BBB-- BrianB's Buggy Build

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Postby ElijahTurtle » 19 Thu Nov, 2009 11:09 am

Have you considered using beetle glove box doors? Glass in a pocket with about the same size opening just a little shallower than a standard beetle glove box & use the glove box doors with a thin cork or rubber seal around the edge to make them water proof or close to it. I'm sure you could find freeby doors from people junking out bugs.
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Postby BrianB » 20 Fri Nov, 2009 6:59 am

Sounds like a good idea. I'll just have to look at it and see. Anyone have a spare glovebox door laying around?
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Postby BrianB » 18 Mon Jan, 2010 4:47 pm

Did a little welding yesterday on the roll bar. I predrilled some holes where the pipe connects to each other and ran some stranded wire through(kind of like fish tape only more plyable). This will allow me to pull the wiring through for my LED lights I intend to use for overhead lights.
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Postby BrianB » 18 Mon Jan, 2010 4:50 pm

The wires enter the pipe right below the gauge area. There are two wires one fore each overhead pipe. I'll be installing a third brake light in the main hoop and I'll run that wire from the driverside directly into it.
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Postby Bryan Porter » 18 Mon Jan, 2010 6:00 pm

It's about time you get back too it Fredricksburg is just around the corner.
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Postby BrianB » 19 Tue Jan, 2010 6:44 am

Ya I know. The roll bar should be complete tonight. The cross braces are now welded in now for the bottom plate.
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Postby tx_1987_gta » 19 Tue Jan, 2010 9:59 pm

That is looking very cool.... Cant wait to see more as you move along.
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Postby BrianB » 25 Mon Jan, 2010 6:24 am

Cuple of updates from the weekend.
The rollbar is finish welded except for the bottom plate. I think I should have made the rollbar about one inch taller.
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Starting to extend the pods inorder to be able to bolt them on
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One shot to see how it will look with wheels and pods.
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Postby Texasbuggys » 25 Mon Jan, 2010 8:26 am

Looking really nice Brian!! Man it looks really nice compared to the last time I seen it. Greta job!
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Postby BrianB » 26 Tue Jan, 2010 5:57 am

Texasbuggys wrote:Looking really nice Brian!! Man it looks really nice compared to the last time I seen it. Greta job!

You should come to Katy this weekend and bring your fiberglass tools and mat and get r done for me in one fell swoop. That way I could make the classic in style and you could use me for some advertising :lol: :lol: :lol:
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Postby Texasbuggys » 26 Tue Jan, 2010 7:31 pm

Your doing a fine fine job!!!
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Postby BrianB » 29 Fri Jan, 2010 6:56 am

Got some original hood decals in from the original builder of Thunderbug Buggies. He also send a copy of the build manual they sent out with the bodies.
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Postby BrianB » 05 Fri Feb, 2010 6:41 am

I have been doing some glassing lately. The plan is to bolt these pods on so I made flanges on both ends. I have to rework one of the pods to match the other one in height but it shouldnt be too much trouble.
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This is where I had to add about one inch to the top of the pod. I will also have to rework the front arch to move it the same distance.
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Postby Bill K » 05 Fri Feb, 2010 10:48 am

Great work Brian. I think you and Corey could get into the fiberglass body repair business. You guys are "Smokin' Hot".

One piece of advice from experience. Don't match one pod to the other thinking it will fit the other side. Most of the time there is no exact uniformity in these bodies from one side to the other.
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Postby BrianB » 05 Fri Feb, 2010 11:04 am

Bill K wrote:One piece of advice from experience. Don't match one pod to the other thinking it will fit the other side. Most of the time there is no exact uniformity in these bodies from one side to the other.

That is not what I am going for exactly. I just dont want one pod to be noticably higher that the other one. I have already set both up to the body and determined what needs to be done to make them close enough that it wont jump out at you. The way it is now my wife even picked out the decrepancy :shock: Either way I plan to have most of the glass work finished this weekend.
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Postby Aquabuggy » 05 Fri Feb, 2010 8:35 pm

Looking good!
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Postby BrianB » 08 Mon Feb, 2010 7:31 am

Did some Glassin this weekend.
The body was being held back by this bar.
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So I cut a wedge out and pushed the front of the body in so it would clear.
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Glassed it in place.
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Built up the body flange.
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I had trouble with the body high centering on the tunnel so I sectioned out the back body flange and reglassed it on.
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Thats it until tonight when the side pod fitting continues :shock:
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Postby David Head » 08 Mon Feb, 2010 5:04 pm

You glass guys are getting me all itchy!!!
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Postby BrianB » 08 Mon Feb, 2010 5:25 pm

David Head wrote:You glass guys are getting me all itchy!!!

Tell me about it! I cant put on a long sleeve shirt cus the glass is pokin out :shock:
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Postby BrianB » 12 Fri Feb, 2010 12:26 pm

Working out in the garage today. Lots of glass happinin. Next time the pods just get glassed to the body and be done with it :x We'll see if I can get it all done by Monday evening :shock:
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Postby Texasbuggys » 12 Fri Feb, 2010 10:59 pm

Brian, you are doing a great job on that body man! I am very impressed! Between you and Cory!!
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Postby BrianB » 14 Sun Feb, 2010 10:20 pm

The pods are pretty much done :x Ran some flexible conduit through them for the wiring. Patched up more holes. I guess today I am on gallon number four of resin :shock:
Oh ya I should have drop spindles by Tuesday and a solid trans mount by Friday.
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Postby Jack Duncan » 19 Fri Feb, 2010 2:33 pm

Now you're talking! :)
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Postby BrianB » 19 Fri Feb, 2010 3:40 pm

Pictures for your viewing pleasure.
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Postby Mook » 20 Sat Feb, 2010 1:17 am

how many cans of that foam did you end up using?
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Postby CoryN » 20 Sat Feb, 2010 8:28 am

How heavy did they get?
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Postby BrianB » 20 Sat Feb, 2010 8:51 am

It took four cans per side. If you look at the can it is 16oz's so I added 4lbs per pod. Not very noticeable in the overall scheme of things. They just sound more solid.
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Postby Texasbuggys » 20 Sat Feb, 2010 11:53 pm

And will surely add some bump protection. Brian you are doing a great re-build on that buggy man! Great work!
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Postby BrianB » 22 Mon Feb, 2010 9:09 am

My son welded the bottom plate on the roll cage for me.
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Postby BrianB » 05 Fri Mar, 2010 8:45 am

Got my Third brake lights in. Just have to cut the roll bar up to mount them in.
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Postby Bryan Porter » 06 Sat Mar, 2010 9:34 am

Are you going to be done for the classic
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Postby Mook » 06 Sat Mar, 2010 8:46 pm

looking good I like that third brake light. What did it come from?
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Postby BrianB » 08 Mon Mar, 2010 6:32 am

Here are some progress pictures from the weekend. Yes Bryan I have my fingers crossed to finish in time. There is also the Spring Fling in Rosenberg coming up as well.
beginning the dash work.
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Installing reinforcements where the windshield bolts up.
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Cut out in roll bar for 3rd brake/tail light
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3rd brake light trial fit.
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Almost complete dash with bedliner texture.
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trial fit of the Koleck Industries Dash insert. 8-)
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And pretty much ready for paint 8-) 8-) 8-) 8-)
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Postby Bill K » 08 Mon Mar, 2010 8:32 am

Hey Brian, the Spring Fling is a great show. I'm pretty sure I'll be there again and I hope you will too. It would be great to have a Buggy Bud there.
Your work is looking fantastic.
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Postby Bryan Porter » 08 Mon Mar, 2010 9:52 am

When is the spring fling ?????
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Postby Bill K » 08 Mon Mar, 2010 10:11 am

The Spring Fling is a two-day show. This year it is April 10 - 11, Rain or Shine. Judging is on Sunday and some people enter, but only come on Sunday.
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Postby BrianB » 08 Mon Mar, 2010 12:56 pm

Bill K wrote:The Spring Fling is a two-day show. This year it is April 10 - 11, Rain or Shine. Judging is on Sunday and some people enter, but only come on Sunday.
Do you have a show flier or link?
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Postby Bill K » 08 Mon Mar, 2010 3:29 pm

They don't have a website, but if you will email or PM me your email address I will scan the flier and email you a copy.
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Postby BrianB » 11 Thu Mar, 2010 6:45 am

Got the rear tires mounted. Thanks Don they are perfect.
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Postby Fred » 14 Sun Mar, 2010 9:49 am

Thats coming along great, I can hardly wait to see the Thunderbug in person. Are you gonna spray it? I had Maaco spray mine,2 coats primer and 3 coats of enamel for 499.00 and I didnt have to deal with overspray and my limitations (I'm a lousy painter, no patience) C-YA Fred
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Postby BrianB » 26 Mon Apr, 2010 10:23 am

Check list of to do's in order to get this thing rolling down the road
1, shorten shift shaft
2, shorten throttle,clutch cables.
3, install tie rods and halfway align the front.
4, install battery and cables and test the various electrical systems.
5, install the wiper mechanism and wire.
6, install fuel tank with sender and wire.
7, install hood
8, install windshield.
9, make brackets for tail lights and mount.
10, install motor.
11 Bleed and adjust brakes.
Most parts should be here by Thursday

Next Saturday all day I am inviting all you buggy guy's over for a garage day and to work on our buggies. Or as Bryan suggested yesterday point at what needs to be done so someone else can do it :lol: I will have lunch and beverages for everyone .
Give me a shout if you think you can make it.
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Re: BBB-- BrianB's Buggy Build

Postby BrianB » 03 Mon May, 2010 5:07 am

I got another step closer this weekend. I stopped at Kermits new place on Saturday and picked up a few items. I got a bushing for the starter so I could put this 40hp motor in temporarily. So I'll have a 6volt starter with a 12 volt system for a short time. Anyway the motor is in. I got the shift rod shortened and in place. Man its a Bi&tch to put the shift rod bushing in. I would think with a regular bug floorpan it would be almost impossible. Got the tierods on. Got the fuel sender installed and the gas tank mounted. So with my son home this week between semesters I should be able to at least run down the road soon with his help. My camera died a couple of weeks ago so I'll catch up the photos at a later date.
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Re: BBB-- BrianB's Buggy Build

Postby Jack Duncan » 03 Mon May, 2010 12:12 pm

Brian, just a word of caution before you button up your hood. Plug up the air vent comming out of the tank and vent from the very top of your filler neck, or you will be puking gas all the time. They announced that my car was leaking gas at the Classic, and that was the problem. I moved the vent and problem solved. :oops:
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Re: BBB-- BrianB's Buggy Build

Postby BrianB » 03 Mon May, 2010 3:24 pm

Do you have any pics showing this mod? I dont think I can vet through the cap I have.
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Re: BBB-- BrianB's Buggy Build

Postby Jack Duncan » 05 Wed May, 2010 4:24 pm

Brian, sorry about the delay. No, I don't have any pictures of this because I didn't take the hood off to fix this. I just removed the filler neck and drilled and tapped for a barb fitting in the side of the filler tube. It didn't envolve the cap at all. Of course, I plugged the old vent tube and reconnected the left over hose to the new fitting. It runs down to the charcoal cannister at my front beam, then overboard. No gas fumes in the garage anymore. Works great! :D
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Re: BBB-- BrianB's Buggy Build

Postby blackthree4me » 06 Thu May, 2010 12:17 pm

Jack Duncan wrote:They announced that my car was leaking gas at the Classic, and that was the problem.


stick a spark plug at the end of a tube and next time you turn a corner hit the switch and whala you could set the road on fire behind you
that would be sweet! :D
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Re: BBB-- BrianB's Buggy Build

Postby Jack Duncan » 06 Thu May, 2010 9:27 pm

No! My butt's too close to the ground, it might get a little warm. Besides, gas is too expensive. :lol:
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Re: BBB-- BrianB's Buggy Build

Postby ckolek » 11 Tue May, 2010 4:44 pm

are we done yet?
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Re: BBB-- BrianB's Buggy Build

Postby BrianB » 11 Tue May, 2010 6:07 pm

ckolek wrote:are we done yet?

Assembly is pretty well done. A few minor things left. Should be running this weekend. Ran into a small parts issue that the vendor(and sponsor) will take care of right away. I can still drive it in the mean time once it's running. Updated pics coming soon.
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Re: BBB-- BrianB's Buggy Build

Postby Bill K » 11 Tue May, 2010 6:15 pm

Bring on the pictures. We're all anxious to see.
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