karu's buggy build

joescoolcustoms · Posted: Tue Aug 19, 2014 4:53 am Post subject:

I agree with Gary, a better column suited would be a column from either a Beetle or Karman Ghia of '67 and earlier vintage. The early ones are a tube to the top and have the top/rear support bearing in the tube, not the big clunky black housing.

Do not get a 50's model with the course splines from a Oval, real hard to get wheel adapters for those.
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race

Everyone is gifted. Some just do not open the package.

Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone

karu · Posted: Sun Aug 24, 2014 11:51 am Post subject:

Here is another mock up. I still have a ton of things to do on the chassis.

Image may have been reduced in size. Click image to view fullscreen.

joescoolcustoms · Posted: Sun Aug 24, 2014 12:06 pm Post subject:

Wow!

That is looking great.
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race

Everyone is gifted. Some just do not open the package.

Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone

karu · Posted: Sun Aug 24, 2014 2:24 pm Post subject:

joescoolcustoms · Posted: Tue Aug 26, 2014 4:57 pm Post subject:

Yesterday I went over to Karu's house to take him some parts and give suggestions on how some things can be done to give him ideas and he can choose what and how he wants it done his buggy.

Steering column and a couple other bits.

Got to take a good look at his work and his chassis and it is super nice, and very well done. Fit and finish is top shelf quality. His fuel tank is a small piece of art. This will make a very sweet, comfortable driver friendly buggy. Looking forward to seeing it done and cruising with him next Spring!
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race

Everyone is gifted. Some just do not open the package.

Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone

karu · Posted: Tue Aug 26, 2014 6:27 pm Post subject:

karu · Posted: Sat Sep 06, 2014 11:34 am Post subject:

Last few days I have been working on the fuel tank. After fabrication, I found that the tank did not fit in the space and was interfering with the hood. Had to add two new sides (marked with arrows).

I also added two baffles to the tank.

Then I pressure tested to 10psi. Had to re weld few leaks.

Here are few more pictures.

Next, I am working on welding some steel flat bars around the tank so it can rest on the fiberglass body.

This took up lot of my time specially as I had to modify it after doing all the welding. However, I am quite happy with it.

joescoolcustoms · Posted: Sat Sep 06, 2014 12:16 pm Post subject:

Looks good! Progress.

I will be over in your area tomorrow, (run to Lowe's for bolts) and will drop off a shift rod for you. My truck is full of new metal roofing for my house, so I will pick up the parts at a later time.
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race

Everyone is gifted. Some just do not open the package.

Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone

karu · Posted: Sat Sep 06, 2014 12:41 pm Post subject:

karu · Posted: Sat Sep 20, 2014 1:41 pm Post subject:

Done with all the welding.

Time to prep for painting. Poured some phosphoric acid (30% strength) and have been shaking the tank about every 10-15 minutes. Need to take the mill scale out before painting.

Joe (joescoolcustoms) suggested that I can tie in the tank and the front end of the body and attach the tank to the chassis body mounting holes. Made two 'legs' and drilled holes for the bolts. Thanks for the idea Joe!

I think this will tighten up the front end quite nicely without any other support. I will post pics later once I mount the tank.

karu · Posted: Thu Sep 25, 2014 3:16 pm Post subject:

Finished the gas tank. Here are some pics.
Used rattle can paint, duplicolor titanium. together with etching primer. I like the color. Not too flashy.

joescoolcustoms · Posted: Fri Sep 26, 2014 1:57 pm Post subject:

Looks nice!

Did you figure out the final capacity?
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race

Everyone is gifted. Some just do not open the package.

Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone

karu · Posted: Fri Sep 26, 2014 9:04 pm Post subject:

karu · Posted: Sun Nov 02, 2014 6:41 am Post subject: steering column

It has been slow going for my buggy build. I was looking at various options for steering column. Joe (Joescoolcustoms) let me borrow his early steering column to get an idea.
Finally I decided to go with a generic GM style chrome column commonly available on ebay. Next question is how to attach it to the vw steering box. I got some suggestions from jsptown (thanks!) but decided to slightly change it.
I got a .75" to 1" DD universal joint and a 0.75" rod which I shaped to .75"dd on one end and turned down to .64" on the other end. Here is the set up.

I am planning on drilling the clamping piece and put about 2 plug welds and also weld partially around the top of the piece to the metal rod. I want to avoid putting too much weld which may create weak points.

Question: Does anyone know what material the clamping piece in the picture is made of? I am assuming it is mild steel (low carbon) and hence ok to weld. Correct me if I am wrong.

I will be partially grinding the two 'wings' which should also give me an indication of the material.

Also, any suggestions as to the best way of welding this?

I am also thinking about welding two small gussets from the rod to the partially ground wing. Let me know what you guys think.

Note: I am only welding the rod to the clamp. NO WELDS ON THE U JOINT!!!

karu · Posted: Fri Jun 17, 2016 3:49 pm Post subject: Re: karu's buggy build

It's been a while since I posted any updates on the build. I have been working on few items. Here are some pictures of side pods. It took me lot of time to fit them in and also ran into trouble with my larger front wheels not clearing the pods.

karu · Posted: Fri Jun 17, 2016 4:31 pm Post subject: Re: karu's buggy build

This the another thing I was working on.

Could not get the ideal location for the fuel door because of the scoops.

fiaroadster · Posted: Fri Jun 17, 2016 11:58 pm Post subject: Re: karu's buggy build

Any final b/p on the tank with the latest mods?

karu · Posted: Sat Jun 18, 2016 4:45 am Post subject: Re: karu's buggy build

karu · Posted: Sat Jun 18, 2016 11:15 am Post subject: Re: karu's buggy build

I was curious about sandwich core construction they are using in aircrafts; mainly in experimental/home built ones. They say it is strong but I had to convince myself.

Here is a 10"X10"X1/2" of common insulation foam sandwiched with 2 layers of 6 oz glass each side supporting my weight.

Not bad at all!!!

So I decided to use the technique to construct a custom dash.

There is still lot of finishing and also need to make a cutout for the steering column.

andygere · Posted: Sat Jun 18, 2016 12:05 pm Post subject: Re: karu's buggy build

Great craftsmanship and nice documentation of the work. I'm looking forward to seeing the finished product, as I'm sure you are.


Hello! Log in or Register \| Help \| Donate \| Buy Shirts	See all banner ads \| Advertise on TheSamba.com

Forum Index -> Kit Car/Fiberglass Buggy/356 Replica		Share:
		Print View

	Forum Index -> Kit Car/Fiberglass Buggy/356 Replica	All times are Mountain Standard Time/Pacific Daylight Savings Time Page: Previous 1, 2, 3, 4, 5, 6 Next
Page 5 of 6