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December 16th, 2012, 03:40 PM
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#1
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Hi there...new guy/TDI bug project
Just checking in, saying Hi  making my first intro post.
I'm new to this site but not the VW scene.
I recently began work on my first "fenderless" bug which started life from the frame of a baja project I had started.
the frame was stetched for a longer wheel base...so perfect for the "pushed out front look" only problem , i designed it with the suspension raised 3"...so it was time to cut an re-weld. 
Heres some pics.
P.S this project will powered by a 2002 VW TDI water cooled engine so I'll included a pic. of another of my veedubs with a similar TD set up. 
Last edited by hendrick; December 16th, 2012 at 03:42 PM.
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January 3rd, 2013, 04:31 PM
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#2
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Found time to mock a test trans and engine.
Began rebuild of TDI engine , starting with the head that will receive new valves,guides,seals, and lifters.
Last edited by hendrick; March 18th, 2013 at 02:04 PM.
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January 3rd, 2013, 04:44 PM
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#3
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Here's my donor roof that I will be using for the roof chop. 
Last edited by hendrick; March 18th, 2013 at 02:05 PM.
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January 7th, 2013, 04:57 PM
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#4
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
I originally drilled the frame head for K&L front beam because of its superior strength, ideal for a Baja and off road abuse.
I intended the beam to be bolted directly to this frame head. To extend the wheel base for this application I drilled another plate and welded a stock BJ frame head to it. I intend to build a tube frame support brackets that will extend back to the firewall .... Like a mini roll cage.
Last edited by hendrick; January 14th, 2013 at 06:39 PM.
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January 7th, 2013, 05:01 PM
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#5
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Last edited by hendrick; March 18th, 2013 at 02:10 PM.
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January 7th, 2013, 05:02 PM
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#6
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
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January 8th, 2013, 05:11 PM
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#7
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Separated body from the pan so I can reinforce frame, now that I am happy with stance.
Last edited by hendrick; January 9th, 2013 at 03:52 PM.
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January 11th, 2013, 09:09 AM
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#8
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Began the process of fitting the two pan halves, I will leave the centre section of the frame which is 4" wide uncovered so I can tuck my coolant pipes in there.
Cutting this aluminium sucks!  ... So I think I'll drag the cut sheet to my buddies shop and shear it!
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January 13th, 2013, 03:37 PM
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#9
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
In the meantime, prepping these arms for some new ball joints
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January 14th, 2013, 06:30 PM
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#10
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Pans trimmed
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January 14th, 2013, 06:33 PM
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#11
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Got the body placed back on the frame ... See how I did with my measurements? 
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January 14th, 2013, 06:35 PM
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#12
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Not too shabby. 
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January 15th, 2013, 03:09 PM
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#13
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Finishing up some welding inside, firewall and heater channels. 
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January 15th, 2013, 03:10 PM
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#14
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
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January 16th, 2013, 02:48 PM
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#15
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Test fit of my hydraulic pedal assembly.
I plan to cut firewall so I can locate pedals in stock location. 
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February 5th, 2013, 04:04 AM
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#16
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Front wheels back from powder coater! 
Last edited by hendrick; March 12th, 2013 at 03:48 PM.
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February 11th, 2013, 05:15 PM
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#17
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
I decided I must modify the firewall and install pedal assembly in order to lay out the front beam support frame and radiator.
Last edited by hendrick; March 12th, 2013 at 03:49 PM.
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February 11th, 2013, 05:24 PM
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#18
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Test fit
Last edited by hendrick; March 12th, 2013 at 03:52 PM.
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February 11th, 2013, 05:25 PM
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#19
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Last edited by hendrick; March 12th, 2013 at 03:53 PM.
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February 13th, 2013, 12:41 PM
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#20
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Now that I have the body situated on the frame where I want it, I now plan to mock- up my steering so that I am sure that when the front beam support frame is made, it will clear. 
Digging around in my parts supply.... Found this 1998 VW jetta power steering rack and column... I can salvage the parts I need from it.
Last edited by hendrick; March 4th, 2013 at 06:59 AM.
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February 13th, 2013, 01:03 PM
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#21
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Last edited by hendrick; March 4th, 2013 at 07:01 AM.
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February 13th, 2013, 01:30 PM
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#22
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Last edited by hendrick; March 4th, 2013 at 07:03 AM.
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February 13th, 2013, 01:34 PM
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#23
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
I will leave the bearing support shaft un-cut until I mock this assembly up in the car to get the proper length
Last edited by hendrick; March 9th, 2013 at 05:29 AM.
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February 13th, 2013, 01:35 PM
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#24
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Test fit bearing, and length of shaft.
Last edited by hendrick; March 4th, 2013 at 07:04 AM.
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February 16th, 2013, 12:22 PM
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#25
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Forum Member
Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
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Re: Hi there...new guy/TDI bug project
Salvaged these front beam brackets from an old baja kit.
Last edited by hendrick; March 4th, 2013 at 07:05 AM.
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