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.
I am putting the finishing touches on the motor. I have completed the vacuum lines as well as the intake plenum. I have also gone over all the wiring and am now pretty much finished with the motor. I am past ready to start this thing.
Some more wiring and plumbing. I am getting very close finishing up everything to start this beast. The rear of the car is ready to go.
The wiring is close to completion, I will check most of the systems before I connect the computer. I still need to finish the ABS sensors and I am also still working on the plumbing. Getting very close to starting the engine.
With most of the wiring figured out, I still have a few wires that will travel through the center console. Before I do this I want to finalize the console and paint it. So I completed the shifter cable location through the rear firewall as well as the front of the fuel box. I trimmed the console down repainted and reinstalled it. I also completed the fuel level sending unit and fuel pump wire harness. Getting closer.