Building custom cars in my backyard

After determining how I was going to suppot the VW bug's front suspension framing, I constructed a foam mock-up of my 1x1 inch steel tubing. I then traced my markings onto the steel tubing and cut them out. I again cut them a bit long and slowly ground them down to fit. They fit nicely [...]

With the VW bug's front strut link and lower support tack welded in place, I must further support the assembly with additional bracing for triangulation. I believe I will use some 1x1 inch steel tubing and connect the front nose of the frame with the top outside portions of the strut link member.

After spending some time lining everything up perfectly, I finally tack welded the VW bug's front end suspension members together. This alignment was critical to insure that the front suspension track and ride correctly. I am happy with the results so far all I have to do is add some triangulation bracing to strengthen the [...]

Both of the lower VW bug strut link support members are in place and ready for welding. I spend a lot of time lining everything up to get all the members in the perfect positions. All I have to do now is weld it.

The front VW bug lower strut support members have now been cut to size from my foam templates. The main frame rails rake down a bit from the rear to the front so the strut supports need to be ground down on the back side to be perfectly vertical. Once they are the right size [...]

I cut the outside pieces off of my foam template to see how they fit under the VW bug strut link. I put both pieces on one side and it appears that they fit very well. Once the tubing is cut, I will have to grind the back side down a bit to get a [...]

With my new foam board template created, It appears that everything will line up correctly. I drew a center line down the center of the foam board and used half of each measurement to get everything exactly symmetrical. I can use the outside pieces of the template to cut out the steel tubing.

I now have the vw bug's front strut link complete. With the link reinstalled atop the MR2 struts, I can now plan out the support structure that will attach the strut link to the main frame members. I will use the foam board once more to align and center everything.

I cut the top out of the VW bug front link channel member to fit over the strut link itself. After cleaning it up a bit I clamped it to the strut link. I can now through drill it so I can bolt the two together with some grade 8 hardware. Once this is done [...]

The VW bug front strut link channel is a little closer to being complete. After cutting it to lenght I carefully measured where my bolt holes should be and drilled pilot holes. I will now cut out the top of the channel and test fit it to the strut link.