have either an oval or a split section grafted to the rear section of the car, basically you can cut it from drip rail to drip rail and drop it in since the entire roof has not been altered a nice rear clip would just fall into place, the hard part is finding one.

bugdust April 22nd, 2008 02:47 PM

Re: Fernons Chop
I must be becoming a purist...time to ditch this place I guess. What a waste...and with a perfectly good late model to cut up sitting right there. Let's see, a faded hot pink 72 that escaped from the late 80s-early 90s or a nice rust-free 62 body...which one do I hack up?:Idunno: And then, to do a Capella chop!:ohmy:

Fab work looks good though.:thumbsup:

1slo3 April 22nd, 2008 02:49 PM

Re: Fernons Chop
so i shouldn't cut on my 343 then? dang (insert 'snaps fingers' smiley here)... at least it is a very nice done chop! i love it when folks get the windows right! :thumbsup:

jkien65 April 22nd, 2008 03:21 PM

Re: Fernons Chop

Originally Posted by bugdust (Post 309737)
I must be becoming a purist...time to ditch this place I guess. What a waste...and with a perfectly good late model to cut up sitting right there. Let's see, a faded hot pink 72 that escaped from the late 80s-early 90s or a nice rust-free 62 body...which one do I hack up?:Idunno: And then, to do a Capella chop!:ohmy:

Fab work looks good though.:thumbsup:

Whats wrong with a capella chop? I am thinking of doing one, but altering it some.

kyle242gt April 22nd, 2008 03:38 PM

Re: Fernons Chop
Well, the capella chop (how's it get that name, anyway?) gives a wedge look, where a cut and paste and cut and paste can have any profile you like. "Traditional" chops give a flatroof look similar to big US sedans from the 40's.

jkien65 April 22nd, 2008 03:47 PM

Re: Fernons Chop
Hmm, I dont see the big bubble butt on Fernons. I think it looks pretty good, enough to emulate it anyways. I think its a good starting point anyways. I would probably extend and widen the roof to fit the pillars.

kyle242gt April 22nd, 2008 03:54 PM

Re: Fernons Chop
- hence the edit - bubble butt was a little pejorative, apologies all 'round - changed to "wedge".
Here's an example:
See how the tops of the doors are nearly flat, and the effective height of the door and quarter glass is the same?

I agree that the Fernon Chop looks great - not trying to be negative, just throw out a possible explanation for a preference one way or the other.

jkien65 April 22nd, 2008 04:22 PM

Re: Fernons Chop
I get it. I think it might be a good idea for a first time chop. "appears" to be minimal cut and fill doing it this way.

I do like the looks of that split. I just dont know if I have the skills yet to take on a chop like that and graft in an oval clip. An oval clip is a must in my opinion, like it alot better than the big back window.

Unkl Ian April 22nd, 2008 05:11 PM

Re: Fernons Chop
It's just metal.

Like Walt says: You just have to be smarter than a roof.

jkien65 April 22nd, 2008 05:26 PM

Re: Fernons Chop
Thats a good attitude to have, but i have ZERO skills in metal work. But I am gonna take it on soon.

volksmike April 22nd, 2008 08:01 PM

Re: Fernons Chop
would it be rude to say I have an oval clip and a rag top section waiting for my next un-suspecting early model?:sawzall:

jkien65 April 22nd, 2008 08:12 PM

Re: Fernons Chop
Hehe, Rude? Yes. J/k man. Good for you, i need a rag section for my VR. I have the oval clip lined up already.

Hebster52 April 22nd, 2008 10:30 PM

Re: Fernons Chop
Well done! The cuts and welds look very clean and made with afterthought too! :sawzall:

I dont see why grafting an ovalclip would be any more difficult in that than in any other chop?

bustedknuckles April 23rd, 2008 01:08 AM

Re: Fernons Chop
Damn that looks good.

fishguts April 23rd, 2008 04:14 AM

Re: Fernons Chop
I've always liked capella chops and have been tempted to do one, just don't care for the fact that the decklid no longer fits and requires stand-offs. Is there a way to rectify this? Is the problem that lid hits the alternator or that the lid mounting surface as been distorted? Also, what happens to the roll-up windows when the pillars are leaned in? Do they still work?

Hebster52 April 23rd, 2008 04:31 AM

Re: Fernons Chop
Wasn't Bulldog's choptop a Capella chop?:Idunno:

kyle242gt April 23rd, 2008 08:15 AM

Re: Fernons Chop

Originally Posted by fishguts (Post 309897)
I've always liked capella chops and have been tempted to do one, just don't care for the fact that the decklid no longer fits and requires stand-offs.

Originally Posted by Hebster52 (Post 309900)
Wasn't Bulldog's choptop a Capella chop?:Idunno:
yep - and you can see the drama there. Thanks for the heads-up on that, Fishguts - I'd forgotten.

tiz April 23rd, 2008 09:38 AM

Re: Fernons Chop

Originally Posted by fishguts (Post 309897)
just don't care for the fact that the decklid no longer fits and requires stand-offs. Is there a way to rectify this?

my buddy and i did a capella style chop on his ride,we took the whole luggage area out with the roof,the deck lid still fits but he might have to clearance the alternator pully because he`s raised
the tranny 2inches.have a look through his build thread and you`ll
see what i mean.

capella style chop

BullDog April 23rd, 2008 03:20 PM

Re: Fernons Chop
no mines not a capella... but the same issue laying down the oval clip.

fernon May 26th, 2008 07:57 PM

Re: Fernons Chop
This is probably redundent

You can read more about the chop in the Members Intro Page.

So I finally got a hood for the ride and started to strip it down, the car already looks a thousand times better with the hood.

Then the task of stripping down the Fat Chick, or as it has been kindly referred to lately as The Onion (with every layer that has been taken off this Piece of Shit car it brings a tear to your eye)

The only reason I bought the car to begin with was for the engine, it runs strong and is a great starting point for the volksrod.

Lifting the old body off the frame.

And now the moment we have all been waiting for, the placing of the 1962 chopped body on the 1972 IRS Pan.

The body fits like a glove, no clearance issues with the motor or deck lid like everyone said there would be, the only thing that I am concerned with at this point is lowering the front end, I know that the Tinbeater front end lowers another 2" but I need another 6" and I already have 2-1/2" dropped spindles, We'll figure something out, we always do.

OK, back to work, with the body off we can start to see how bad the pans really are. Fuck It, new pans and heater channels, I'm not going to spend my life chasing rust, new metal is far more cheaper than my time.

Another layer to The Onion, the tunnel is fucking trashed, time to start fabbing a new one.

Now I just need to cut the other side and drop the new pan in and then I can start cutting up more metal on The Onion.

So its the last day of the three day weekend and I have to say my neighbors probably wish I was dead, between the grinding of the metal, drilling out what seemed like a thousand spot welds and the air hammer ripping up the metal to take out the old pans it has been nonstop all weekend long, but we have new metal in the bottom half of the car and what a difference it makes.

Here is some of the fab work that was done to the fucked up tunnel. Better than the original, my brother-in-law can weld like a MOFO but I am a crazy grindin' son-of-a-bitch, after the bodywork you will never be able to tell. (sorry bug guys no JB Weld or Foam Fill in this car).

It was very easy to put the pans in with the heater channels so that you can line everything up, then after they are welded in you unbolt the heater channels and set the body on, then replace the heater channels on the car one side at a time, I will have photos of that for you to see when we start doing that.

Make sure you use the original spine in the back if you can, it is stronger than the aftermarket pans and it helps lining up the pans, just drill out the spot welds and separate the spine.

One side in, now it's time to fix the other.

More fab work to the other side. (The Evil Metal Genius loves it when I photograph him - NOT!!!)

So here is a recap of this weekend, we stripped the Fat Chick, finally took the cancer ridden body off, replaced the floor pans, did some fab work to the tunnel, sat the new body on, stood back for a moment and said OOOOH - AAAAH then lit off some fire works (maybe we got that backwards???), cut the back shock tower mounts (remember this is a 1962 body going on a 1972 IRS pan), did a bunch of cursing and calculations and made a plan for our next long weekend. Not bad for three days!!!

bugdust May 26th, 2008 08:01 PM

Re: Fernons Chop
Looks like some good progress!:thumbsup:

fernon May 26th, 2008 08:08 PM

Re: Fernons Chop
Thanks, you have been officially taken off my People to Kill Today List, by the way if you want the fat chick body (comment from a previous post) it's all yours, but you can see from the pictures why I did not use the 72 body, with every bolt that came out of that car at least 5 lbs. of rust followed.

bugdust May 26th, 2008 08:17 PM

Re: Fernons Chop

Originally Posted by fernon (Post 317223)
Thanks, you have been officially taken off my People to Kill Today List, .

Whew!! I have been really sweating that!:panic:

No, somedays I must be on the rag...if I come across as an asshole it is only because I am.:hmm:
I'm still not a fan of Capella chops but I am a fan of good craftsmanship.:thumbsup:

fernon May 26th, 2008 08:27 PM

Re: Fernons Chop
Actually it is a variation of a Capella Chop, I agree I am not a big fan of that style chop either, I have only seen it look good once or twice and I didn't want that wedge look to the roof line either. We decided to modify and mainly guess on how we wanted things to line up and work, I have been getting flooded with PM's on measurements and the only thing I can tell people is the initial measurement we made but we must have trimed it a thousand times before we got the look that we wanted. Oh, and as far as being an asshole don't worry, because without assholes we would all be full of SHIT!!!

66 Shorty May 27th, 2008 04:36 AM

Re: Fernons Chop
Sweet work Man!:bow: You guys got alot accomplishied! :clapping:

fernon July 7th, 2008 08:34 AM

Re: Fernons Chop
Time to Turn Up The Heat-er Channels

So we decided to tackle the heater channels over the three day weekend, thus putting all the structure back into the car so that we can proceed with working on the doors. The first line of business was to remove the old channels, we decided it would be best to bolt what was left of the old channels to the new pans so that everything was lined up and then brace the inner doors so that the body wouldn't tweek when we cut the channels off. Working one side at a time we proceeded to cut the heater channels off.

Since this car is in South Florida and it always feels like the surface of the sun here we decided to cover all the holes in the channels since they look like shit and if you want heat roll down a window.

Now that the DOG DICKS are cut off we can start to fab in the holes.

Yes he does have all of his fingers - he's just shooting a semi-bird.

All tacked in and ready for Grind Master Flash.

A little skim coat and you will never tell it was there.

All welded up and ready to be put back in the car. There are a shitload of holes and strange angles to be welded on these heater channels.

Cutting the inner fender well to replace more metal.

Checking the fit. Yes we are going for a Darwin Award setting the front of the body on the bar stool, that's OK the Pepsi can is keeping it from falling.

Just need to clean up the welds and it will be all done. Notice no holes.

Next thing to do is cut out the heat tubes and close up that hole.

We also shaved the drip rails around the front of the door. Hmmmm I wonder if that means we are putting suicide doors on???

J_J_ July 7th, 2008 09:54 AM

Re: Fernons Chop
Love it!, Looks Damned Good! thats what I started doing then changed half way through after decidint it was more work to fix the rolled over roof than go sections didnt realize before cutting into it how bad it really was so now it's 65/66 roof with a 71 super skin.. it works but gonna have decklid issues as well.. oh well..

HeidelbergJohn4.0 July 7th, 2008 06:57 PM

Re: Fernons Chop
Have you worked out the window frames on the doors yet? O know the fronts have to be canted in to match the roof. I've looked at that style chop and always worry the door windows won't roll properly. A small vent window may help out, but that's a hell of a job itself.

fernon July 7th, 2008 07:09 PM

Re: Fernons Chop
Actually we have an alternative for the windows on the door but we are keeping it under wraps until we actually do it. All I can say is that it is going to make everyone's head hurt just thinking about what we did when they actually see the final door window setup...

fernon July 16th, 2008 09:55 AM

Re: Fernons Chop
More of the Same

Back to work on the passengers side heater channel, after replacing the heater channel we decided to replace all of the lower metal on that side as well.

Another nice big hole to fill - the bottom end on this car is being replaced with all new metal- no more rust.

OK - I have to rant a little, it is amazing what we have found on both of these cars since we have been working on making the Volksrod.

We have come to the conclusion that most people are FUCKING RETARDED when it comes to repairing cars, the fundamental fact thatif you are not going to do it right don't do it at all just does not seem to register with most of these people, we have pulled more shit out of these cars and have seen some pretty fucked up ways to make repairs than we thought humanly possible.

Don't get me wrong I think JB Weld and Great Stuff have there place in the world and are great products but you can't build an entire fucking car out of that shit.

Here is an example of what I am talking about, these are the hinges to the doors, notice the nuts JB Welded to the plate (Priceless)...

Sorry... I had to vent. OK back to the build, the back panel has been cut out to be replaced.

This is what was cut out. More rust...

OK - so I was moving the shop vac around to vacuum up some of the mess that we were making and I noticed it was kind of hard to move around so I decided to open it up and look inside, well there was about 23 lbs of rust and metal that we had been vacuuming up since we started this project.

I thought about putting it in little bottles and selling it to the Samba Douchbags as Original 1962 Patina but I know some purist over there probably would have bought it and I would have to tell them to
"Stop punching me in the dick with their mouth".

walt July 16th, 2008 10:59 AM

Re: Fernons Chop
Rather than to repair / replace all of those lower panels you could have just sectioned about 7" out of the bottom of it.

Just something to keep in mind for the future.

fernon July 16th, 2008 11:04 AM

Re: Fernons Chop
The thought crossed our mind several times to section the car, unfortunately we thought about it after we started, you know the old saying...
"Hindsight 20/20"
O'well next time...

Jon July 16th, 2008 08:19 PM

Re: Fernons Chop
Car looks great.

Would it be possible to see some pics of the firewall inside and out ?

Texasbuggys July 16th, 2008 08:20 PM

Re: Fernons Chop
Looking good, man rust suxz!

bmph8ter July 16th, 2008 09:19 PM

Re: Fernons Chop
Damn you guys do good work; keep it up!

J_J_ July 17th, 2008 11:52 AM

Re: Fernons Chop

Originally Posted by walt (Post 330342)
Rather than to repair / replace all of those lower panels you could have just sectioned about 7" out of the bottom of it.

Just something to keep in mind for the future.

I like the way Walt thinks!!:grin:

fernon July 18th, 2008 07:14 PM

Re: Fernons Chop
Jon - Here are the firewall shots

We haven't really worked too much on the inside yet and we are not sure of how we are going to finish off the firewall and package tray area yet (I really like what Bulldog did with the curved sheet cover - although I really like what bulldog has done with everything on that car) but I am playing around with some Teak and Stainless finish too...

Someone also asked if a 5" Monster Tach would fit in the speedo opening - YES!!!

We are still not sure what we are doing with the dash yet???

volksmike July 25th, 2008 10:58 AM

Re: Fernons Chop
"Yes we are going for a Darwin Award setting the front of the body on the bar stool"

So long as that stool didn't come from Harbor Freight, you'll be fine...

Jon July 25th, 2008 02:27 PM

Re: Fernons Chop
Out of curiosity, How much was taken out of the firewall ?
This has gotten me re thinking my plans.

fernon July 25th, 2008 07:51 PM

Re: Fernons Chop
Firewall Follies

Jon, there is really no simple answer to that question, but I will try to do my best to explain what we did.

First we cut the firewall about 2" from the top of the lip that rolls over on the firewall. You can also see where the roof will sit inside the openings that were created from removing the roof.

Here you can see the blue line and the many question marks on the side of the car. This is approximately where we wanted to end up when we where done.
(Major note here, in order to avoid the wedge look of a typical Capella Chop you need to trim and adjust, roll it outside and look at it from all angles, then trim and adjust then... well you get the picture)
We took approximately 2" out of the back end and moved the roof forward about 2" to meet up with the initial 4" taken out of the A Pillars. Remember the only measurement that never changes is the A Pillar cut everything else is trimed to fit the look that you are going for.

Here you can see after everything is cut and put where it needs to be the back end begins to take shape

Here you can see that the firewall (A) actually sits in front of the window deck (B) even after the entire roof was moved forward 2" (Try and figure that out!!!) actually since the roof has been cantered and the roof also sits inside the body it actually winds up behind the firewall, thus making it easy to fab up an enclosure for the back end.

I hope that this explanation helped you and everyone that reads this, but more than likely it just raised more questions. Hell everytime we figure one thing out, something else happens and we start all over again, that's what we are all here for.
(Cut, Weld, Ask a Shitload of Questions, Drive)

Jon July 25th, 2008 10:05 PM

Re: Fernons Chop
Makes perfect sense to me. I had already gathered the roof fitting into the firewall like it did. I was just missing that all important 2" part of the equation. I would expect there to be a cut, trim, adjust, cut trim and adjust again....... method to this kinda chop and would have no problem doing so.

My plan originally was to either do the Capella style tilt but not cut the firewall loose or just cut it out go for it and then piece it back in afterwards in one trimmed piece.

I like the look and proportions to this one, and was half thinking that maybe tacking the decklid in place while doing this might help get the look right if I were to vary more or then you did on your chop. But genrally on a early body 4" seems to be the magic number.

Anyway, thanks for the great responses and quick, complete, detailed answers.

redfinger August 4th, 2008 09:57 AM

Re: Fernons Chop
I know this might be kinda late, but you can put an oval clip on a cappella chop

I know about making the mods to get the decklid ot fit, but that is alll part of the plan on mine. BTW, great looking build.


fernon August 4th, 2008 10:11 AM

Re: Fernons Chop
Yes, you can put an oval clip on this kind of chop, that is one of the reasons we went this way because the roof line was untouched/unmolested an oval clip will fit right in, and as soon as I get one, I intend to do just that.

V8SuperBeetle August 4th, 2008 01:58 PM

Re: Fernons Chop
Amazing work BTW! Looking good!

fernon December 30th, 2008 06:58 PM

Re: Fernons Chop
How I Spent My Summer Vacation

I know it's been a while but I have been a little busy since my last update. Let's see on 08/08/08 I was in the process of taking my family to The Most Happiest Place On Earth - Disney World. We decided to get an early start to the day so that we could avoid all the morning traffic, unfortunately fate had other plans for us, we were less than a mile from the house and everything was going great the wife was happy and my son was excited that we were going to spend a whole week in Orlando, nothing could go wrong or so we thought, but in a blink of an eye everything changed.

I am still not sure what happened me and my wife have gone over it a thousand times and we still are not sure what happened, there wasnít a car in front of us as far as the eye could see, I turned to look at the truck next to us for a second and the next thing I knew there was a car stopped in front of us, needles to say I didnít even have time to hit the breaks, I slammed into the back of the car in front of us and that car was then pushed into the car in front of it. When I got out of the car, the car in front of the one I hit had taken off, more than likely they cut off the person in front of us and slammed on the breaks (Haitians do this in South Florida all the time so they can sue you) but when they realized they caused an accident they took off.

Our airbags went off and the car filled with smoke from the propellant, my son was hysterical not from the accident but from the thought that he was not going to Disney World, fortunately he was fine not a scratch on him, my wife on the other hand was not as lucky it seems that she took the brunt of the crash fortunately she only suffered from a sprained ankle and a couple of bruises from the seat belts, as for me I was more concerned with there well being to even worry if there was anything wrong with me, I was just banged up a little, no more that I usually am. I was just grateful no one was seriously hurt

After calming our son down and reassuring him that we were still going to go on vacation we took care of everything we had to with the car since the Insurance Company totaled it there on the spot we went back to the house and got in the truck and proceeded to go to Orlando thinking that our troubles were behind us we finally got up there, then on the third day we were there my truck starts acting strange, it starts sputtering and backfiring, it seems that the coils went bad and was making the truck misfire so I had to get that fixed.

Needles to say this vacation cost me a small fortune between totaling a brand new car, having to replace most of the ignition system in my truck and the fact that gas was at its highest cost ever, then having to go out and purchase a new car. I really havenít been in the mood to do anything with the Volksrod or anything else for that matter.

Here are some photos of the car.
The scary part is we were just going less that 30 mph.

bugdust December 30th, 2008 07:10 PM

Re: Fernons Chop
Man, sorry to hear about all that. I'm glad everyone is alright. I'm even sorrier to hear you had to go to, Disney World.:funny: I thought I was done with that place but then we had another kid.:hmm:

Cat Box December 30th, 2008 07:16 PM

Re: Fernons Chop
im glad you and your family are ok and had a semi good time.

now go finish the car and post us some pics as i have wanted to see it finito for a very long time.

mkparker December 31st, 2008 08:23 AM

Re: Fernons Chop
Glad you guys are OK!! Things sure can go downhill fast sometimes!

fernon December 31st, 2008 09:14 AM

Re: Fernons Chop
Thanks Guys, I really wasn't posting this to get sympathy, just to let everyone know why I havenít been around, but I forgot this place is like a family, a misguided dysfunctional family, but family none the less and people actually give a shit here, thanks for all the support.

Don't worry, all is not lost, fortunately I also have a great family that always goes above and beyond to help each other out, and no one more so than my brother-in-law, The Evil Metal Genius, he has really outdone himself this time.

Letís just say that there is a light at the end of the tunnel and itís a Volksrod moving full speed ahead.

carlbugs January 1st, 2009 08:22 AM

Re: Fernons Chop
4 Attachment(s)
here is a car that randy (dentfxr65) is building for a customer. when i was in his shop before Christmas, the car was finished except for the decklid, but i didnt take any pics

Mikelrome January 1st, 2009 09:23 AM

Re: Fernons Chop
I love that thing!

vwfanatic January 1st, 2009 09:55 AM

Re: Fernons Chop
pretty sure those front fenders were by arnie boyle, the same guy that did the original molds for cliffs volksrod (pirahnna) kit.

71fatty January 1st, 2009 10:03 AM

Re: Fernons Chop
man those front fenders are bad ass

Boom January 1st, 2009 10:13 AM

Re: Fernons Chop
those fenders are definately different I am not sure I like them but the workmanship to do that is outstanding I really like the chop and how they angled the B pillar forward and losing the drip rails

mkparker January 1st, 2009 10:49 AM

Re: Fernons Chop
Freakin' awesome GREEN too!!!:thumbsup::thumbsup:

Oldkid January 1st, 2009 01:42 PM

Re: Fernons Chop

Originally Posted by carlbugs (Post 368834)
here is a car that randy (dentfxr65) is building for a customer. when i was in his shop before Christmas, the car was finished except for the decklid, but i didnt take any pics

Man I wish you didn't take any more photos. lol

onelowzuki January 1st, 2009 01:51 PM

Re: Fernons Chop
That car makes my panties wet

ratlook63 January 1st, 2009 02:04 PM

Re: Fernons Chop
Not my cup of tea with the front fenders, the big wheels and the slanted pillar but that is some amazing work!

fernon January 1st, 2009 04:38 PM

Re: Fernons Chop

Originally Posted by carlbugs (Post 368834)
here is a car that randy (dentfxr65) is building for a customer. when i was in his shop before Christmas, the car was finished except for the decklid, but i didnt take any pics

Amazing work...
We really need to see more of this bug...
I love the Flat n' Fat look it's got goin on
and the front end is fuck'n rad. Love It!!!
:clapping: :clapping: :clapping:

fernon January 1st, 2009 05:06 PM

Re: Fernons Chop
What would you do with an extra 10-1/2" Inches?

Yes kids that's right not 8", not 10" but a whopping 10-1/2" inches.
Just so that we can say I bet you never seen one of these this big beforeÖ

OK, like I said, the Evil Metal Genius really outdid himself this time, he went ahead and fabricated a 10-1/2Ē beam extender for the bug.

As usual, we pulled the beam off the car to find more rust and more holes to fix.

The Evil Metal Genius making some final adjustments to the beam. Notice the OSHA squint.

Doing some test fitting before its all welded up.

fernon January 1st, 2009 05:21 PM

Re: Fernons Chop
Let's see you make it fit Smart-Ass

So now that we have the beam extender we have to see if it all fits under the hood

A little cut here, a little cut there and what do you know...

That steering box is going to have to go.
Looks like we're going to put a rack and pinion set-up in here so we don't have to cut the hood!!!

Yes, we do have top and bottom plates for it, we are just test fitting before we weld it all up.

Damn That's Sexy, Now we just need to weld it all up.

bugdust January 1st, 2009 05:33 PM

Re: Fernons Chop
Looking good!! I need to get started on my next extension design!

fernon January 1st, 2009 05:34 PM

Re: Fernons Chop
That's Too Fuckin High

OK, so the beam extender dropped the front end down another 2" but the car still looks like a Gasser, so once again the Evil Metal Genius does a Cut and Turn and now it has the right stance.

After the Cut and Turn. What a difference that made.

It's starting to all come together now...

kitbox56 January 1st, 2009 06:30 PM

Re: Fernons Chop
Hey Fernon,
You've gone this far.........I think you would be happy if you and the genius would cut the humps (smooth out) out of the front fender wells. The car looks great !

volksmike January 1st, 2009 07:09 PM

Re: Fernons Chop
that is nice... I had to channel the front of the body on mine to get it to hide the beam like yours. It looks great when you can get the hood to almost touch the ground!

fernon January 3rd, 2009 09:45 PM

Re: Fernons Chop
Hey Babe Nice Rack!!!

Well we finally got the rack and pinion set-up tacked in and it looks and works great.
It is a Wright Rack and Pinion, it is super simple and very strong, but very hardcore, probably overkill for our purpose, but what the hell everything else we do is overkill.

Again everything tucks up under the hood nice and neatly.

mkparker January 4th, 2009 11:36 AM

Re: Fernons Chop
Lookin' great man!! Any reason you didn't mount the Wright in the center?

Unkl Ian January 4th, 2009 12:03 PM

Re: Fernons Chop
I would definitely mount it in the middle, so the tie rods are even lengths.

fernon January 4th, 2009 12:04 PM

Re: Fernons Chop
By mounting it where the stock steering box was it does not throw off the geometry of the front suspension and therefore you don't have the problem with bump steer and all the other problems that most people have when they extend the front end. Yes it would look better if it was centered but I intend to drive the hell out of this thing.

mkparker January 4th, 2009 01:42 PM

Re: Fernons Chop
Most every off-road car I've owned has had a center mounted Wright R&P. I'm sure they had much more travel than you will have and bump steer was not an issue. And they all were driven very hard. The benefit of a center mount would be equal length tierods. I'm not trying to be argumentative, just sayin'.....

Even a center mounted stock box can work great if done correctly.

duct-tape January 4th, 2009 02:56 PM

Re: Fernons Chop
thats hot

Unkl Ian January 4th, 2009 05:49 PM

Re: Fernons Chop

Originally Posted by fernon (Post 369387)
By mounting it where the stock steering box was it does not throw off the geometry of the front suspension and therefore you don't have the problem with bump steer and all the other problems that most people have when they extend the front end. Yes it would look better if it was centered but I intend to drive the hell out of this thing.

Your left tie rod needs to be shorter than stock,
so you end up changing Ackerman and bump steer.

fernon January 4th, 2009 07:01 PM

Re: Fernons Chop

Originally Posted by mkparker (Post 369402)
Most every off-road car I've owned has had a center mounted Wright R&P. I'm sure they had much more travel than you will have and bump steer was not an issue. And they all were driven very hard. The benefit of a center mount would be equal length tierods. I'm not trying to be argumentative, just sayin'.....


Originally Posted by mkparker (Post 369402)

Yes, I agree that a center-mount Rack & Pinion set-up works great when you have a raised suspension and plenty of travel, but when your beam is slammed to the ground and you have less than 2" of travel in your suspension everything is exaggerated and a pebble in the road feels like a boulder so we tried to eliminate as much play in the suspension as possible so this thing doesn't drive like a go-cart. Plus we also didn't want the steering shaft to cut across he front end we need the space for something else we are doing. Nice rides by the way...

rostigbug January 4th, 2009 11:30 PM

Re: Fernons Chop
:funny::funny: I gave up trying to explain all of that shit to people, everyone thinks they are an expert. All I get is arguement :funny::funny:
Besides I am in Iraq, so I 'otta STFU.

fernon January 19th, 2009 08:19 AM

Re: Fernons Chop
A Dashing Idea

So after getting the front end set-up we wanted to get the steering in so that we could start working on the dash, as usual we couldn't just use a stock steering shaft that would be too easy, so we decided to custom fabricate our own since we are going to do something very cool to it later on.

I was able to score a 1959 Bus dash pod and perfectly working clear needle speedo so as usual, we decided to start cutting it up to fit our needs.

Welding in a new plate to cover the bottom.

Filling in all the holes in the dash.

Cutting out an opening in the dash.
(I love sparks)

The pod is offset away from the dash quite a bit because again we are going to do something different than just setting a bus pod in a dash, but you will have to wait and see.

All tacked in, now we have to start working our magic with the dash.

fungus January 19th, 2009 09:51 AM

Re: Fernons Chop
Totally badass!!! I've never been a fan of the type 2 dash in a beetle, but that looks awesome!

JiI January 19th, 2009 09:56 AM

Re: Fernons Chop
I was thinking about something like that for my rod as if I put it in flat it would hit the gas tank.

carlbugs January 19th, 2009 09:58 AM

Re: Fernons Chop

Originally Posted by vwfanatic (Post 368857)
pretty sure those front fenders were by arnie boyle, the same guy that did the original molds for cliffs volksrod (pirahnna) kit.

Pretty sure they are from BGW, Randy is in petty tight with them.

Next time I go by his shop I"ll take some updated pics and start its own thread.

hotsauce January 19th, 2009 11:29 AM

Re: Fernons Chop
Damnit Fernon, i was gonna do a center mounted bus dash pod in mine. shit. Looks awesome tho!!!!!!! Keep up the sick work.:bow:

mkparker January 19th, 2009 11:38 AM

Re: Fernons Chop
Nice work...looks great!

Daniel January 19th, 2009 01:37 PM

Re: Fernons Chop
Looks awesome!

fernon January 24th, 2009 04:45 PM

Re: Fernons Chop
Starting to take Shape

It's back to work on the dash, since we can't just stick a bus pod in the center of the dash we decided to actually make it look like it was suppose to be there by using the body lines and curves of the original dash. That being said we had to make a jig to shape the metal for the dash. We started by heating and bending a steel rod to the radius that we wanted.

Then we proceeded to form the metal to the shape that we wanted.

After we got the look that we wanted we had to start building up the sides.

Then it was time to strip down the dash and start to make everything fit.

With both sides tacked in it was time to work on the top

Now this is what it looks like all welded in and ground down, after we finish welding up the dash and adding a skim coat it will look factory (or what the factory should have done). Notice how the top of the dash flows into the pod and all of the radiuses match up (OOOOOOOOOOH Detail)

vwfanatic January 24th, 2009 04:50 PM

Re: Fernons Chop

Trebor13 January 24th, 2009 05:36 PM

Re: Fernons Chop
what he ^^ said.

fungus January 24th, 2009 06:18 PM

Re: Fernons Chop
WOW. :bow:

hotsauce January 24th, 2009 06:55 PM

Re: Fernons Chop
Holy shit!!!!!!!!

way cooler than mine was gonna be. Carry on.:bow:

XrayDean January 24th, 2009 07:21 PM

Re: Fernons Chop

Originally Posted by Trebor13 (Post 375258)
what he ^^ said.


bugdust January 24th, 2009 07:40 PM

Re: Fernons Chop
Very nice...gonna have to get you guys up here when I start mine.:grin:

fernon January 25th, 2009 05:04 PM

Re: Fernons Chop
Column Drop

We started working on mounting the column and then thought it would look better if it had a column drop, so as usual it's back to fabbing a custom piece for what we want.

Once we set the steering height that we want we will start to work on the column (we have something a little special we are going to do to this), again you have to wait and see.

Also finished welding all the panels in the dash, now I just need to grind the shit out of all the welds.

Flipper_1938 January 25th, 2009 09:13 PM

Re: Fernons Chop
Looking good. Keep up the good work. :thumbsup:

fernon February 15th, 2009 06:26 PM

Re: Fernons Chop
Suicidal Tendencies

Time to do a little work to the doors, and as always time to replace a shitload of metal. We started by replacing the entire bottom of the doors since most of the metal was gone we had to replace the front and backs at the same time.

As you can see the back half of these doors are shot.
(Like the pissing on purists logo - never mind)

OK, back to work welding up the back of the door.

With the back welded in we can cut the bottom of the door off so we can replace the metal.

Now we just Cleco the panels together and start welding the door skin on.

My son is a little excited about getting the car done.

OK, so we got our hinge kit in and let me tell you this kit is nice, it is a Williams Hidden Hinge / Suicide Kit and they did a nice job making this kit.

The kit also came with Bear Claw latches and the latch install kit.

Starting to cut into the body for the hinges

Hinges installed on the body, now we just have to make the doors fit.

One side done. - That's it for today...

trikertroy February 16th, 2009 06:02 AM

Re: Fernons Chop
How are the doors attached to the hinges? and Id love to see the latch set up.. You made it look too EASY!! :bow:

fernon February 16th, 2009 02:18 PM

Re: Fernons Chop
Remember, it takes twice as much work to make it look easy.
Just like all of those Ass Clowns on TV, there is a lot that you don't see that happens behind the scenes. So here are some shots of the hinges on the door, keep in mind everything is just tacked in right now and not cut down, this is our test door (Passenger side) to see if everything works out before we mangle the Drivers side.

We also added some bracing to the inner door panel so that we had something to weld the hinge to.

This hinge system is a dream to work with, the tops and bottoms are connected so you don't have any twisting when the door opens and the action on them is smooth.

Close-up of the top hinge in the door.

Close-up of the bottom hinge in the door. the hinge doesn't sit very deep in the door so extra bracing is required.

All times are GMT -8. The time now is 09:21 PM.

Powered by vBulletin
Copyright ©2000 - 2021, Jelsoft Enterprises Ltd.
ALL text, images, graphics and content herein are Copyright ©2002 - 2020 Three Pugs Design - Cut Weld Drive Forums