Beach buggy project- car thread

[pits]

If some of you remember last year I restored a Smart car for a friend, been having a clear out this year and decided that it was time to put my beach buggy on the road, bought it around the dawn of time and it has mostly sat in my garage


And this is a rather long post with a lot of copypasta

Anyway

As I bought it
https://i34.photobucket.com/albums/d112/pitslayer/47b3d622b3127cce9b932085bd110000001.jpg
https://i34.photobucket.com/albums/d112/pitslayer/bug1.jpg
https://i34.photobucket.com/albums/d112/pitslayer/bug3.jpg

Now you think it probably looks good in those photos, but the list of bodges on this buggy is so far never ending, so where we sit now after a week of work

https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_150023_zpsfc0c33f4.jpg
Theres silver under the tasteful gold under the tasteful black bleugh and yes that is my beam being held on with long M10 bolts with nylock nuts.
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_150030_zps30bf08e7.jpg

Still need to clean the inside out
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_150036_zpsf80c9dce.jpg

Crack in rear which is one of the big problems with the body, sure some of you will see it as no probs but I hate fibreglassing.
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_150101_zps58b47178.jpg

Gearbox mount, paint it silver so it looks like part of the gearbox
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_150134_zpse70f08ad.jpg

Earth strap/straps
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_150143_zpsb0ef6131.jpg

Corroded flexis
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_150150_zpsbbc81e80.jpg

Black Gold and rusty master cylinder, thanks to whomever paint over the seals
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_150209_zps6ec0b0bd.jpg

1641 in the process of being built
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_150215_zpsffa3e76c.jpg

Fuel line, yes I snapped that by hand, so brittle.
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_150123_zpsd474e9f8.jpg


More to come, hoping to get the body off the chassis to get some cleaning up of the beam and get rid of that black and gold caked on mess.

Current parts list
In stock > 4 x 462.400.10 Wheel Cylinder, Bleed Nipple, Dust Cover, Each

In stock > 1 x 611.440.10 Clutch Cable, Wing Nut

In stock > 1 x 042.023.10 Tinware, Fanshroud, Twin Port, Without Heater, Black

In stock > 1 x 042.201.10 Tinware, Head Shrouds, Twin Port, Black, Pair

In stock > 1 x 042.151.10 Tinware, Front Tray, Bellhousing, Twin Port, Black

In stock > 1 x 042.126.10 Tinware, Rear Tray, Twin Carb, Without Heater, Black

In stock > 1 x 042.140.10 Tinware, Breastplate, Under Pulley, Black

In stock > 1 x 042.500.10 Tinware, Doghouse Tin, Black, 2 Piece Set

In stock > 1 x 042.610.10 Tinware, Heat Exchanger Bottom Tin, Black, 3 Piece Set

In stock > 1 x 716.500.10 Generator, Backing Plate, Black

REAR HUB SEAL KIT 2
ANTIROLL BAR FITTING KIT 1
REAR WHEEL CYLINDER 2
BRAKE MASTER CYLINDER 1
BRAKE SHOE SET 1
REAR SHOCK ABSORBER 2

To order,
Front slave cylinders
Front shoes
Front drums

If anyone is wondering why I only ordered one ARB bush kit, I already have one on the shelf.

And that isn't my Pepsi Max, Pepsi Max is disgusting

Colour wise, not sure on VW Sea Green
https://www.vwtype3.anomalous.net/sea%20green%202%20.JPG
Or BMW BRG 312 Elekta
https://img.pistonheads.com.s3-eu-west-1.amazonaws.com/Fullsize/bmw/m5/bmw-m5-267934-1.jpg

Floor pan off

https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130409_190148_zps2c9f9284.jpg

Got to go an locate a master cylinder tomorrow if I can so I can run new brake lines.

Rear brake backing plates mostly built back up, hub seals to be done tomorrow, run some brake lines, get the rattle cans out and get to work painting over any gold that is left.....I was going to sand blast but I need to look at it realistically money is a factor, and I want a new beam so no point spending money on that really.

New rear shocks on, new steering damper on
Gearbox cleaned and painted, unsure on the silver details.
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130411_172633_zps5d20e35a.jpg

https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130417_180943_zps1a2c638a.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130417_180929_zpsc02d9c2d.jpg

Tomorrow I should hopefully have the gearbox etc back in so finish off the brake lines, get the hubs done and the backing plates back on, build the shoes up, body work wise not a lot left to do actually

A lot of these cracks have been filled and covered now, just the big one which is the issue
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130416_202919_zpsca611b05.jpg


Plucked up the courage to cut my body, cut a hole in the inner side of the tub, then the damage section, fibreglassed from behind,
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130418_192756_zpsad742cee.jpg
Fibrefilled from the front, sanded back and a light skim of filler afterwards
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130419_154356_zps649e0e3e.jpg
Some high build as a guide coat to pick up any high points
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130419_203235_zps898b5a3c.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130419_202944_zpsb3d12599.jpg

Will get some more better pictures of the tub when it is lighter, hoping to maybe have the tub primed by the end of the week.

Chassis wise, cleaned it up

https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130420_193039_zps5d777854.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130420_193034_zpsf54cf816.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130420_193102_zps846bbd72.jpg
Rear end mostly buttoned up now, got to set the final brake line placement and then tighten them up, all new gearbox mounts front and rear, hub seal kits mostly done, slave cylinders on

brakes built up
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130427_190803_zpsae09cde2.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130427_190757_zps5f89d3df.jpg

Engine 90% complete, thwarted by lack of torque wrench to do the flywheel nut up to the correct torque, and another bodge to add to the list
1300 twin hotspot AR coded engine so that puts it 72-75, 12v engine, 12v starter motor....6v fly wheel which has been chewed up by the starter motor.
Anyway
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130427_142457_zps9e615f73.jpg

Built up
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130427_193906_zps20e86eb4.jpg



We decided to have a look at the dashboard and fixing it better to the car, so I placed the bonnet on so it was square and looked right, then put the dash frame in (the bonnet has always been wonky and it annoyed me somewhat) well, here is the reason why
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130427_210030_zps52bdc932.jpg

Where the dash frame actually wants to be, where the holes were drilled
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130427_210025_zps0203e393.jpg

https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130427_210038_zps6eda2d93.jpg

Now lets move the dash frame to where the holes were drilled
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130427_210141_zps05d36662.jpg



And onto the floor pan, so the body doesn't sit straight on the floor, and it had silicone all over it to make it fit, well I cut the silicone off today and put the body back on to assess just how bad the floor pan is, so near side floorpan is an inch too short on width and the offside is an inch too wide on width, the body is almost an inch too high at the rear where the floor has been built up to meet the body and half inch too far forward at the front.


Measure twice, cut once......measure once cut twice......don't measure at all

https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130427_202958_zps2f931242.jpg


Now we are at the present date
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130607_161727_zps09fbb67b.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130607_161733_zps98163308.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130607_161742_zpse34d6d49.jpg

Now primered
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130607_175054_zps3a65610e.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130607_165947_zps8bd394b3.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130610_163524_zps150ecb55.jpg


Almost ready for paint, happy with the repair on the rear corner
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130607_175034_zps87847a8a.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130607_175059_zps21477bff.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130607_175045_zps550ad53b.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130611_175954_zps3f2bd1e6.jpg

The body is this wonky, there is no filler here
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130611_180017_zps9d0cd581.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130611_180026_zpsda596b96.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130611_180034_zps4a7ab449.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130611_180010_zpsf7cde291.jpg


Tiny more filler primer in places and hopefully it will be green by the end of the week.

I also appreciate that Beetles are crap, I will make no bones about it, but I quite fancy something without a roof to drive and I already had this in the garage.
____________________
Stinkwheel: You have no right to free speech
00:32:08 Blau Zedong: yes, i am a massive CB400 fan and collector
00:33:00 Blau Zedong: the CB400 is my favourite road bike

[andyscooter]

cool project

complete different colour have a look at the red on my pcx think it would suit that car brilliantly
____________________
gilera runner vxr200 (chavped)
if its spelt wrong its my fat fingers and daft auto correct on my tablet

[pits]

[Ollie1995]

midlife crisis?
____________________
XR 125, DT125 LC, Greeves Scottish, RS200, XS400, GPX600r

Theory Passed - 18/7/13 MOD1 Booked - 24/9/13

[Chalky.]

You're a fucking ledge.

[pits]

[oldpink]

always wanted a sand rail kit to build
would love to put a 1L bike engine into one of these

https://img.photobucket.com/albums/v325/wildcatkit52/Piranha/RickSchenkerPiranha9.jpg

but hats off to you thats quite a project and rebuild
____________________
I have become comfortably numb

Theory & hazard 24-may 2016, CBT 8th June 2016, MOD 1 2nd Aug 2016 Mod 2 2nd-Nov 2016 - Current bike CBR 600 RR

[pits]

[Ollie1995]

[Aff]

Nice one, enjoyed the Smart thread.

Posting for updates.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[oldpink]

[pits]

[Ollie1995]

[pits]

[pits]

Not forgotten about this, been waiting for a few bits should get some more frequent updates now as the hard part is over.

Chassis rails needed replacing, the old ones were crap made out of 3-4 bits of box section badly cut and welded together, pretty rubbish way of doing it, so came up with another much neater way


Started off with some 20x50 box and started cutting it out
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_143632_zpsf271babd.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_143650_zps9e4ea696.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_144026_zps58550f55.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_143724_zps98365a3d.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_144009_zpse8c43200.jpg


To give you an idea of the curve from one end to the other
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_150302_zpscad05655.jpg

Tacking it in
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_150243_zps45e8c772.jpg

Better, I can't see daylight through the body and the chassis rails now, and it also shows how badly built the floor is, the rail is where the body needs to sit, the floor pan is where it used to sit on the old rail
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_152420_zpscf25c576.jpg

https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_152435_zpsb8237b5b.jpg

Same on the otherside
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_163923_zpsf9a14eab.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_150247_zpsbc9d2cee.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_162328_zpsfcf86c16.jpg

These are now set to the shape of the body, as opposed to the body being set to the shape of the floor pan
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_163941_zps69a38036.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130710_163913_zpsc405bbd8.jpg


There might be an update later today with some paint going down.
____________________
Stinkwheel: You have no right to free speech
00:32:08 Blau Zedong: yes, i am a massive CB400 fan and collector
00:33:00 Blau Zedong: the CB400 is my favourite road bike

[pits]

Sit rep...it is now green....am I happy with it...well no not really, but it is what it is and it will never be 100% correct
Firstly I as you will see, I know longer have a spray booth, dust is a contender here, a very big one.
My gun has gone walkies meaning I had to use the back up gun, wrong nozzle and generally gives a shit finish.
The body is 30 years old and well just ruined, so I know I am slapping lipstick on a pig, it leaves me with few options, but the main one at the moment is another coat, a flat down and clear coat it.

In an ideal world I would have had it re-gelcoated, but it isn't and to be honest it's just a car for mucking about in, I don't really care.

That said the colour is lovely, but you can see the state of the gun just from its spray "pattern" it's a pattern, it's not the pattern it should be, I would class this pattern as "all over the place"
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_133822_zps4701fbc1.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_133804_zpsa1dd81b6.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_133811_zpsd903f78b.jpg


second coat on
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_135224_zpsbda4a4e3.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_135242_zpsb6a52499.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_135214_zps713940b0.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_135234_zps54e336e7.jpg


Bonnet didn't come out well, we had technical problems during the paint, hence the general finish, luckily you can't see the epic run in the front where the gun blocked up and then unblocked itself, this is why I like using my gun, it's reliable, it never blocks up it never leaks, it never fires 1000litres of paint out in one go.

https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_145034_zps383c5a4b.jpg
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_145030_zpsdef0f03f.jpg

Actually I lied, this is what happens when your gun decides to stop working for a second then fire the remainder of the pot out at your bonnet, that will get repainted with the dash I think.

https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_145043_zps3bffdeaf.jpg



https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130711_145141_zpsfa8b12c7.jpg


Not bad though, it is being rebuilt on a shoe string in a dirty workshop, everything on it isn't worth spending time on sadly as just about everything has been badly neglected.

Theres no point in having an amazing floor pan, which will cost me a couple of thousand to do nicely and a rubbish body, just like there is no point in having an amazing body and rubbish floor pan.

When money allows I will have the floor pan rebuilt and the body gelcoated, but for something I want on the road in a few weeks, it'll do.
____________________
Stinkwheel: You have no right to free speech
00:32:08 Blau Zedong: yes, i am a massive CB400 fan and collector
00:33:00 Blau Zedong: the CB400 is my favourite road bike

[fatjames]

My pc screen in work must be shit. Paint looks great from this end!
Great job mate. Keep us posted.

[trevor saxe-coburg-gotha]

Nothing says great day at the beach like stagnant pond green.
____________________
"Life is a sexually transmitted disease and the mortality rate is one hundred percent."

Mobylette Type 50 ---> Raleigh Grifter ---> Neval Minsk 125

[Pete.]

[SQL]

[pits]

some pics of it in the day light, happier but I still flatted it down and going to put another coat on when it cools down
https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130712_120018_zpsd1ec496a.jpg

https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130712_120048_zps1bbc6d18.jpg

https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130712_120039_zpsb8aefea7.jpg

https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130712_120026_zpsda6eb971.jpg

https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130712_120051_zpsdc984e18.jpg

https://i34.photobucket.com/albums/d112/pitslayer/Buggy%20build/IMG_20130712_120034_zpsb2e20803.jpg
____________________
Stinkwheel: You have no right to free speech
00:32:08 Blau Zedong: yes, i am a massive CB400 fan and collector
00:33:00 Blau Zedong: the CB400 is my favourite road bike

[pits]

Well I wasn't in the mood yesterday felt awful, then out of nowhere mates turned up, next thing I know
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130824_003511_zpse9865e53.jpg

Followed by

https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130824_010537_zps9eda4d7c.jpg
https://i34.photobucket.com/albums/d112/pitslayer/IMG_20130824_012315_zps4b777417.jpg

Got some bits turning up next week for it hopefully.
____________________
Stinkwheel: You have no right to free speech
00:32:08 Blau Zedong: yes, i am a massive CB400 fan and collector
00:33:00 Blau Zedong: the CB400 is my favourite road bike

[sidewinder]

Looks great especially on a low budget Can't help thinking a scooby lump would go well in it

[prawny1]

Would be a shame not to ditch the swing axle in favour of irs whilst you have the body off.

I think these always look better with the side pods for the body too imo.
____________________
hellkat wrote:

Some people are only alive cos its against the law to kill them.

[pits]

Side pods are not available to buy anywhere, and IRS conversion is money.
The chassis is rubbish in the grand scheme of things and not worth spending any money on other than making it safe to use.
____________________
Stinkwheel: You have no right to free speech
00:32:08 Blau Zedong: yes, i am a massive CB400 fan and collector
00:33:00 Blau Zedong: the CB400 is my favourite road bike