Spatz Buggy "SPAZ"

[66 Shorty]

Well, since there were so many people posting off topic stuff in my thread I was going to keep as a Build thread for my Buggy, I decided to start a REAL build thread for the Buggy.
This is the Bug I started with seen here: (click the pic to the link of "Bunny's Bug")

This is the Chassis that came from the above Bug:




I completely tore down the chassis, removed the trans., beam, almost every nut & bolt from the chassis.

This is after replacing a pan, wire wheeling the entire chassis, the girls started to Master Series the entire chassis (thanks Girls!):



This is the bottom of the chassis after 2 coats MS & 2 coats of Rustoleum Gloss Black:

(I still need to post some top pics of the chassis)
I know there are a lot of pics missing form the build & some may be out of order... I've never done a good job on keeping a build thread...
I blasted & pained all the brake parts, the beam, & other bits & pieces, including drop spindles from Dave (Fishguts). Re-assembled the beam with the spindles, brakes & all, & attached it to the chassis.

Found a Long Body Buggy on Craigslist... It need A LOT-O-WORK!!!
This is when I picked it up:




Bunny & I started to strip the old paint off the buggy:





Swapped out the original hood for one Tc found for me:


It took me a while, but, TC helped me find a windshield for the Buggy! He also found me a front & rear bumper/cage for it, but, I haven't taken any pics of them yet...
Here's the w/s:

Got a Shifter from Battlebug:

Then I started making some bits, & pieces for the Buggy.
Roller Pedals:



E-brake handle, & buttons:






In the meantime, I had decided on gauges, I'm using a 914 Tack, a Beetle Speedo, & 3 smaller gauges from a VW Cabrio. I can't find pics of any of them though...
I also picked up some Headlights from Dan (Vwfanatic). Thanks again Dan! I don't have pics of them yet, but, I'll take some soon & add them as well.

After I had painted the chassis, (it was ready for the bug body to go back on) I realized I had to remove the stanchions, & seat adjusters to use the chassis as a buggy, which ended up being a good thing, because I found 2 small holes that would have rotted through in a short time. So, I welded them up, wire wheeled the areas I had uncovered & re-painted them (pics to come of the re-painted chassis.).
Stanchions removed:







Tried to figure out a gauge lay-out & w/s angle:



Plus, I drew a lay-out concept:

That's it for now... I'll add more later, I know they'll all be out of order, but, at least I'm adding them to a build thread that won't get so off topic I get dizzy!

[66 Shorty]

Here's a couple of pics for an up-date to what I did the other week... AT this point I still need my new brake lines put on. I already had the shifter & pedal assembly in, but I removed them & wrapped them up for the time being.
Pics are a bit dark, but, there's not much light in my garage, so, that;s how I work...




Tie rods are just sitting on... (I know I had the long one sitting on back wards, it's fixed now.) They hit the frame head right now, because there is no weight on the front suspension. I have to find some wheels & tires to roll my chassis around till I get my other wheels blasted & painted... Then I need new tires...




Stub axles in & brakes all painted up...







Here's the body at this point...



As you can see it's getting filthy from me not keeping it covered while I'm working go on other areas & projects in the garage with it in there... So, I started covering it. I hope that keeps the over spray & grinding sparks/dust off of the paint & it doesn't get any worse... I know they are out of order, but, I'll throw the ones of what the brakes looked like before re-doing them...

Hope you all enjoy!

[66 Shorty]

Here's a little up-date from when I couldn't get on the site.

I started mocking up the steering support:


I cut out some 1/8" plate to go inside the sides of the hood to help support the windshield.



did a dry fit:


Put down a layer of glass & clamped the plates in place:




Then while it was too cold to go out to the garage I made a 3D rendering of a dash idea. Bored out some PVC at work, then mocked up the gauge cluster...













Then I realized I couldn't keep the cardboard there , so, I re-did it with Popsicle sticks & hot glue. & also made a template for some a wood backer to staple some fabric to.





Forward to the present: (not much has changed)

TC came by this past weekend. We got a bunch of stuff done!

We built a steering column brace that supports the steering, & goes across under the hood to support the windshield & hood. (it's only tacked in for now)
OOPS, forgot pics.. (pics later)

I didn't take any pics of the plates with the holes in them for the w/s either... I'll have to take some over all pics of the support all tacked together.

Then we attached the windshield to the hood & support/cross brace.

(We opted to put it on with the groove toward the back to make the front have a more finished look, but, now I'm thinking I might want to put a top on the buggy at some point.)


TC did some 'glass work filling in some spots with Duraglass. (no pics of this)

TC doing his best Vanna impression...


He also did some welding on his Fiat 600 rear deck lid.


& he took a break to act like a kid & try starting a fire with the cigarette I threw out...


That's all for now...

[66 Shorty]

OK, here's a "Multi-up-date" for ya:

I scored some HHR tail lights for the Buggy, now I just have to figure out how I want to mount them...
I've come up w/3 ways they could be mounted:
1) Stand proud (just like on the HHR only sideways.)
2) Frenched in
3) Flush mounted (easiest, but, will be angled upward, I don't like that...)
So I guess I really narrowed it down to 2 choices...
What are your thoughts?
Here are the lights.

This is what they look like on the HHR: (see what I mean by "stand proud"?)

I also scored some (used) Marine Speakers, & a (new) Marine sub woofer tube for the buggy!
Here are the speakers & the tube...
(these are stock photos taken from the web...)


I also made part of an "eyebrow" for my dash... It came out "OK", so, we'll see how it all works out. So, things are coming together, slowly, but, still coming together nonetheless!
Here's a couple of pics of the eyebrow before I trimmed it down a bit.


Yes, I know I have to clean up my garage... & I NEED more light!


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Made some tubes for my tail lights. Still need to shorten them a bit. Let me know what you think.

[IMG]http://img.photobucket.com/albums/v628/Aquamanx/Buggy/04-25-10_1541.jpg[/IMG

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I am picking up the technique of the 'glass. The tubes came out nice & smooth. I used a roller , & I'd recommend it to anyone doing 'glass work. I made 3 tubes this weekend, which will all be cut into smaller tubes. 2 for each side for the rear lights & the 3rd one I made will be cut into 3 pieces to be used around my gauges (which I finally got back). I'll have to take a few pics of the gauges I have. I think they'll all look nice in the design I came up with. Now I just have to try getting it all to come together.
I haven't really had much time to work on my project. My fiancée lost the function in her last kidney transplant. So, she just went back on dialysis. She's got no energy & can hardly keep any food down... :( SO, I've basically been just taking care of her, the house, the kids & well, pretty much everything on my own... I hope she'll be healthy enough soon to get back to life with us. But, for the time being, I'll keep plugging away at some work here & there.
I did also do some work on my rims that I had for another project I bought almost 20 years ago... It's great to finally be able to use them on something. They are Old School, ET-II aluminum slotted wheels. They are badly oxidized, so, I've been hitting them with some emery to clean them up before I polish them. First I've been hitting them by hand with emery, then I got a chance to throw 2 of them in a Lathe here at work to spin them up with finer emery. They are coming out pretty decent for sitting around getting crappy for so long. I'm finding I should have stored them inside the garage. :o
Here's a couple of pics of them. It gives a decent idea of what I started with & where I'm at right now with them. The front rims are 8" wide, & the rears are 10" wide.







This one was only after hand sanding. I can't seem to find the pics of them in the lathe, & the rim by itself after spinning it. But, you get the idea, I'm sure.

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Did a little more work last night...
Here's a sneak peak at the pods... I know the gauges are a little dusty from grinding/sanding the PVC & fiberglass tubes...



In the background, you can see the reverse light pods are almost done, just need to be shortened a little.

[66 Shorty]

A little more done last night...

I cut the Tail light pods to fit. Still have to shorten the reverse light pods though.

Here you see the 'glass tube I made, because I was too stupid to check the other PVC tubes I had. I found the right size PVC, so, I cut a couple of pieces that the gauges fit perfectly in. Good thing, cuz, it was taking forever to sand down the outside of the 'glass tube to fit in the PVC coupler I'm using for the gauge bezel.

This pic shows how I had to notch the back of the larger PVC coupler in order to get the Speedo to fit.

Rough idea on how the smaller gauges fit in their pods with the PVC tube in them instead of the 'glass tube I made.

And here's a quick pic of all the gauges in their pods.

Let me know what you guys think! :D

[66 Shorty]

Hey Guys, it's been a long time since I have done any work on the Buggy. The summer was a very buzy summer for me!

So yesterday while I was at work, I made a couple of aluminum bezels for the gauge pod I'm making. I made them out of solid 6061-T6 aluminum. I also made a couple of brackets for my front bumper... I know it's not a lot o work, but, I don't get much free time anymore. :-( I had some pieces of aluminum set aside in the scrap pile to make the larger gauge beles, but, when they sent the scrap off to be recylced, they sent the pieces I had set aside. I guess I really should have just taken the pieces & stored them in my toolbox.







I'm still not sure how I'm going to finish off my gauge pod, so, I tried to stretch some fabric over a test piece & resin it. That was a FAIL! I'm guessing I either didn't use enough hardener, or it was too cold outside last night, cuz, it's still wet this AM. I'll try again later today & make sure I'm using enough hardener. The problem is, I only wanted to make a small batch, so, I just poured some into a tuna can, I didn't measure how much I was using, so I guessed at the amount of hardener. I need to find some small measuring cups locally, in order to get the correct ratios.

[66 Shorty]

Well, I didn't get to the 'glassin' yet, but, I did make the large Bezels! :D
& pics of the start, to finish... Don't mind the old machine I made them on... Or the Blurry pics :roll:












In a couple of the pics above you can see the Bumper Brackets I made last week , with the smaller bezels. This week I put angles on them...
That's it for now...

[66 Shorty]

I got some more work done on the pod the past few days. I got the material stretched & had a little problem area, but, I sorted it out enough till I get it 'glassed. Then last night I resined it & let it set-up. I was originally going to glass it from the inside, but, I'm not sure if there's enough room to get a good lay-up in there, & I can't build up any material around the small pods. (in the area of the aluminum disc's) If I do I won't be able to fit the bezels I made...

[66 Shorty]

[66 Shorty]

DAMN this thing was coming out great too! Gettin back to it finally!!!