Stretched 68 Sand Rover Buggy!

[STCarter]

Got a buggy in August last year and just completed it other than a cage. Thought I would share my journey!

When we brought it home. And figuring out what to do with the battery.

[STCarter]

Rebuilding the whole front end.
Front suspension. Added an adjuster to top beam.
Replaced all brake parts.
Found and old bug gas tank and fitted it back into the front tank area. The corners needed some modification for the hood to clear properly!

[STCarter]

Rear Seat and trunk construction.
Since the body was stretched to fit a full frame, I had enough room to make small lockable trunk! And there is more storage under the seat between the heel board and the buggy body.

[STCarter]

The entire rear of the body was suspended in midair so I built a sub-frame to support 2 more passengers. I also didn't like how the body was bolted to the frame with a larger washer, a gap, another washer, another gap, etc... It had the lower surface of the body warped up. So I made one really long washer to sandwich the body to the frame. Took a 2.5" piece of metal and bent it 1.75" to make a piece of angle 1.75x.75". Cut splits in it to make the bends and then welded it back up.

[STCarter]

Previous owner had part of an original bug steering column mounted. It was missing the collar, the turn signal everything, and just crappy looking. I bought a 28" Ididit column with tilt and turn. NICE!

[STCarter]

Getting the body ready for paint. This thing was in bad shape. The very small "fire wall' area in the front alone had 23 holes in! Crakes everywhere and where the body had been stretched, needed a little attention. So nothing to do but get small fiberglass and start rubbing!

[STCarter]

Finally getting to put it back together!
It's been a long project but it was worth it. Still need to build a cage but at least I can enjoy it now.

[STCarter]

And the final product minus the roll cage!

Well how did I do?

[andygere]

Fantastic build and nice documentation. You are going to have a lot of fun with that Buggy.

It looks like you are using a Hurst shifter. How was the fit with the cup holder console you are using? I have a full pan Manxter, and that console looks like a good solution. How is it attached to the tunnel? Did you shorten your e-brake handle, or is it stock.

[STCarter]

Thanks, The shifter is just one of those EMPI trigger shifters. It was in it already. Works and fits just fine.

The cup holder came from moore parts. It's a little flimsier than I would have liked, but after screwing it in, it seems pretty stable enough. We can put two large drinks in it and it doesn't fall over. I am satisfied enough with it that I would buy it again. It attaches with 3 screws. One each side at the shifter and 1 near gas pedal.

eBrake is all stock. In fact the whole pan and all is stock.

[E-smoke]

Nice!
Looks like a great family ice cream getter!
a couple of questions, what did you use to power those speakers up front? Is it worth it in a buggy, as in can you hear the music?
Thanks,
E

[STCarter]

The radio is a JBL PRV-175. Look at the dash picture, the radio is on the right. It's loud enough to hear. Your not going to win any sound offs but good enough. The radio does have RCA outs of you wanted to amp it.

[BIGMIKEY]

What wire harness did you use or did you make your own? Nice neat build.

Mike T
_________________
BIGMIKEY

Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=

1973 Beetle Driver, Marina Blue.

[hillmotorsports]

Would you please share details of the steering U-joints?
_________________
Rosemarie and Paul Hill
Morrisburg, Ontario

(With way more projects than spare time!)

[STCarter]

The wiring harness came from eBay. It was a Keep it Clean branded from a Seller named JohnnyLawMotors. The one I got was an 18 circuit for $87. Couldn't find the item number of mine but here is a 16 circuit item number. 181846651378 And to make grounding easy, I got a ground bar from HomeDepot that goes in a house panel. So simple. Just solder the wire ends first the screw em in!

The u-joint setup is from another post I saw. Don't remember if it was here or not, but very simple. We all know you can't find a u-joint to fit the steering box, so. I have an Ididiti steering column 28" tilt. Top u-joint is a 1" DD to 3/4" DD. 3/4" DD shaft to a 3/4" DD to 5/8" 36 spline. The 5/8 -36 spline does not fit so a little modification is needed. I drilled out the splines with a 5/8 drill. I then drilled a (I think - or whatever size the other set screw is) 90 degrees from the other set screw and tapped it to match. The u-joint is still a very snug fit over the shaft so some persuading is still necessary! Before persuading I marked where the set screws would be and dimpled the shaft. After that a drove it on, tightened up the set screws and it works fine. Being the over doer that I am I did tack one spot of the u-joint to the shaft. Drimel can cut the tack easy enough if it has to come off.

[STCarter]

Finally got around to building a cage for the buggie! Tell me what ya think...

[STCarter]