Baja Bug (RE)Build

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#1: Baja Bug (RE)Build Author: FLBaja , Location: Florida Post Posted: Mon Jan 10, 2011 05:28 AM
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In the past few months I have gotten very close to selling my baja to get money for other projects I have going on. But every time I get close, I end up going offroad and having a blast so I have made the decision to keep it!
So since I am going to keep it I have decided that I need to fix a few things that have come up after over a year of beating on it. I have been pretty lucky as the only mechanical problems I have had is a broken throttle cable and (just this weekend) the bearing in the drivers front wheel.

#2: Baja Bug (RE)Build Author: FLBaja , Location: Florida Post Posted: Mon Jan 10, 2011 05:33 AM
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Some of the things I need to fix are:

Reweld the patches I did where the post came up in front of the rear side windows. They have started cracking.

Find a better way to attach doors. I cut so much out of the door pillars that they have twisted and the doors wont stay lined up correctly

Put in a windsheild!!!

Paint the flat black (since the sun has now turned it grey) gloss black

Install an engine and front skidplate

Get new seat covers

Seal up the gaps between the diamond plate and the tubing in the front to help keep water out of passenger area

Get the brakes working better

#3: Baja Bug (RE)Build Author: FLBaja , Location: Florida Post Posted: Mon Jan 10, 2011 05:55 AM
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Here is the best pic I have to explain what Im talking about with the door pillars. My idea is to cut out whats left of them just under the bottom area of the windsheild and cut a piece of 3/16 or 1/4" steel to replace the door pillar and just bolt or weld the hinges to it


This is my idea to fix it


If anyone has a better idea or can think of anything I might want to consider please let me know. Im open to all ideas

#4: Baja Bug (RE)Build Author: FLBaja , Location: Florida Post Posted: Mon Jan 10, 2011 06:05 AM
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Not sure if you can see what Im talking about in this pic, but when I cut the diamond plate pieces to enclose the footwell area I left a 1/8" gap all the way around it so that the aluminum didnt move and start rubbing on the tubing. You would be amazed at the amount of water that comes through that gap when you hit even a small puddle at 60mph lol. Even though I like how easy the panels will come off, I havent had to take them off yet, so I am considering just siliconing the gaps. But I would rather do it in a way that still allows me to remove them if anyone has a better idea


#5: Baja Bug (RE)Build Author: FLBaja , Location: Florida Post Posted: Mon Jan 10, 2011 06:13 AM
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My idea right now is to repaint the flat black epoxy primer with a gloss black but I am up for any suggestions for a better idea. Since the flat black is a primer and I like how the flames turned out I would like to just tape off the flames and spray over the black (which is now grey) with another color. Maybe white??

#6: Re: Baja Bug (RE)Build Author: bajawarrior Post Posted: Mon Jan 10, 2011 07:20 AM
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FLBaja wrote:
Not sure if you can see what Im talking about in this pic, but when I cut the diamond plate pieces to enclose the footwell area I left a 1/8" gap all the way around it so that the aluminum didnt move and start rubbing on the tubing. You would be amazed at the amount of water that comes through that gap when you hit even a small puddle at 60mph lol. Even though I like how easy the panels will come off, I havent had to take them off yet, so I am considering just siliconing the gaps. But I would rather do it in a way that still allows me to remove them if anyone has a better idea



When I do the panels I cut 1/4 or 5/16 rubber hose. I cut it up the length
and slip it over the panels. you can use wether strip glue to keep it in place on the panels this keeps water out good and you can still remove them


#7: Baja Bug (RE)Build Author: FLBaja , Location: Florida Post Posted: Mon Jan 10, 2011 10:22 PM
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Thanks thats a much better idea than the silicone. Now that I am going to be keeping the baja, I should be ordering some new seat covers from you soon.

#8: Re: Baja Bug (RE)Build Author: FLBaja , Location: Florida Post Posted: Sat Feb 05, 2011 04:41 AM
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I finally got a chance to take a look at the baja. Had the flu for the past couple weeks but ready to get some work done on it now. Pulled the wheels off the front and it wasnt the bearings that locked up, it was just the brakes!
Kind of happy about that cause I was worried that if the bearings went bad enough to look up a tire that they probably would have done some real damage to the combo spindle.
Gonna pull the calipers off tomorrow and hopefully get them working again without a rebuild kit

#9: Re: Baja Bug (RE)Build Author: perrib , Location: Chandler Post Posted: Sat Feb 05, 2011 05:22 AM
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Good to see you keeping it.

#10: Baja Bug (RE)Build Author: FLBaja , Location: Florida Post Posted: Sat Feb 05, 2011 08:51 PM
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Well I feel like an idiot, it was the bearings! Sad Tried for a while to seperate the hub from the spindle on the drivers side with no luck, so I just removed the whole thing to take to the local VW guy to see if he can do it without trashing the spindle



I was able to seperate them on the passenger side just to find a mess of ground up bearings. I am very dissapointed with the grease I used. Evil or Very Mad Im sure the drivers side is much worse



#11: Baja Bug (RE)Build Author: FLBaja , Location: Florida Post Posted: Sat Feb 05, 2011 11:07 PM
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Messing around with photoshop I came up with this for what it would look like white. Any opinions on if I should go with white or gloss black?


#12: Baja Bug (RE)Build Author: crestfallen , Location: Wheeling, WV Post Posted: Sun Feb 06, 2011 12:33 AM
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White

#13: Re: Baja Bug (RE)Build Author: perrib , Location: Chandler Post Posted: Sun Feb 06, 2011 08:27 PM
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White. Black shows every defect old and new.

#14: Re: Baja Bug (RE)Build Author: MojaveRacer208 , Location: Lake LA - SoCal Mojave Desert Post Posted: Mon Feb 07, 2011 05:37 PM
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perrib wrote:
White. Black shows every defect old and new.

Count it 3 votes for white. Perrib is right!

I'm quite bored with the flat black deal anyway. I had my Baja in primer for 35 years Now it's pale gray with bright blue tubework. The graphics on yours look better with white too.



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