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The DUNGBTL Build
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DUNGBTL Premium Member
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PostPosted: Sat May 04, 2024 7:35 pm    Post subject: Re: The DUNGBTL Build Reply with quote

Funny story…
I spent several hours the other day trying to fit the ‘front’ bumper on the car. Wouldn’t fit the brackets. The extreme corners would contact the fenders long before the bumper was contacting the brackets. So I slid the brackets all the way out…the inside bracket attachments could bolt up, but the outbd ones were way off! It was a head scratcher.

Then I remembered! I had used the front bumper for the rear because I found (like many others before me) that the front bumper fits the rear of the car so much tighter to the contours than the OEM one.
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I was trying to fit the rear bumper to the front and it will not fit! DOH! Embarassed

So I ordered a single chrome Brazilian front. Since I intend to paint the bumpers, the single chrome will be easier to sand off. I have to say, except for a slightly wavy stamping (nothing a little Bondo won’t cure), the bumper I received is quite nice. Fits straight and square.

I took the OEM brackets and modified the mounting slots to allow for a full tuck…as much as they would allow before jamming in the fender slots. In my case, a 1” slot extension did the trick. The brackets got a dose of ‘drillium’ for good measure. ~1 lb reduction.
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The bumper fit right and tight! 3/8” clearance to fenders, 2” to bonnet.
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Next up is fitting the Kamei front spoiler and modifying it with an air intake for the radiator.
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J.
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H2OSB
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PostPosted: Sat May 04, 2024 8:59 pm    Post subject: Re: The DUNGBTL Build Reply with quote

Looking good, my friend.

H2OSB
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Epilog79
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PostPosted: Sun May 05, 2024 10:03 am    Post subject: Re: The DUNGBTL Build Reply with quote

I have been enjoying your build since day one. Your creativity and meticulousness are amazing. I have always been a fan of the 911 RSR look and adding those cues to your build are awesome.
My son and I went up to PNW Spring Meet in Puyallup Wa last weekend. There was this killer Subi Swap that used a front spoiler like you are planning. Here is a picture of how he did it. I didn’t ask what size radiator or if the cooling was effective. But sure looks subtle and stealth.

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Keep up the good work.
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Rome
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PostPosted: Sun May 05, 2024 11:37 am    Post subject: Re: The DUNGBTL Build Reply with quote

That Subi-Beetle has what appears to be a lovely early Porsche 911 wood-rimmed steering wheel! Very Happy

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bruceo98
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PostPosted: Sun May 05, 2024 4:45 pm    Post subject: Re: The DUNGBTL Build Reply with quote

That fits nice . When painting over chrome you should sand blast it and coat it with some etching primer before painting it for the paint to stick to chrome.
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DUNGBTL Premium Member
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PostPosted: Sun May 05, 2024 8:37 pm    Post subject: Re: The DUNGBTL Build Reply with quote

H2OSB wrote:
Looking good, my friend.

H2OSB

Thank you! Very Happy

Epilog79 wrote:
I have been enjoying your build since day one. Your creativity and meticulousness are amazing. I have always been a fan of the 911 RSR look and adding those cues to your build are awesome.
My son and I went up to PNW Spring Meet in Puyallup Wa last weekend. There was this killer Subi Swap that used a front spoiler like you are planning. Here is a picture of how he did it. I didn’t ask what size radiator or if the cooling was effective. But sure looks subtle and stealth.

Keep up the good work.

Thank you! I appreciate you posting a reply.

I came across that car somewhere on the web and copied a few pictures of his build for ideas and inspiration.
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Will probably copy his air intake (I believe he’s maintained the OEM MAF to throttle body distance and is picking up ‘cold air’ from the side vent channel) and his exhaust (I like how low profile it is and how he maintained the ‘pea-shooters’). The whole car appears to be very well engineered. It’s very well done and it appears that the builder is a true craftsman. I hope to see it in person some day.

Rome wrote:
That Subi-Beetle has what appears to be a lovely early Porsche 911 wood-rimmed steering wheel! Very Happy

Indeed! Keen eye Rome! Very Happy

bruceo98 wrote:
That fits nice . When painting over chrome you should sand blast it and coat it with some etching primer before painting it for the paint to stick to chrome.
I use a 36g sanding disc to remove the chrome…to get down to the copper (if triple coated: copper, nickel, chrome) then a DA w/60g and etch prime. That’s what I did to the rear bumper (which is ACTUALLY the OEM front bumper!)…
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The new front is a cheapie Brazilian “single chrome” (chrome over steel?) and should be much easier to sand off than the OEM triple chrome one.

J.


Last edited by DUNGBTL on Mon May 06, 2024 6:36 am; edited 1 time in total
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H2OSB
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PostPosted: Mon May 06, 2024 4:38 am    Post subject: Re: The DUNGBTL Build Reply with quote

I absolutely love the exhaust that guy used. Is that a one off? It looks like a VS, kinda. Flanges are very thick.

H2OSB
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Rome
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PostPosted: Mon May 06, 2024 5:13 am    Post subject: Re: The DUNGBTL Build Reply with quote

Coolant lines from front radiator back to the engine mounted under the right running board for ground clearance- clever!
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PostPosted: Mon May 06, 2024 6:33 am    Post subject: Re: The DUNGBTL Build Reply with quote

H2OSB wrote:
I absolutely love the exhaust that guy used. Is that a one off? It looks like a VS, kinda. Flanges are very thick.

H2OSB

I have no other info on his exhaust other than the picture. I assume it’s custom made. Even the muffler looks custom.

“VS”…?

[Thinking out loud] Send-Cut-Send could do the thick flanges and sectioned exhaust tubing can be pieced together to make the runs…I believe I can fabricate a copy, however I can’t TIG weld so it’ll probably be a JET-HOT coated MIG welded version. Ground clearance will be the primary design goal…although from what I’ve seen, the shortened oil pans are always the ‘rub-spot’ on these builds.

What he made is a work of art!

J.
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PostPosted: Mon May 06, 2024 7:13 am    Post subject: Re: The DUNGBTL Build Reply with quote

Vintage Speed
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Puppy67
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PostPosted: Mon May 06, 2024 9:47 am    Post subject: Re: The DUNGBTL Build Reply with quote

Agree, I'm pretty sure that's the Vintage Speed Super Sport for fitting a type 4 into a beetle (see link - https://store.vintagespeed.com.tw/TYPE-4-INTO-TYPE-1-150MM-SUPER-FLOW-MUFFLERS-50-35-p132807877)

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They do a few others that will likely also work https://store.vintagespeed.com.tw/Type-4-into-Type-1-c33978028, then you just have to make the engine to type 4 flange manifolds.
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DUNGBTL Premium Member
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PostPosted: Mon May 06, 2024 2:22 pm    Post subject: Re: The DUNGBTL Build Reply with quote

Puppy67 wrote:
Agree, I'm pretty sure that's the Vintage Speed Super Sport for fitting a type 4 into a beetle (see link -

AH HA! Good detective work! Thanks for the links.

J.
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PostPosted: Tue May 14, 2024 1:50 pm    Post subject: Re: The DUNGBTL Build Reply with quote

Kamei Spoiler

I bought a repo Kamei spoiler off of EBay 2 yrs ago just after dragging the DUNGBTL home. It’s been hanging out in the shop ever since, literally collecting dust. Here’s two yrs worth dust and debris from working on the DUNGBTL…
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I inspected the piece after receiving but never tried to mount it. It’s very well made and finished. Surprisingly light and stiff. The stiffness isn’t too surprising as the compound curvature lends to increased stiffness. Made entirely out of fiberglass. Attaches to the bumper by three fasteners across the bumper center section and by ‘clamping’ either side between the R&L lower bumper bracket.
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The plan was to create a duct to funnel the air directly into the radiator. A duct that allows the air from its opening to be channeled directly into the radiator. Duct to be attached to the inside and not have any attachments visible on the front face.

Porsche used balsa wood and fiberglass construction in the past on their race cars to obtain stiffness with lightness, primarily on deck lids, hood, and other body panels. I was going to do the same but found that .100” thick MDF is cheaper and easier to fabricate. It is heavier than balsa, but at .100” thickness and the amount used, the weight penalty is negligible. The MDF provides an armature to which I can cover with fiberglass to strengthen the joints and weather proof.

Many template iterations ensued along with hours of fit-up…not easy as there’s not a lot of room to work between bumper and apron.
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I found an artist clipboard made out of MDF at the local ACE which had the right dimensions. It was cheaper than buying a .100” MDF panel online.
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Duct construction was started by ‘tacking’ the lower panel to the inside of the spoiler. The lower panel is fastened to the apron flange. It was clamped in place to capture that position. Fiberglass mat and resin is used to make the attachment to the spoiler.
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The two sides were bonded to the spoiler and lower duct panel using JB Weld.
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…the top panel was bonded likewise to the sides.
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After the duct ‘box’ was formed and bonded to the spoiler, the whole mess, bumper and all, was removed from the car and the duct was glassed in for added joint strength and weather proofing.
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After remounting and leveling, the intake opening was laid out. Sliding the square against the lower edge of the spoiler and marking across the top of the ‘ruler’ captured the curvature of the spoiler bottom edge.
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2” hole saw created the 1” bottom radius…1” hole saw was used for the upper radii.
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I think it looks somewhat like the mouth of a Baleen whale!
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The duct and spoiler will be finished in satin black. I’ll use SEM Trim Black for the outside. I’ve used this product on other projects and found it to be very durable. It’ll make the spoiler easy to repaint after it gets chipped up by rocks, etc.

Lots of finish work to do now!

Cheers,
J.


Last edited by DUNGBTL on Wed May 15, 2024 7:13 am; edited 5 times in total
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bruceo98
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PostPosted: Tue May 14, 2024 7:10 pm    Post subject: Re: The DUNGBTL Build Reply with quote

Came out great . You must be retired? You have too much time on your hands. lol.
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Last edited by bruceo98 on Wed May 15, 2024 9:58 am; edited 1 time in total
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PostPosted: Wed May 15, 2024 6:15 am    Post subject: Re: The DUNGBTL Build Reply with quote

Guilty as charged! Laughing Thumbs Up Thumbs Up
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PostPosted: Mon May 20, 2024 10:51 am    Post subject: Re: The DUNGBTL Build Reply with quote

Headliner material is in…
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With the roll bar, there’s no room for the OEM headliner.
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I would just paint the roof but it needs acoustic insulation. Color fits the car’s palette too… Rolling Eyes
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J.
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PostPosted: Mon May 20, 2024 5:17 pm    Post subject: Re: The DUNGBTL Build Reply with quote

Should do the trick

H2OSB
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PostPosted: Tue May 21, 2024 7:15 am    Post subject: Re: The DUNGBTL Build Reply with quote

What color is the headliner going to be?
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PostPosted: Tue May 21, 2024 7:27 am    Post subject: Re: The DUNGBTL Build Reply with quote

bruceo98 wrote:
What color is the headliner going to be?

This color…
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…no over cover. The ‘jute’…not the foil.

J.
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PostPosted: Tue May 21, 2024 7:33 am    Post subject: Re: The DUNGBTL Build Reply with quote

DUNGBTL wrote:
bruceo98 wrote:
What color is the headliner going to be?

This color…
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…no over cover. The ‘jute’…not the foil.

J.

So the foil side gets glued to the roof and the jute is the visible headliner?
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