With both the front and rear aprons on, I can start mock-up on one complete side of the VW bug. I searched high and wide to find some hints on widening fenders, found none, this is how I am doing it. I am installing small support tabs to try and shape the fender. I will finish widening the fenders and running-board with small steel plates.
Now with the rear apron in place I can go ahead and start positioning the VW bug widened fenders. Since the front fenders will also be widened I must position the front sheet metal all at once. Once everything was positioned I drilled small holes through the front apron flanges to reposition for welding. I am ready to widen the front fenders.
To finish up the exhaust I must determine where the two tail pipes are going to attach to the 3 inch main tube. To do this I need to finalize the rear apron and to do that I need to fit all of the rear sheet-metal. I fit the rear fenders, deck lid and apron and then welded on the apron and marked out the holes for the exhaust tips. Each tip is stainless like the main tube.
Once all the interior panels were created I covered everything with the sound deadening and heat blocking materials. The underside of the engine compartment lids have a fiberglass/foil material applied that is good to 1200 degrees F. Everything is now sealed off from the passenger compartment.
With the VW bug Roll-bar finished I can start sealing off the engine bay and the passenger compartment. I am sealing it off with various sheet-metal panels and covers. Everything from the floorboards up has a layer of heat/deadening material.
The VW bug Roll-bar has finally been positioned. I had to determine where the shoulder harnesses attached and where the seat belts would mount. With everything tacked together, I removed the entire roll bar assembly to finish up the seat-belt mounts, welding and painting it. I welded in some gussets to strengthen the entire unit on each corner of the inside hoop. Now that the roll bar is finished and back in the car, I can shake the whole car from the roll-bar.
I can now install the VW bug roll bar. I bought a kit off the internet for a VW bug roll bar. Since this really isn’t a VW bug, I will modify the kit completely. I had to remove 3″ from the main hoops as well as about 6″ from the rear supports. I slowly cut, cut, and recut each piece to fit. After I tack the rear pieces together I will remove the whole assemble to weld and paint it.
With the VW bug now running, I can concentrate on getting some of the other systems working. I am replacing the original 6V wiper motor with the Toyota MR2 wiper motor. This will give me the different speeds as well as the intermittent function. The horn is easy just wire it up. I am also starting the fitment of the roll-bar. I am starting with a kit made for the bug and will then modify it. Backyard Build
This has been a long time coming, but I finally got the VW bug running. All in all it runs pretty good but will still need some tune up. To do that I need to get it on the road so I am continuing with all of the other systems. Got the horn now I need the wipers.
Both electrically and mechanically I am ready for engine start. I am getting ready to program both the wide-band O2 sensor as well as the main Vi-Pec computer itself. I am waiting on a few parts to finish up, so I am replacing the front sway-bar drop links with some spherical ball end joints which will be much stronger than what I had. I am also trying to get the front toe-in just right.