In order to weld the VW bugs “x” member properly to the main frame, It must fit perfectly. I cut this first piece long and slowly ground it down to insure the proper fit.

After cutting out the VW bugs “x” member paper template, all I need to do is to transfer the profile to the 1.5 x 1.5 inch steel tubing. I will cut this piece a little bit long because I don’t want to throw it away. I will slowly grind it down to get the perfect fit.

Once I marked the paper template to match the VW bug lower frame work, I can draw straight lines from corner to corner. I then centered the “x” member tubing on each center line and traced around them. I can cut out these template profiles and tape them onto the tubing to transfer the markings.

I have now tacked on all three lower VW bug frame members. Now I need to create an “x” member setup between the center two cross-members. I will accomplish this by under-laying the frame with thick brown wrapping paper and tracing out the profile. This profile will be used to determine the shape and size of each part of the “x” member.

With the Vw bug’s front framing members in place, I need to continue with the lower frame units. I will use three cross-members in the lower frame. There will be one at the very front to stabalize the nose and two more will be spaced along the lenght of the frame.

These slide shows basically show the completion of the VW bug front frame and suspension members. The MR2 front lower control arms have been positioned.

The vw bug’s front frame members have now been tacked into place. From here I will be building the lower framing to support all of the MR2 gear.

After putting all of the VW bug front end suspension pieces together, I need to move the MR2 front torsion bar mounts down about 1/2″. I notched the frame and angled it down a bit to match the new location of the nose member. I am now ready to weld it all togther.

All of the VW front suspension pieces have been finished and the front of the main frame rails have been cut to length. I will soon weld everything together.

Both VW bug main frame rails have been reattached and are in place for the final time. I have also reinstalled the MR2 lower control arm mounts. All I have to do now is to cut a bit more off of the front of the main frame rails to line up the front frame member. Once everything is correct I will weld it all together.