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.
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.
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.
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.
In this video you have to look for the changes. The engine is tilted back at the correct angle for the Toyota MR2 3SGTE engine. I also have blocks supporting the engine from below (no weight on the chains of the shop crane). I still need to install the rear cross-member to get everything exactly where it needs to be in the VW Bug rear end.
After installing the MR2 passenger drive axle, I can now bolt the wheel on. The wheel will sit in the wooden box for the VW bug rear end alignment.
After installing the MR2 transmission, I am now able to start the rear end assembly. As you can see I have installed the passenger side rear drive axle.