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Baja Forums -:- AzBaja.com Members -:- New Members -:- How to build a budget baja bug (please add to this)
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How to build a budget baja bug (please add to this)
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Billy
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Post Post subject: How to build a budget baja bug (please add to this)
Posted: Fri Jan 12, 2007 05:31 AM
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So yu gotta bug and yu wanna make a baja? I, and hopefully othres, will give you some quick tips to get yu started. I will add more as the days go and I have more time. Warning: Using a superbeetle is a pretty bad idea from square 1.

First step: Gotta take it apart.
The way I started this was from the outside. The socket and or wrench you're gonna use most is the 13mm so keep it handy. The fenders, and I believe the bumper brackets will use the 13. Taking these off can be a challenge if you got stubborn bolts or a bad back. Do't get frustrated and don't be distraught if you spend all day taking bumpers and fenders off. You might also take the front hood and engine compartment lid off too. Be careful when taking off the front hood- those spring loaded arms hurt when they hit you in the head. Believe me, it happened to me.
Now if you're like me, disassembling can be frustrating and boring because again if you're like me, you wanna build it up and see progress. Keep your cool, this has to get done first.
The interior doesn't necessarily have to be taken out. All depends on what you plan on doing. Taking out the seats can be as easy as sliding them forward or as difficult as getting on your knees and tampering at it with a screwdriver, but more on that tomorrow. Taking out thback seat is easy, just find and unbolt the bolts that mount it and the seat belts in with a 17mm. Unless you wanna make a baja with a powerful engine, I recommend (now this is my nonexperienced advice so take it for what its worth) keeping the backseat out and leaving just the 2 front seats. Ive driven with 3 average sized people in my daily bug and man does it crawl.
Like I said before, you might be a builder. Well there is something you can put on now, should you choose. Your front fenders double as rear fenders, and quite well. Durability, added with, whhel clearance, and the cost are basically what make them better than spending money on fiberglas ones, but you may choose to go fiber. To use the front fenders as rear:
-Take them off of the front
-The left front fender becomes the rear right fender, and vise versa with the other fender. Neat huh?
-Dry fit them, maybe even put in one or two bolts to hold them in place.
-using a permanent marker, draw the lines of where you will cut them to get the most usage out of them.
-Cutting can be done with a sawzall or a jigsaw.

Ok so now you have a bug stripped of the larger metal pieces and seats and rear fenders. Not a bad start for having spent nothing so far huh? Suspension lifting can be done for free too, assuming you have the tools already. I will cover this later. This link oughtta help you with thi and other things though sandlizrd.baja.com/bajatech.htm

Hope this is a good starter. If you see anything wrong with this or anything else I add, please PM me immediately, or if you think it is worth covering a detail I may have left out. Hope this helps some of the people getting started.


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Billy
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Post Post subject: Re: How to build a budget baja bug (please add to this)
Posted: Sat Jan 13, 2007 02:48 AM
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Removing the stabilization bar will allow your front suspension to become indepent suspension. This mean one wheel will be able to craql over something without taking the other wheel with it! This is another free upgrade, but it can be a pain in the exhaust if yurs are rusted or you don't life the car. The following steps on removal of the bar come from a shop manual I have, not me:

1. Raise the car on jackstands and remove both front wheels

2. Bend the lugs up on the clips and tap the clips off the damper.

3. Remove the clamps

4. Pull the stabilizer out.

Bada-boom independent front suspension. Here is a picture of the bar incase yu don't know:

That should help, if you need to I'll go take more detailed pictures of my own. But wait! Don't throw that bar away! We can use it as Jeff Hibbard points out and I will show you later on!


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locutisj
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Post Post subject: Re: How to build a budget baja bug (please add to this)
Posted: Sat Jan 27, 2007 11:07 PM
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Good stuff so far, but I'm WAY past all this. I know, baby steps.
I picked up a 68' from a friend a few years back whom stripped the thing all the way. I mean no interior, carpet, carpet padding the works. Even had the front and rear chopped off. I've very slowly been getting it back together. I've worked the front end by beefing up here and there, added adjusters for the torsion tubes. Now I'm finishing up the rear suspension. I added adjustable plates as well as replacing all the rubber with urethane bushings (front too). My next project will be to lift the body to replace both floor pans.
Any tricks on that?
My plan was to lift the body off with an engine hoist and rest it on a couple (4) saw horses. Each sh can support 1000lbs. Then roll the chassis out and do my thing.


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Post Post subject: Re: How to build a budget baja bug (please add to this)
Posted: Sun Jan 28, 2007 01:25 PM
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I used my tree stump puller to lift the body, then rolled the pan out.


Last edited by kcnaz on Mon Jan 29, 2007 01:07 PM; edited 4 time in total
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locutisj
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Post Post subject: Re: How to build a budget baja bug (please add to this)
Posted: Sun Jan 28, 2007 05:46 PM
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Your pic didn't come through.


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Post Post subject: Re: How to build a budget baja bug (please add to this)
Posted: Sun Jan 28, 2007 07:46 PM
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2 or 3 guys can lift the body off.

there is a neat pic on another site where a guy constructed a work rack for his baja project.

it was a high leg table (for the most part). the body rests on top while the pan (with wheels) rolls underneath for storage.



floor pan sections may be replaced pan off or on. off is most desired. for those without room or equipment to yank off the body, remove the seats and all flamables.

make sure you have the proper floor pan section for the proper side Shocked

when you remove the old floor pan section, be sure to cut it 1/2" less than the new section. this will allow the new section to rest on the pan and be welded in. if ya think Im nuts, the pan will shrink when welded. an exact cut will shrink too much on one side to allow a weld on the opposite.


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Post Post subject: Re: How to build a budget baja bug (please add to this)
Posted: Mon Jan 29, 2007 01:40 PM
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Found this on the web... One Day Baja

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Post Post subject: Re: How to build a budget baja bug (please add to this)
Posted: Mon Jan 29, 2007 02:42 PM
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Oh man that is SCHWEET!
If only I could get away (legally speaking) with that chop job on the fenders. Va. has restrictions on how much tire protrudes the fender and that set up would get me noticed by the men/women in uniform.

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Post Post subject: Re: How to build a budget baja bug (please add to this)
Posted: Fri Feb 09, 2007 03:35 AM
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Will that type of fenders pass in AZ. What are the minamal requaments.?

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kevin
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kevin

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Post Post subject: Re: How to build a budget baja bug (please add to this)
Posted: Fri Feb 09, 2007 06:40 AM
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fenders??? what fenders???

az is pretty easy about those. if your vehicle gross weight is over like 2k pounds, then you have to have fenders. a lot of sand rails are street liscenced with no fenders.


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