1/28/2007 Donor Vehicle Acquired!-- 1996 Chysler Concorde. 174,000 miles, the motor and trans are quite solid. Chassis deemed unsafe
after running over mailboxes and curbs! This 'Hooptie car' was purchased for $350 and has many more usable parts than I'd anticipated..
I'll start by getting my chassis formed around this drivetrain, then replace it with an identical a lower mileage, 6 year younger all aluminum
300M drivetrain.
after running over mailboxes and curbs! This 'Hooptie car' was purchased for $350 and has many more usable parts than I'd anticipated..
I'll start by getting my chassis formed around this drivetrain, then replace it with an identical a lower mileage, 6 year younger all aluminum
300M drivetrain.
2/18/2007 Chassis Build-- Acquired manual mandrel tubing bender. Also decided that using my flat
utility trailer is ideal for a rigid, mobile platform for developing the 1.5" round tube chassis.
Modifications to the trailer will include detachable chassis mounting points, and screw-type leveling
jacks. Here is the engine cradle w/ rear sway bar to get started.
utility trailer is ideal for a rigid, mobile platform for developing the 1.5" round tube chassis.
Modifications to the trailer will include detachable chassis mounting points, and screw-type leveling
jacks. Here is the engine cradle w/ rear sway bar to get started.
5/28/2007 Skin Donor Acquired!-- So ugly, it's cute! (that's what they say, anyway) I hate to so seriously manipulate this
otherwise mostly solid '74 Superbeetle car body, but it was the cheapest one I could find...and no one seemed to want
it:( Many usable parts got sold to people trying to revive their bug/sand rail. Very little was wasted. Well, it wasn't so
rock solid after all- the 'new floor' was pop-rivited in to keep you from doing the Fred Flintstone.
otherwise mostly solid '74 Superbeetle car body, but it was the cheapest one I could find...and no one seemed to want
it:( Many usable parts got sold to people trying to revive their bug/sand rail. Very little was wasted. Well, it wasn't so
rock solid after all- the 'new floor' was pop-rivited in to keep you from doing the Fred Flintstone.
10/10/2007 Progress-- The front body-half is now altered to approximately the way I'd like it to end
up (yet to be channeled). The back half hasn't really been altered yet, just scooped out, and yes--
the motor does fit in the 'back seat'!
up (yet to be channeled). The back half hasn't really been altered yet, just scooped out, and yes--
the motor does fit in the 'back seat'!
11/04/2007 Slower Progress-- It's getting colder, windier, and wetter. This machine now has a heartbeat! Power
steering was changed to a '94 Dodge Neon...happens to work perfectly w/VW. 5gallon gas can converted to my fuel
tank. Wheel base is currently 103", probably will further be reduced to 99". Stock bug wheel base is 95". 53A's was
112". Things are already working together better than before....and I just might keep the front fenders.
steering was changed to a '94 Dodge Neon...happens to work perfectly w/VW. 5gallon gas can converted to my fuel
tank. Wheel base is currently 103", probably will further be reduced to 99". Stock bug wheel base is 95". 53A's was
112". Things are already working together better than before....and I just might keep the front fenders.
12/12/2007 Almost a Grinding Halt-- I took the time to build it a shelter for the winter. Radiator, Dash, Steering wheel
approximated. Further adjustment to rear 'turtle shell'. Rear lower suspension is finalized...upper is still being
approximated with adjustable coil-over shocks and adjustable toe-in and camber-- a Multi-tasking component:
fabrication not so easy....
approximated. Further adjustment to rear 'turtle shell'. Rear lower suspension is finalized...upper is still being
approximated with adjustable coil-over shocks and adjustable toe-in and camber-- a Multi-tasking component:
fabrication not so easy....
01/08/2009 Little details that are so important...Proper placement of brake pedal,
steering wheel, seats-- all accomplished! Coil-over shocks simulated with1/2" pipe
and "noodle" floatation devices. Original radiator determined NEVER to
fit...considering a '96 Plymouth Sunfire- designed for a 3800 lb car, 3.0 liter
V6...pretty close? And a whole bunch of frame work progressed...and I'm strongly
feeling the need to shorten wheelbase.
steering wheel, seats-- all accomplished! Coil-over shocks simulated with1/2" pipe
and "noodle" floatation devices. Original radiator determined NEVER to
fit...considering a '96 Plymouth Sunfire- designed for a 3800 lb car, 3.0 liter
V6...pretty close? And a whole bunch of frame work progressed...and I'm strongly
feeling the need to shorten wheelbase.
01/04/2009 Coil over shocks...so expensive and so important.
Can't determine the spring rate until the vehicle is finished...can't
finish the vehicle without the coil-overs. Well my solution: mock-up!
Instead of $900 worth of suspension, I'll settle for $27 fakes for the
moment!
Can't determine the spring rate until the vehicle is finished...can't
finish the vehicle without the coil-overs. Well my solution: mock-up!
Instead of $900 worth of suspension, I'll settle for $27 fakes for the
moment!
10/31/2008 The upper A-arms of the front suspension have been attached to a triangulated sub-frame, attached to the
lower frame. Part of the triangulation is the rack & pinion support. Now the front wheels have full articulation and the
geometry looks like it is going to perform as originally anticipated. Fire wall of original bug body lands perfectly onto tube
frame, and brake pedal & booster are being calculated with their neighbor- the 16 gallon fuel tank. Lucky weather allowed
all this to happen...usually it rains on Halloween!
lower frame. Part of the triangulation is the rack & pinion support. Now the front wheels have full articulation and the
geometry looks like it is going to perform as originally anticipated. Fire wall of original bug body lands perfectly onto tube
frame, and brake pedal & booster are being calculated with their neighbor- the 16 gallon fuel tank. Lucky weather allowed
all this to happen...usually it rains on Halloween!
10/12/2008 Now the work starts to show! Four 'real wheels' configured properly.
Upper A-arms in front suspension await attachment to front "arm-rail" part
of the chassis, exact location yet to be determined. Preliminary
measurements suggest: "No problem!"
Upper A-arms in front suspension await attachment to front "arm-rail" part
of the chassis, exact location yet to be determined. Preliminary
measurements suggest: "No problem!"
9/20/2008 Nice advances. Got the front suspension linked to the rear. So for the bottom 3" it's starting to
resemble a car! Very happy- because all measurements are very tight inside the bubble level...there are five
planes to measure and seven intersections. This is the platform on which the Z-dimension of the frame is to
be built upon. Now I've figured that compared a Type1 (bug), this vehicle will be 6" wider and 7" longer. A
lil extra work to the fenders (and better leg-room), but this engine is huge- so to have a larger footprint to
grab Earth may be safer in the long run.
resemble a car! Very happy- because all measurements are very tight inside the bubble level...there are five
planes to measure and seven intersections. This is the platform on which the Z-dimension of the frame is to
be built upon. Now I've figured that compared a Type1 (bug), this vehicle will be 6" wider and 7" longer. A
lil extra work to the fenders (and better leg-room), but this engine is huge- so to have a larger footprint to
grab Earth may be safer in the long run.
7/31/2008 Fortuitous extra curricular work landed me a perfectly-built piece of iron that had been used to protect an air
conditioning unit. I welded this green square steel to the trailer frame as to extend the work area to allow fixture of chassis
support. Next I build the front suspension lower A-arms, then bridge the sub-assembly to the rear.
conditioning unit. I welded this green square steel to the trailer frame as to extend the work area to allow fixture of chassis
support. Next I build the front suspension lower A-arms, then bridge the sub-assembly to the rear.
2/9/08 Winter Hermit: Still Alive-- These are the upper A-arms for the upper-rear
suspension. They'll be doing the job that the Chrysler struts used to do. I've decided
to utilize the exact same suspension in the front as well (that's where it originally was
anyway, and then many things will be close to equal front-to-back, simplifying
design). An important component is not pictured: attaching the ball-joint of the upper
A-arm to the top of the hub assembly where the strut attached. Well, it's been
created....
suspension. They'll be doing the job that the Chrysler struts used to do. I've decided
to utilize the exact same suspension in the front as well (that's where it originally was
anyway, and then many things will be close to equal front-to-back, simplifying
design). An important component is not pictured: attaching the ball-joint of the upper
A-arm to the top of the hub assembly where the strut attached. Well, it's been
created....
03/23/2009 Too bad it's not going to be a hard top! Wheel base is now 95".
Perfect 4 wheel alignment- to within virtually unmeasurable 1/16". Front
suspension, fuel tank, master cylinder, vacuum boost, radiator&fan, steering
column&linkage, seats...all tack-welded complete. Working on B-Pillar, which
leads to seat belts. Contemplating Lambo hinges.
Perfect 4 wheel alignment- to within virtually unmeasurable 1/16". Front
suspension, fuel tank, master cylinder, vacuum boost, radiator&fan, steering
column&linkage, seats...all tack-welded complete. Working on B-Pillar, which
leads to seat belts. Contemplating Lambo hinges.
05/10/2009 Lots of little things have been done, yet the appearance is not much different, except the
front fenders. Fourth draft on the rear bonnet hinges. They will allow the use of 'stock' exhaust cutouts
in the body. More frame work, opening up the pathway for the wire harness (which is an organized plate
of spaghetti right now).
front fenders. Fourth draft on the rear bonnet hinges. They will allow the use of 'stock' exhaust cutouts
in the body. More frame work, opening up the pathway for the wire harness (which is an organized plate
of spaghetti right now).
07/07/2009 The engine (needed work from having sat dry for a year) runs well, coolant and pwr steering
fluid are leak-free. E-fan wired in&works. Exhaust finished (a questionable concept of 2 cat converters,
2 glass packs, and 2 resonators, and fluctuating pipe diameter to tumble&help knock down some dB, but
works well enough where I think I won't get a ticket) Entire chassis front to B-pillar completed, fully
welded & ready for pavement. Front fenders stretched&smoothed, 1st draft of rears. Wire harness
significantly installed. Seats&belts installed.
fluid are leak-free. E-fan wired in&works. Exhaust finished (a questionable concept of 2 cat converters,
2 glass packs, and 2 resonators, and fluctuating pipe diameter to tumble&help knock down some dB, but
works well enough where I think I won't get a ticket) Entire chassis front to B-pillar completed, fully
welded & ready for pavement. Front fenders stretched&smoothed, 1st draft of rears. Wire harness
significantly installed. Seats&belts installed.
07/24/2009 Touchdown
08/04/2009 4.5 hrs at the Secretary of State and it's licenced. All electrical is operational. All major mechanical
complete. Weighs in at 2400 lbs, 62% in rear. So, a lil bit rear-heavy, but the next gen 3.5L is about 200# lighter,
and with doors, floor & a bit more stuff up front, I'm hoping to end up 58% weight in rear. 30 Miles accrued. My first 5
minutes of trial run included a standing applaud from a 4 year-old. Wow, I am truly touched!
complete. Weighs in at 2400 lbs, 62% in rear. So, a lil bit rear-heavy, but the next gen 3.5L is about 200# lighter,
and with doors, floor & a bit more stuff up front, I'm hoping to end up 58% weight in rear. 30 Miles accrued. My first 5
minutes of trial run included a standing applaud from a 4 year-old. Wow, I am truly touched!
08/26/2009 380 mile accrued. 30 more than after 53A was stolen. So far, so good- spring rates as determined by
purveyor were WAY wrong. Oh well, it's an educated guess anyway. Friend V saved me on this one. It does
85mph smooth as silk. Accelerates swiftly. Steering is a bit tight. I do think of The Botfly when I go somewhere in
one of my 4 cylinder cars:) Oh so slow... Overheating problem was cured- a rubber nipple on a vestigial radiator
overflow tank fitting was allowing air to get sucked in. Hottest summer weather indicates this system will survive.
purveyor were WAY wrong. Oh well, it's an educated guess anyway. Friend V saved me on this one. It does
85mph smooth as silk. Accelerates swiftly. Steering is a bit tight. I do think of The Botfly when I go somewhere in
one of my 4 cylinder cars:) Oh so slow... Overheating problem was cured- a rubber nipple on a vestigial radiator
overflow tank fitting was allowing air to get sucked in. Hottest summer weather indicates this system will survive.
12/11/2009 Diligent work rewarded! 1400 miles accrued. It performs! Handles reliably and
predictably around corners as if to defy physics. Best brakes in my life I've ever had the privilege
to stomp on...must consider tailgaters! Cabin heat, blower motor, and associated flap controls
installed. Although ductwork is temporarily composed of 1/4" styrofoam, it provides a pattern from
which metal will be formed. 8-way power seats. Windshield wipers (w/mist delay!). I relaxed the
steering ratio articulation a little by lengthening steering arms. Original beetle door propped up to
help visualize work for the scissor (Lamborghini-style) door hinge. Also shows how I put the body
together, leaned the windshield, and gave it the nose-down attitude.
predictably around corners as if to defy physics. Best brakes in my life I've ever had the privilege
to stomp on...must consider tailgaters! Cabin heat, blower motor, and associated flap controls
installed. Although ductwork is temporarily composed of 1/4" styrofoam, it provides a pattern from
which metal will be formed. 8-way power seats. Windshield wipers (w/mist delay!). I relaxed the
steering ratio articulation a little by lengthening steering arms. Original beetle door propped up to
help visualize work for the scissor (Lamborghini-style) door hinge. Also shows how I put the body
together, leaned the windshield, and gave it the nose-down attitude.
12/20/2009 Winter is here. I installed a wood-burning stove in my garage to facilitate & accelerate fabrication this winter.
I will NOT be freezing snot to my face again this year! This will be phase 2: Scissor doors, front aerofoil, air intake and
trans cooler induction in the rear, floorboards, rear firewall.
I will NOT be freezing snot to my face again this year! This will be phase 2: Scissor doors, front aerofoil, air intake and
trans cooler induction in the rear, floorboards, rear firewall.
2/13/2010 Cold-air intake (painted white) was rear 1/4 panel/tail lamp section from
Concorde. Cardboard mock-up front aero. Removed side panel exposes frame to
support scissor hinge. Also, not shown, I've acquired hand brake cooperative
caliper to supplement rear caliper.
Concorde. Cardboard mock-up front aero. Removed side panel exposes frame to
support scissor hinge. Also, not shown, I've acquired hand brake cooperative
caliper to supplement rear caliper.
3/28/2010 Rear suspension limiters installed. Lowered front end 3/8", raised rear
end 1/2". Running board 'outers' installed in prep for sheet metal. Bumpers
installed & exhaust tucked a bit further in. While replacing a water-pump seal,
also discovered one cam shaft had been slipped a tooth on the timing belt for
who knows how long, but oh well- it runs!
end 1/2". Running board 'outers' installed in prep for sheet metal. Bumpers
installed & exhaust tucked a bit further in. While replacing a water-pump seal,
also discovered one cam shaft had been slipped a tooth on the timing belt for
who knows how long, but oh well- it runs!
4/17/2010 Running boards fabricated. Cold-air intake & trans oil cooler
permanently mounted. Horns relocated to the front. Driving lights installed.
Windshield washer reservoir mounted, plumbed, wired. 1700 miles accrued: it's
running even better now with the timing belt where it should be. Of coarse.
permanently mounted. Horns relocated to the front. Driving lights installed.
Windshield washer reservoir mounted, plumbed, wired. 1700 miles accrued: it's
running even better now with the timing belt where it should be. Of coarse.
5/31/2010 Roll bar re-do into a parabola for better rear-view. Sheet metal on
rear skirt, side scoops. Cardboard template floor pan and gunnel. Pulled rear
spoiler lower&closer to body. Moved battery to very front of car for better
weight distribution & handling. This includes post chassis-build relocation of front
sway bar. Passenger firewall built, driver's half-built. Passenger heat 100%
finished, included moving front firewall all the way forward to gas tank. Firming
up center console. Installed radio w/power antenna. Silenced many squeeks
with creation of bumpers for rear 'clam-shell'. 8-way power seat switches
relocated. 2400 Miles accrued.
rear skirt, side scoops. Cardboard template floor pan and gunnel. Pulled rear
spoiler lower&closer to body. Moved battery to very front of car for better
weight distribution & handling. This includes post chassis-build relocation of front
sway bar. Passenger firewall built, driver's half-built. Passenger heat 100%
finished, included moving front firewall all the way forward to gas tank. Firming
up center console. Installed radio w/power antenna. Silenced many squeeks
with creation of bumpers for rear 'clam-shell'. 8-way power seat switches
relocated. 2400 Miles accrued.
7/01/2010 Driver's firewall finished. A quick stitch for some temporary canvas
top. Installed XM add-to the stereo and cleaned up the 'flow' of center
console. Door Hinges Installed! Whew! I was wondering if I was ever going to
get to them. Many troubles, everything dependant on the thing before it and
only one thing to be done at a time. The hinge bolt has thrust needle bearings
(w/races-1/8" thick) and tensioned with a heavy spring backside. A lot of work
yet to be done on the doors. 2900 miles accrued.
top. Installed XM add-to the stereo and cleaned up the 'flow' of center
console. Door Hinges Installed! Whew! I was wondering if I was ever going to
get to them. Many troubles, everything dependant on the thing before it and
only one thing to be done at a time. The hinge bolt has thrust needle bearings
(w/races-1/8" thick) and tensioned with a heavy spring backside. A lot of work
yet to be done on the doors. 2900 miles accrued.
7/27/2010 Creation of the DMP (Detroit Man Purse)- a 50 caliber military
ammo box modified to lock via hasp and secures into vehicle by means of
trunk latch, the most theft resistant glove box I think there is... I've been
hemming and hawing on the latches for the doors. The best placement
has a little more interference with door glass than I would like. Problems
with cylinder#5 have resurfaced. I've replaced the coil-pack, ignition wire,
spark plug, and fuel injector and the computer still reads a mis-fire. I'm
wondering about hydraulic lifters and camshaft now.
ammo box modified to lock via hasp and secures into vehicle by means of
trunk latch, the most theft resistant glove box I think there is... I've been
hemming and hawing on the latches for the doors. The best placement
has a little more interference with door glass than I would like. Problems
with cylinder#5 have resurfaced. I've replaced the coil-pack, ignition wire,
spark plug, and fuel injector and the computer still reads a mis-fire. I'm
wondering about hydraulic lifters and camshaft now.
8/20/2010 Scissor door mostly finished- Hydraulic lift rods from the rear hatch of Chrysler
minivan makes door feel gravity neutral. Internal&external door latches, power locks&mirrors
fully operate. I'm very pleased with the contours- *whew* sigh of relief! So the driver's door
will take about 4 hrs to fully fab, since the passenger took 7. All done just in time for the
Woodward Dream Cruise to get rained out until 6pm,lol!
minivan makes door feel gravity neutral. Internal&external door latches, power locks&mirrors
fully operate. I'm very pleased with the contours- *whew* sigh of relief! So the driver's door
will take about 4 hrs to fully fab, since the passenger took 7. All done just in time for the
Woodward Dream Cruise to get rained out until 6pm,lol!
12/10/2010 More body work: Rear bonnet shaved a bit in regards to it's
association with B pillar quarter panel. Plexiglass (temporary) rear window:
working on making it motorized raise/lower. Ducting for headers and lower
engine derived & modified from a 70's Type2 air intake. When I finally
make the rear wheel wells, these will all work well together. Serious
inquiry into next gen 3.5 liter sport package. Playing with a rearward skirt.
association with B pillar quarter panel. Plexiglass (temporary) rear window:
working on making it motorized raise/lower. Ducting for headers and lower
engine derived & modified from a 70's Type2 air intake. When I finally
make the rear wheel wells, these will all work well together. Serious
inquiry into next gen 3.5 liter sport package. Playing with a rearward skirt.
01/03/2012 'Infotainment' center at steering wheel control, heated seats,
removable carbon fiber hard top- much more to come on body parts!
11,500 miles accrued.
removable carbon fiber hard top- much more to come on body parts!
11,500 miles accrued.
02/29/2012 The rear skirt has increased mileage 1.2mpg. This was surprising at
first, but I guess goes hand-in-hand with the diminished wind noise. It also
reduces the passenger compartment noise produced by the exhaust. I'm also
developing auxiliary front calipers as a secondary hydraulic system. The Ford
calipers were chosen because they have provisions for a cable-hand brake.
first, but I guess goes hand-in-hand with the diminished wind noise. It also
reduces the passenger compartment noise produced by the exhaust. I'm also
developing auxiliary front calipers as a secondary hydraulic system. The Ford
calipers were chosen because they have provisions for a cable-hand brake.