The Baja - Progress Thread

[Hawk Tuah]

I have myself a little winter project.

 

[Hawk Tuah]

Yay -the rain has gone and I had nothing else to do. Time to crack on with this!

I've had plenty of time to think about this, but I don't know if this is going to work or not. Still, worth a try.

This is how I left it. Unfortunately the turbo doesn't fit when the alternator is back in.

I had a brain wave. Time for some fabrication.

Now it fits!

I'm doing a draw through turbo, so I have to find a way of mounting the carb, and getting the air into the engine... This was going spare...

Hmm, looks about the right size.

 

[Hawk Tuah]

Few more bits arrived in need of adapting...

It actually fits.

Another step closer to being complete.

 

[Hawk Tuah]

Looking good mate! I've been shown this project once or twice over the years, but only just started using the forum. Great to see how it's progressing! Been wanting to get a baja for a while now (2007 was my dubbing year, had 2x1968 beetles, and spent a LOT of time on VZi. I've kept plenty of beetle bits in reserve - a decent exhaust, a stinger, a progressive carb, some 5x112 drums and front arms and a rev counter. Probably more stuff I can't remember!

Turbo should be fun

Do you find the tyres ever catch the wings? It's got very soft suspension. And I'm sure there're ways of getting rid of the rear camber without going IRS setup - possibly making hubs that automatically give negative camber, so you end up with neutral? I can't remember what the rear hub design is like tbh, I've not looked at one in nearly 4 years!

You sound like you've got more spares than me.

The rear tyres only catch at extreme angles or jumps. There are a few ways to fix the rear camber. The cheapest is to lower it - which wouldn't help with the rear tyres catching. So I'd have to run smaller tyres. The more expensive options are IRS, or reduction boxes. Both require replacing the gearbox, so out of the question at the moment.

I'm going to try to add dual shocks once I get the engine sorted -so that my help with the harder impacts.

 

[Hawk Tuah]

It's a baby goat you pervert

It's a fully grown Pygmy.

 

[Hawk Tuah]

Fitted the new rear lights today. Much tidier and with no connectors in the wheel arch. The turbo is much closer to being complete too.

 

[Hawk Tuah]

Nice, what sort of power will it make with the turbo?

No idea. I'd be happy if it just runs.

 

[Hawk Tuah]

Got loads more to do. The oil supply to the turbo will be fixed as soon as some adapters arrive, and I need to tidy up pipes so they're well away from hot stuff, as well as fit an additional oil cooler at some point. Plus make this idle somehow.

 

[Hawk Tuah]

I haven't updated this for ages. It took me a year and a half to get everything roadworthy again. I gave up on the turbo. It didn't work very well.

I've had a busy day, making a new exhaust. I've modifed the dual cannons to fit 3 bolt bike exhausts. I've now got a pair of Suzuki Hayabusa end cans on it.

It does remind me, I still need to refit the rear cage a bit straighter!

I made a quick video to show how it sounds. I'm quite pleased with it. It still sounds loud enough to annoy the neighbors, but it does take the edge off it a bit.

 

[Hawk Tuah]

Sorry, neglected this thread for a while.

I promised the Baja that this year I'd take care of it's neglected exterior. As well as a load of fibreglass cracks, the lower doors and rear cowl needed attention. I cut away the rot and replaced with new metal.

 

[Hawk Tuah]

Then to help prevent it coming back, gave it a good thick coat of red oxide.

Sanded smooth ready for new paint.

 

[Hawk Tuah]

This time, instead of Tank Paint - I'm using Battleship paint. :lol:

The lower doors weren't fully smooth yet, but couldn't ignore a warm sunny weekend - so I began the first coat elsewhere.

 

[Hawk Tuah]

I got around to straightening up the rear bars.

And finished the paint.

 

[Hawk Tuah]

In preparation for the MOT, I've had to sort a lot of electrical problems. The rear stop / tail lights must have water in them - as there was a short between the stop and tail wires that was causing problems. Also, it appears my battery had died over the winter, and my ignition smoked every time I tried to start the car. All of that was replaced - and it is now working fine.

I also updated the 'fit' of the rear bench seat from the Audi, and stealthily added two speakers in the small gaps either side / under. Note, the cables are still loose, as the bench will have to come out again soon.

 

[Hawk Tuah]

In keeping with the new look I fitted led headlights, a roof bar and led side lights.

Also, the replacement rear stop / tail lights.

 

[Hawk Tuah]

New tyres arrived.

Whilst I'd like some beadlocks from the USA - it's very hard to find a set the right size, that will fit any kind of adapter to a Beetle hub without going custom and spending an absolute fortune. So, I've tidied up my existing wheels.

Plus, we need to get some new tyres for the Nissan. Can I convince the wife...

 

[Hawk Tuah]

I wasn't happy with the finish of the paint when it was rolled / brushed, it came up like rhino skin - even though the paint says clearly on the tin - for rolling / brushing, thin for spraying. So I sanded it back and tried again using thinners and a paint sprayer. It's far from a perfect finish, but better than before.

I then used the spare red oxide to cover all the underside of the car, and some other out of sight areas.

With the wheels back on.

So now they match again.

 

[Hawk Tuah]

New exhaust cans.

 

[Hawk Tuah]

Nothing recent (I've been looking after it a bit!), but this was from 2009.

https://www.youtube.com/watch?v=liRTl-CUy8s

 

[Hawk Tuah]

I suppose this is somewhat of an update. Engine died. I've stripped the engine entirely and found the problem. Oil starvation to the middle of the crank caused the central bearing to overheat and warp (bottom). Hopefully the crank itself looks ok, just need the motivation (and warm weather) to put it back together.

Will be putting it in a new case and replacing lots of bits while I'm at it.