I now have all of the VW Bug wheel boxes constructed. These boxes are an exact fit and a bit snug on the tires. The boxes help to hold the wheels and tires verticle as well as determining their position on the concrete floor.
After playing a bit more with the ride stance of the VW Bug, I created legs for the platform and bolted everything to the concrete floor. I have also started building boxes to contain the wheels and tires.
The VW Bug is now blocked up to correct ride height. I have been mocking up and aligning the rear drive train as well to determine exact ride width.
I set the VW Bug body with attached platform back down on the floor. I then placed wooden blocking under the platform to determine the correct body angle and ride height. To aid in this determine I hung all the sheetmetal on the body (fenders, doors and hood).
I have now finished the bottom plywood template/platform. This will bolt directly to the bottom of the car.
With the VW bug lower rails repaired, I can now fit for the plywood template/platform. I set the beetle body down on plywood using the bolts to mark where the holes need to be to create the template. This video is shaky when in telephoto mode.
Once I had the VW bug lower rails filled with foam and cleaned up, I welded the new rail plates to the lower rails. The bolts sticking out of the plates are to mark hole locations in the plywood template.
I cut the excess foam off flush with the bottom of the VW rails and cleaned the edges with my hand grinder and a belt sander. Preppin for welding.
I am spraying foam into the VW lower rails to dampen any vibrations and try and prevent moisture buildup.