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1971ish Baja Bug Pre-Runner
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Lughead Motorsports
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PostPosted: Tue Jun 02, 2015 12:34 pm    Post subject: 1971ish Baja Bug Pre-Runner Reply with quote

ok well its time to document my first build thread on here.

A little about me first. I've been building vw's since i was in high school (im 27 now id still consider myself new to it) built my first 1969 street car that i still have today. then a 68' orange baja bug and a 67' black baja bug shortly after that one. could talk about those guys for a while but not what this thread is about. since sold both of those and started my own business Lughead Motorsports to build custom off-road race chassis and suspension design. i have a degree in mechanical engineering and work in construction to pay the way to making the business full time some day. This build is my first car under the business name and intend it to be a bad ass Pre-runner Baja. also this will be the precursor to my full on Class 5 Unlimited after this guy is complete.

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Now for this build i started with a 1971 standard beetle (the yellow one). i have a good 74' engine case to build a good 091 core of unknown internal condition. i want to put a widened front link pin, 3x3 trailing arms, full roll cage, all the accouterments to a pre runner. running 33" tires, 3" body lift, Porsche 930 CV's, the 091 custom rebuilt from German Transaxle of America, and a custom built 1955 cc engine that i will put together. of course there is a lot of specs and little things to go along here but you get the jist. here's where i started about a year ago and will continue to post progress photos as i have time this week over the last year.

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and now i gotta get back to that day job. lemme know what yall think.
_________________
"Mistakes are proof that you're trying"

1969 Street bug --- For Sale... maybe
1968 Baja"The Orange Bug" ---Sold
1970 Baja "The Black Bug" ----Sold
1971 Baja "The Pre Runner" ---In Progress
1974 Race Car --- Collecting parts and funds
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Lughead Motorsports
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PostPosted: Tue Jun 02, 2015 3:34 pm    Post subject: Reply with quote

So as i was demoing the body and pans i found the rear of the yellow car to be in REALLY bad shape. to buy the new quarter panels and fire wall and assorted tin through mid america it was gonna be something like 1400$. so insted i found a 71' super beetle body in excellent condition that i could rob sections off of for 250$. WIN! but being a super beetle on a standard frame of course i couldnt use the front end really at all and the more i looked into the spots i needed to replace it was going to be easier to cut the two cars in half and frankenstine them into one! so thats what mostly going on here

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_________________
"Mistakes are proof that you're trying"

1969 Street bug --- For Sale... maybe
1968 Baja"The Orange Bug" ---Sold
1970 Baja "The Black Bug" ----Sold
1971 Baja "The Pre Runner" ---In Progress
1974 Race Car --- Collecting parts and funds
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sloboatnova
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PostPosted: Wed Jun 03, 2015 7:14 am    Post subject: Reply with quote

not bad not bad.
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3BT Baja build page
http://www.thesamba.com/vw/forum/viewtopic.php?t=417564&highlight=3bt+baja
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Lughead Motorsports
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PostPosted: Wed Jun 03, 2015 11:42 am    Post subject: Reply with quote

So then after i got that welded up and got it back resting so i could move it around a little (unfortunately i didn't get any pictures of the weld, note to self document pictures better check!) I spent some money! first traded in my trans core for a 091, with a super sand differential, a 002 5.38 ring gear, welded 3rd and 4th gears, and a 002 bus bell housing. then i swapped out the drive flanges for my 930's and put on the 10 degree mount and set it in the car. then i bought a complete 1955 cc motor kit through Mike Crist at ReWerks and started the engine build. (which by the way is not the first time building a vw motor, started with the 1600 in the orange car, a 1641 in my blue street car, a 2107??? dont remember the exact size BIG in the black bug) here is all of those pictures (BTW we are about 2 posts away from being caught up to current status)
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_________________
"Mistakes are proof that you're trying"

1969 Street bug --- For Sale... maybe
1968 Baja"The Orange Bug" ---Sold
1970 Baja "The Black Bug" ----Sold
1971 Baja "The Pre Runner" ---In Progress
1974 Race Car --- Collecting parts and funds
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Lughead Motorsports
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PostPosted: Wed Jun 03, 2015 2:06 pm    Post subject: Reply with quote

Then as i was working on the engine Lots have parts have arrived

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The trailing arms you see there are going to be for the Class 5 Unlimeted build.

then i got to mocking up all of these new parts.


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and lastly now i am working on the body to have it ready when my body lift arrives from Bug Zyla and at that point ill start welding in and making the roll cage.



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And Thats where I'm at! please there is a lot of specs and stuff ive left out and exact plans i cant remember them all ask questions.

I do have a few design questions for yall too. Front suspension limit designs? i dont care to much for the hook and rod design as there is no give in that at all, also i have a racing buddy on his sand car that continously broke sock bolts because his limit strap was attached to that bolt. i dont want to keep replacing that bolt or have my front end fall apart all the time so im looking into better designs that i could Fab a urathane stop? i dunno any ideas are welcome. youll also notice the steering rack is still under design review not sure on how that goes my first time building a rack and pinon steering like this so its a little guess work in there too.
_________________
"Mistakes are proof that you're trying"

1969 Street bug --- For Sale... maybe
1968 Baja"The Orange Bug" ---Sold
1970 Baja "The Black Bug" ----Sold
1971 Baja "The Pre Runner" ---In Progress
1974 Race Car --- Collecting parts and funds
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EnjoyNukaCola
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PostPosted: Wed Jun 03, 2015 8:22 pm    Post subject: Reply with quote

WOW! Great work and nice stuff.
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Jcr. Kat
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PostPosted: Wed Jun 03, 2015 9:24 pm    Post subject: Reply with quote

Everything looked good until you said bodylift.off-road bugs don't need a bodylift
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race-desert
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PostPosted: Thu Jun 04, 2015 1:24 am    Post subject: Reply with quote

Nice work!
.
.
.
I'm gonna go out on a limb here .. but your buddy that is breaking shock bolts, I'm quessing there's probably no compression stop on his car and the shock is bottoming and being used as the stop... which transfers a Hugh impact load to shock bolt! I have never seen a shock bolt break because of strap being attached if done right. just my 1 peso worth!
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Aerindel
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PostPosted: Thu Jun 04, 2015 2:10 am    Post subject: Reply with quote

It doesn't make any sense that a limit strap would be breaking shock bolts. If you think about it the only force a limit strap is stopping is your own torsion bar force, a force that is being dampened by your shock in the first place so it will never be a high velocity force and the strap itself will have a buffering effect.

Now, when bottoming out in the downward direction there is a lot more potential force, the weight of your front end moving at what ever the vertical velocity is. When trying to figure out stops for my rail I didn't like the idea of hook and rod stops either but it seemed to be the simplest solution and many people swear by it, and having loose straps seemed...messy so I used hook and rod for the upward stop as well. I used a 3/4" grade 8 bolt and then stuck a 1" urethane bushing over it to provide a little cushion. Not sure if that made a big difference or not but it's worked so far.
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Lughead Motorsports
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PostPosted: Thu Jun 04, 2015 7:50 am    Post subject: Reply with quote

Jcr. Kat wrote:
Everything looked good until you said bodylift.off-road bugs don't need a bodylift


there was a LOT of discussion on this matter

Con's-
- Cost
- Weight added
- Is it honestly needed?

Pros's
- With the 33" tires I'm a little concerned of getting enough up travel and still utilizing a decent looking rear fender to keep it kinda sorta road legal.
- A much better way to tie the roll cage into the car, for my Class 5 build i fully intend to make it entirely out of tube just using enough of the car to keep within the rules and on that car there would not be any body lift as it will likely be trailered most places.
- i am 6'2" and so is my old man, having the seats up a little higher, and a little more head room on the cage cant be a bad thing.
- also more room flexibility for the steering modifications.

race-desert wrote:

I'm gonna go out on a limb here .. but your buddy that is breaking shock bolts, I'm quessing there's probably no compression stop on his car and the shock is bottoming and being used as the stop... which transfers a Hugh impact load to shock bolt! I have never seen a shock bolt break because of strap being attached if done right. just my 1 peso worth!


Lemme clarify something first off it wasn't really a friend, buddy or anything. merely a guy who had a sand car when i was much younger and would pre-run the Baja 250 with the team that i was learning and taking pointers from. and aside from the breaking bolts frequently his car looked really cool (granted i was 14 most sand cars are pretty cool). that being said i don't remember how it was exactly set up i know a strap was on one of the shock bolts and it continuously broke. this being my first full on pre runner, and first for a lot of things i have never assembled the link pin beam before, nor have i ever built the all coil over and bypass shocks suspension before either. but the engineer in me definitely agrees the shock (unless your spring rate is WAY to high) should be in relative low amount of sheer stress in jounce it would probably be the full compression that would have been fatigue fracturing the bolts. Interesting hrmmmmm


Aerindel wrote:
When trying to figure out stops for my rail I didn't like the idea of hook and rod stops either but it seemed to be the simplest solution and many people swear by it, and having loose straps seemed...messy so I used hook and rod for the upward stop as well. I used a 3/4" grade 8 bolt and then stuck a 1" urethane bushing over it to provide a little cushion. Not sure if that made a big difference or not but it's worked so far.


i was looking at the car last night and came to a slightly different conclusion but your right that could be a decent solution. did you weld a bung into the tower, a sleeve retainer, and then the bolt through the center? I do kinda like that idea.
_________________
"Mistakes are proof that you're trying"

1969 Street bug --- For Sale... maybe
1968 Baja"The Orange Bug" ---Sold
1970 Baja "The Black Bug" ----Sold
1971 Baja "The Pre Runner" ---In Progress
1974 Race Car --- Collecting parts and funds
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Aerindel
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PostPosted: Thu Jun 04, 2015 5:06 pm    Post subject: Reply with quote

My shock towers are just stock hollow '72 ones with gussets added so all I did was drill a hole straight through both sides and weld a bolt in. I thought about welding in a sleeve so that I could remove the bolt if it was ever damaged but I think the bolt is so much stronger than the stock shock tower that anything that could bend the bolt would just rip it out of the front end anyway. With the shock towers you have I think you have more options.
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Lughead Motorsports
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PostPosted: Fri Jul 24, 2015 9:44 am    Post subject: Reply with quote

Got the Body lift in and been working on the car again. gonna be a couple of weeks still before i can spend some money on it but i can get some labor done here. so here's some more recent pictures

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Transmission details


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set the body on the lift and the shock towers hit the front body (expected this but needed to see it first) i cut some out to rest the body down on the frame but im gonna need to cut more out to fit the coil overs up front.


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so you can see the lift from bugzyla conforms perfectly, looks like its gonna work awesome. clear access to the shift linkage still and looks great.
here you can see the cuts i made to fit the body on but ill need to remove more yet. and i also trimmed off the rear of the super beetle. i gotta cut more of it off yet and cop the bottom of the fire wall down to fit the fuel cell in where i want it. a lot more cutting and fab work coming up Smile
_________________
"Mistakes are proof that you're trying"

1969 Street bug --- For Sale... maybe
1968 Baja"The Orange Bug" ---Sold
1970 Baja "The Black Bug" ----Sold
1971 Baja "The Pre Runner" ---In Progress
1974 Race Car --- Collecting parts and funds
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Lughead Motorsports
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PostPosted: Fri May 27, 2016 10:13 am    Post subject: Re: 1971ish Baja Bug Pre-Runner Reply with quote

Well Well Well, its been a while since i updated yall (sorry my bad). ive been busy too, well here we go...

First i preped the body for paint and welded the sections, stock gas fill cover, and a few other misc pieced on the body

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Then started with the ecth primer on the bare metal,

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then laid down two layers of white primer

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then pulled the frame in and painted that all with truck bed liner

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Then painted the suspension components Blue and assembled

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_________________
"Mistakes are proof that you're trying"

1969 Street bug --- For Sale... maybe
1968 Baja"The Orange Bug" ---Sold
1970 Baja "The Black Bug" ----Sold
1971 Baja "The Pre Runner" ---In Progress
1974 Race Car --- Collecting parts and funds
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Lughead Motorsports
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PostPosted: Fri May 27, 2016 10:40 am    Post subject: Re: 1971ish Baja Bug Pre-Runner Reply with quote

And now I've started Cage Fabrication. First off ill admit that i had the initial 6pt cage given to me and that's where i started. after those pieces were installed all following tube frame work is of my own creation. one thing i always hated about previous bugs is the front cage post that comes with these generic kits lands too far into the doorway because of where the dash is. this makes it hard for my unflexible arse to get out sometimes, and i seem to always catch a foot on that post. for this car i decided i would cut out part of the dash and push this post forward. to do that i needed to make my dash modifications. and well take a look.

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Then the main 6pt Cage begins

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here is how i integrated my roll cage into the 3" body lift

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Then i cut out a hole to lower the top of my fuel cell so i can make my fill tube how i want it.

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Then i started my Rear suspension fabrication

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(Note yes i know my roof rack is ridiculous. please pause this shot was my first try at my idea, and that idea has only changed 5 or 9 times)

Then i Put the engine in for the first time and built a cage and bumper system. and i really like how it turned out. i started with this run of the mill bumper that came with the car,

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then found that i was going to end up changing to much of it to save so i just scrapped it and made my own

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Like i said it turned out awesome. got to make a tow point, skid plate mounts, and light mounts and its finished

then i started up front with my steering wheel and shaft

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Then i made the front beam to cage connections

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After that was completed i mounted my fiber glass cut them back for clearance. and started my front bumper. this is the sketch i made on my iPad
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and heres how it turned out

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And thats where im as of last night! theres still a ways to go but it is coming along fast now Smile
_________________
"Mistakes are proof that you're trying"

1969 Street bug --- For Sale... maybe
1968 Baja"The Orange Bug" ---Sold
1970 Baja "The Black Bug" ----Sold
1971 Baja "The Pre Runner" ---In Progress
1974 Race Car --- Collecting parts and funds
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Outatime
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PostPosted: Fri May 27, 2016 11:58 am    Post subject: Re: 1971ish Baja Bug Pre-Runner Reply with quote

Awesome ! Very nice build.
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dustymojave
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PostPosted: Tue May 31, 2016 10:00 pm    Post subject: Re: 1971ish Baja Bug Pre-Runner Reply with quote

I DO hope you've eliminated that silly spacer of square tube between the rack and its mount brackets. It didn't need a body lift. You spaced the beam from the pan, not the beam from the spindles. Have you cycled the steering???

The front upper beam brace tubes are not exactly the strongest I've seen. Are you intending to let the beam flex around?

What about the lower front beam supports? Will they be tied together? Are you going to add any diagonal bracing in that front end of the cage structure?

I normally recommend against those beam adapter spacers. They don't improve front end strength. But since you're adding tube structure from the beam to the a-pillar, the adapters become meaningless and could be removed with the beam bolts.
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Richard
Offroading VW based cars since 1965
Tech Inspection 1963 - 2012 SCCA/SCORE/HDRA/MORE/MDR +
Retired from building Bajas, Fiberglass Buggies and Rails in the Mojave Desert. Also Sprints & Midgets, Dry Lakes, Road Race cars. All types New and Vintage
SoCalBajas Member
Kicked Cancer's A$$...1st and 2nd round...Fight ain't over yet.
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Lughead Motorsports
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Joined: August 06, 2008
Posts: 22
Location: Oregon
Lughead Motorsports is offline 

PostPosted: Fri Feb 24, 2017 2:45 pm    Post subject: Re: 1971ish Baja Bug Pre-Runner Reply with quote

Well again its been a while. and well I've made a lot of progress in lieu of some issues. looks like the last update was literally just days before i broke my leg and needed surgery + 13 screws in tibia/ fibula ouch... then at the end of recovery work took me out of town for 6 months, and working 7 hours away from the car really puts a hamper on progress.

anyhoo here is some actual progress!

i redesigned my roof rack and created a definite one off custom rack.


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i got my custom ordered Gauges from speed hut in


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in order to keep the finished car street legal i ordered some mudflaps, then made some mounts off my rear bumper/ cage. and i made em so that they will be easily removable


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ordered and recived all my AN fittings and hose, wow that was more expensive than planned...


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with all that done i was able to close in the interior cage/ fuel cell attachment, (and yes the fuel cell can be removed with the drivers seat removed above the seat belt mounts or if i needed to it will also fit out the rear window)


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then i got this cool new tool for Revit nuts! these are awesome!!! with the tool i mounted my side mirrors, made my skid plate and engine cover mounts, and mounted my running boards, and fixed a couple factory body nuts.


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then i built my rear fenders, the passenger side didnt come out exactly the same as the driver unfortunately, still trying to find a way to fix the angle of the dangle but that will come.


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and i built my running boards/ body protection


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and tonight i will be adding a piece on top of those to look like this

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and that concludes this installment of my pre-runner build. thanks for tuning in Laughing
_________________
"Mistakes are proof that you're trying"

1969 Street bug --- For Sale... maybe
1968 Baja"The Orange Bug" ---Sold
1970 Baja "The Black Bug" ----Sold
1971 Baja "The Pre Runner" ---In Progress
1974 Race Car --- Collecting parts and funds
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Bashr52
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Joined: July 16, 2006
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Location: On an island in VA
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PostPosted: Mon Feb 27, 2017 6:08 am    Post subject: Re: 1971ish Baja Bug Pre-Runner Reply with quote

Wow, that's a lot of oil lines! Is there a reason you are not running the stock cooler and went to a full external setup?
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Lughead Motorsports
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Joined: August 06, 2008
Posts: 22
Location: Oregon
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PostPosted: Mon Feb 27, 2017 2:17 pm    Post subject: Re: 1971ish Baja Bug Pre-Runner Reply with quote

Just a design change, when I started the car was going to be smaller and I couldn't get the placement of the oil cooler in mind. I like the way it worked out so I ran with it. So thus I will be blocking off the stock cooler and routing the air down across the cylinders. I don't think that's really a lot of oil lines... one out to the thermostat bypass, one up to the cooler, one back from the cooler to the thermostat, out of the thermostat to the oil filter, and back into the motor. 5 in total, I don’t think I could eliminate anything either.

In there is also a -6 AN line for fuel whereas the oil lines are -8 AN

Edit: I read your comment wrong Bashr52, The main reason I did change my mind is that in order to get better than the stock oil cooler is you have to run the external somewhere outside the main engine compartment with a lot of air flow. Most installs you see are not enough air flow to really effect the cooling of the motor past what you can do with a modern stock oil cooler. Because of the fact I didn't think I could get it up on the roof and protect it, my original design was to only mount an oil filter and keep the stock the way it was. Fast forward to the construction of the roof rack and I got to looking and after changing the design of that 2 or 3 times I found that I had plenty of room and a good angle to mount it I changed my mind. This install, with the aid of the aux fan, it will allow better cooling for those long San Felipe Whoop sections and all day summer Oregon dune rally sessions.
_________________
"Mistakes are proof that you're trying"

1969 Street bug --- For Sale... maybe
1968 Baja"The Orange Bug" ---Sold
1970 Baja "The Black Bug" ----Sold
1971 Baja "The Pre Runner" ---In Progress
1974 Race Car --- Collecting parts and funds
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dustymojave
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Joined: January 07, 2007
Posts: 5802
Location: Lake LA, Mojave Desert, SoCal
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PostPosted: Mon Feb 27, 2017 10:40 pm    Post subject: Re: 1971ish Baja Bug Pre-Runner Reply with quote

The filter should always be the 1st stop outside the oil pump. Especially it should NOT be AFTER the cooler!
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Richard
Offroading VW based cars since 1965
Tech Inspection 1963 - 2012 SCCA/SCORE/HDRA/MORE/MDR +
Retired from building Bajas, Fiberglass Buggies and Rails in the Mojave Desert. Also Sprints & Midgets, Dry Lakes, Road Race cars. All types New and Vintage
SoCalBajas Member
Kicked Cancer's A$$...1st and 2nd round...Fight ain't over yet.
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