After clamping my masonite template to the .25 inch steel plates, I cut out the VW Bug frame pieces with the plasma cutter. One of the frame plates has a taller tab portion to accommodate the passenger side motor mount from the Toyota MR2 3SGTE engine. I will put a slight bend in these plates to match the angle of the main frame rails.
Using the VW Bug foam frame templates I constructed a masonite template to use as a guide for the plasma torch. I made this template .125 inches smaller that the actual foam template because of the plasma cutter’s tip. The template insures that I have an accurate cut on the framing steel which will go around the Toyota MR2 3SGTE motor.
Once the main frame rails are in place, I can now start building the VW Bug rear engine frame plates. I have constructed templates out of .25 inch foam board to determine their locations.
After creating the torsion bar mounts on the end of the VW Bug frame rails, I bolted up the Toyota MR2 torsion bars. I have also clamped the frame rails on the plywood template to be positioned between the front and rear suspension.
Now that I know where the VW Bug main frame rails will be, I am creating the MR2 rear torque bar mounts in the end of the rail tubing.
Creation of the VW Bug frame starts with determination of where and how the frame member will be positioned around the engine. I have very limited space around the Toyota MR2 3SGTE motor. My plan is to create a plate type frame that travels straight through the rear of the vehicle. I started with some small boards glued together to determine the lower profile of the plate so I can trace that profile on to a piece of foam board.
This video shows where the VW Bug main frame rails will terminate at the Toyota MR2 anti-torsion bars attached to the lower rear control arms.
I am placing the basket material (constructed earlier) over the Toyota MR2 3SGTE motor. This gives me a good idea where everything will sit under the VW Bug body. I need this info to start the initial frame planning.
The initial frame plan can start, now that I have the VW Bug’s drive train in place. As you can see I have finished the alignment of the Toyota MR2 3SGTE motor. I have both struts in place as well as the motor mounts and all the accessories (starter and AC unit etc.). Oh and the shop crane has been removed.
I now have the MR2 3SGTE rear cross-member installed as well as tying in all the suspension components. The two lower control arms and the two rear control linkages attach to the cross-member. This is a tight fit under the VW Bug body.