Building custom cars in my backyard

I have now finished drilling out both the driver and passenger side VW Bug plate frame holes. These four holes will be used to mount the plate frames to the Toyota MR2 crossmember. I still need to remove the steel above each bolt hole (where the nuts sit) in order to refit the frame plates. [...]

I am repeating the saddle block process on the VW Bug passenger plate frame unit. I must bolt these members to the Toyota MR2 cross-member.

Here are some long overdue pictures. Please see the MR2 VW Bug Turbo Photos page/link above.

As you can see from this video, I used the pilot hole drilled in my drill press to guile me vertically through the mounting block as well as partially through the plate frame. This mount point will connect the VW Bug’s framing to the MR2’s rear cross-member.

Once I had determined where the VW Bug cross-member holes should be, I removed the saddle blocks and drilled straight holes with the drill press. These holes will be my pilot holes for the bigger drill bit.

I need to drill out the MR2 cross-member bolt holes in the VW plate frame. I need to be very careful to align the holes perfectly so the bolts will be vertical through, not only the steel blocks but the frame unit as well.

Now that I marked the MR2 3SGTE cross-member holes, I can set it up to drill out the VW Bug frame members. As you can see the paint idea worked pretty well.

After bolting the VW Bug saddle blocks to the rear frame members, I can now reinstall and realign the frame members to mark the rear MR2 3SGTE cross-member bolt holes.

Now with the holes drilled out in the VW Bug frame saddle blocks, I need to bolt them to the 3SGTE frame members. After carefully aligning them I will drill out and mount these blocks to the rear frame members.

With my bolt holes drilled out in my VW Bug saddle blocks, I can now mark the locations where they will bolt up to the MR2s rear cross-member. I need to be careful how I position the blocks to insure that the main mounting bolt (vertical through cross-member) will be exactly centered.