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Old December 16th, 2012, 03:40 PM   #1
hendrick
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Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
Default 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.
Attached Images
File Type: jpg Rat frame 2.jpg (10.4 KB, 790 views)
File Type: jpg Rat frame.jpg (8.9 KB, 791 views)
File Type: jpg coyotee TD.jpg (11.6 KB, 792 views)
File Type: jpg red rat body on.jpg (8.4 KB, 794 views)
File Type: jpg red rat front.jpg (9.6 KB, 793 views)

Last edited by hendrick; December 16th, 2012 at 03:42 PM.
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Old January 3rd, 2013, 04:31 PM   #2
hendrick
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Location: Ontario Canada
Posts: 57
Default 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.
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File Type: jpg image.jpg (31.8 KB, 13 views)

Last edited by hendrick; March 18th, 2013 at 02:04 PM.
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Old January 3rd, 2013, 04:44 PM   #3
hendrick
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Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
Default Re: Hi there...new guy/TDI bug project

Here's my donor roof that I will be using for the roof chop.
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File Type: jpg image.jpg (27.0 KB, 7 views)

Last edited by hendrick; March 18th, 2013 at 02:05 PM.
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Old January 7th, 2013, 04:57 PM   #4
hendrick
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Join Date: Dec 2012
Location: Ontario Canada
Posts: 57
Default 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.
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File Type: jpg image.jpg (19.3 KB, 17 views)

Last edited by hendrick; January 14th, 2013 at 06:39 PM.
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Old January 7th, 2013, 05:01 PM   #5
hendrick
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Location: Ontario Canada
Posts: 57
Default Re: Hi there...new guy/TDI bug project

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File Type: jpg image.jpg (22.5 KB, 6 views)

Last edited by hendrick; March 18th, 2013 at 02:10 PM.
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Old January 7th, 2013, 05:02 PM   #6
hendrick
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Default Re: Hi there...new guy/TDI bug project

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Old January 8th, 2013, 05:11 PM   #7
hendrick
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Default 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.
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File Type: jpg image.jpg (74.0 KB, 32 views)

Last edited by hendrick; January 9th, 2013 at 03:52 PM.
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Old January 11th, 2013, 09:09 AM   #8
hendrick
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Location: Ontario Canada
Posts: 57
Default 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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Old January 13th, 2013, 03:37 PM   #9
hendrick
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Default Re: Hi there...new guy/TDI bug project

In the meantime, prepping these arms for some new ball joints
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Old January 14th, 2013, 06:30 PM   #10
hendrick
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Default Re: Hi there...new guy/TDI bug project

Pans trimmed
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Old January 14th, 2013, 06:33 PM   #11
hendrick
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Default 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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Old January 14th, 2013, 06:35 PM   #12
hendrick
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Default Re: Hi there...new guy/TDI bug project

Not too shabby.
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Old January 15th, 2013, 03:09 PM   #13
hendrick
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Location: Ontario Canada
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Default Re: Hi there...new guy/TDI bug project

Finishing up some welding inside, firewall and heater channels.
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Old January 15th, 2013, 03:10 PM   #14
hendrick
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Default Re: Hi there...new guy/TDI bug project

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Old January 16th, 2013, 02:48 PM   #15
hendrick
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Location: Ontario Canada
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Default 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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Old February 5th, 2013, 04:04 AM   #16
hendrick
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Location: Ontario Canada
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Default Re: Hi there...new guy/TDI bug project

Front wheels back from powder coater!
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File Type: jpg image.jpg (41.3 KB, 5 views)

Last edited by hendrick; March 12th, 2013 at 03:48 PM.
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Old February 11th, 2013, 05:15 PM   #17
hendrick
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Default 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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Old February 11th, 2013, 05:24 PM   #18
hendrick
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Default Re: Hi there...new guy/TDI bug project

Test fit
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File Type: jpg image.jpg (32.8 KB, 8 views)

Last edited by hendrick; March 12th, 2013 at 03:52 PM.
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Old February 11th, 2013, 05:25 PM   #19
hendrick
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Default Re: Hi there...new guy/TDI bug project

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File Type: jpg image.jpg (31.1 KB, 5 views)

Last edited by hendrick; March 12th, 2013 at 03:53 PM.
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Old February 13th, 2013, 12:41 PM   #20
hendrick
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Location: Ontario Canada
Posts: 57
Default 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.
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File Type: jpg image.jpg (28.1 KB, 7 views)

Last edited by hendrick; March 4th, 2013 at 06:59 AM.
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Old February 13th, 2013, 01:03 PM   #21
hendrick
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Default Re: Hi there...new guy/TDI bug project

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File Type: jpg image.jpg (27.7 KB, 5 views)

Last edited by hendrick; March 4th, 2013 at 07:01 AM.
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Old February 13th, 2013, 01:30 PM   #22
hendrick
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Default Re: Hi there...new guy/TDI bug project

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File Type: jpg image.jpg (27.1 KB, 4 views)

Last edited by hendrick; March 4th, 2013 at 07:03 AM.
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Old February 13th, 2013, 01:34 PM   #23
hendrick
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Location: Ontario Canada
Posts: 57
Default 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
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File Type: jpg image.jpg (20.9 KB, 4 views)

Last edited by hendrick; March 9th, 2013 at 05:29 AM.
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Old February 13th, 2013, 01:35 PM   #24
hendrick
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Location: Ontario Canada
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Default Re: Hi there...new guy/TDI bug project

Test fit bearing, and length of shaft.
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File Type: jpg image.jpg (29.2 KB, 4 views)

Last edited by hendrick; March 4th, 2013 at 07:04 AM.
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Old February 16th, 2013, 12:22 PM   #25
hendrick
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Default Re: Hi there...new guy/TDI bug project

Salvaged these front beam brackets from an old baja kit.
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File Type: jpg image.jpg (27.6 KB, 3 views)

Last edited by hendrick; March 4th, 2013 at 07:05 AM.
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