Building custom cars in my backyard

The main framing pieces for the VW bug's rear suspension are now tacked into place. I used the floor jack to jack the frame up from each rear corner and there was no frame deflection at all. I have also removed the wheels from the wooden boxes so I can jack the rear end up [...]

I am using some 1"x1" steel tubing to strengthen the entire VW bug strut towers and rear engine cage assembly. I am using the foam board to get an idea as to how long and at what angles to cut the tubing. Later I will stiffen up the front and the rear suspension with some [...]

I have now tacked the VW bug's strut-link to frame connectors into place and removed all the bracing. Its amazing how strong a couple of tack welds are, I can push and pull on the assembly with all my weight and it doesn't budge. I have a couple more pieces of tubing to weld on [...]

I now have the VW bug wheels completely vertical and locked into position. Both of the strut link connectors have been aligned and are now ready to be tacked into place. I am very close to a rolling chassis.

The VW bug's rear strut-link alignment continues. I now have the paneling clamped in place to hold the link straight side to side and front to back. I will need to insure that the wheels and tires are perfectly vertical before final alignment.

Alignment of the VW bug rear strut cross-link is proving to be trickier than first thought. After spending so much time lining up the front strut link, I will use it's alignment to help with the rear. I have purchased a cheap piece of paneling from the hardware store and will use the square factory [...]

Both of the VW bug's rear strutlink-to-frame connectors are now finished. I drilled five holes in them to increase the weld bold. I will now refit and align them before tacking them on.

Now that I have my angle iron strut-to-frame connectors cleaned up, I can test fit them to see how everything is going to line up. I will be drilling holes through the weld surfaces to increase the weld penetration and increase the bond. first I need to really get it all lined up perfectly.

I used my foam board templates to trace the profiles of both the 2" and the 3" sides to my steel angles. These angles will connect the upper VW bug strut link member to the lower plate frames on both sides. Once aligned I will weld them on to get my rolling chassis.

With the VW bug rear strut link height determined, I need to create framing members to connect the link to the main frame plates. I am using the foam board again to create these members. I am using a 3" and a 2" strip of the foam board and cutting them to fit. I will [...]