Bugat5speedUS project "Volki"

[Bug@5speed(US)]

Well finally got things undercontrol, and have started the tremendous job of rebuilding from the ground up my 73 SB.

Finally got the tent and work area set up, body off, and now working the pan. Only issue is that my Front Pan Head has some cancer and from the looks of it will have to be completely replaced. I don't think its worth salvaging any part of the pan head or Napolean thingy, so I will go with new stuff. So time to break out the lincoln and have fun.

Here are some pics of what has been going on.

Body off


My new home away from home


Some pics of the cancer: As you can see the ends where the two bolts go thru is completely eaten away, and some rust holes on the tunnel where the pan head meets the chassis.








Hole in the tunnel and a piece of patching material from the other end



Some pics of my dummy box to get things fitted properly at the business end of the chassis





As I get working and have time to upload pics I will be sure to post.
I will post specs.. but as you can see 5 speed, 2.7 lt type 4 with DTM, some GWD stuff, some 944 stuff.. and a lot of nothing on the inside..

[dirk.Gysbrechts]

this is looking great!!!!

[Turbo Haraune2]

Oh no.... cant you just get another pan? that thing is beyond economical repair. there has to be rust free pans in US? california maybe?

But if you fix it... Good luck, you wil need it.!

The trans stuff looks good. cant wait to pick up mine..

[Bug@5speed(US)]

I was about to toy with the idea of finding another chassis.. its a viable option that I may consider.. thanks

Also I have the floor pans, so I just need the pan head, which is about 2-250 and the napolean thing abou 50-75.. I have the pans so that is 0.

But its funny that you can find a whole pan for that prices, the only difficulty is that I would need a trailor so that I can pull it with my truck.. But worst case its a learning experience.

So I ask anyone near NJ got an extra pan? SB with IRS
Alex

[Bugat5speed]

Hi Alex,

nice that you started your project now. Wish you good success on it. Think the other guys are right with another floorpan. The one you have is really bad. Cancer is the right word (as you wrote). Try to get hold of another one. The pans will find their new owner I think.

Always nice to see projects with my own parts (-:

Thanks for using them.

Please keep us posted with more pictures. Hope it won´t get too cold there the next weeks.
Couldn´t do it here, as we already have snow and low temps over here.

Good Luck!

Martin

[Wally]

Yeah, that tranny carrier looks much nicer than the one I made myself. probably lighter too

I would not be mistaken about using another pan, as scraping that one clean is usually no small task either. Plus the paperwork of other chassisnumbers and all, only to find out the other pan is not as rust-free as you thought it would be...
Welding in new metal may not be that hard and you know then its all good inside

Good luck on the project. Its nice to see another super being rescued. They deserve more attention and projects like these!
Also nice to read this one gets a proper aircooled engine LOL (sorry Martin ;-))
The torque of a 2,7 might be close to the 901 limits maybe? Probably depending on use (drag or no dragracing)

[Bug@5speed(US)]

Thanks Wally,

I have been jumping around boards looking for suggestions.. and over at Superbeetlesonly.com some one turned me onto a shop only 30-40 min from where I live.. I will have to visit them, and discuss options with the pan present and take it from there. It may be the more $$ route, but then I avoid messing with VIN # and related items.

The 914 box, should be good for my road racing. I will probably run it detuned for a bit, till I get things sorted out. Regarding the aircooled, it was a close call, as I use to race a subaru turbo, and having driven Martin's car, its a nice setup.. but for now aircooled, I do have a vert, that may get rebuilt, that the 2.7 can go into if I feel inclined, but that is way to far into the future...

Again appreicate the feedback and ideas. It always seem that once you get start down this road, its best to not look back..
A

[Bug@5speed(US)]

Well, the cold weather is making its way to the east coast, but with a little shelter, the work goes on..


Still haven't given up faith on this chassis, I have gone over "Racelooks" thread over at Shoptalk, from which I got a few good ideas.

As you can see I started to clean up the tunnel bottom, the cancer seems isolated at the location where the pan head and tunnel meet.


And a closer look, other side is similiar but not as bad




Rest of the front third of bottom of tunnel looks to be pretty solid

As fell as the front half of the pan head..

[Bug@5speed(US)]

Based on this I think I may patch this front area..
Here is a crude attempt in using power point



First I will replace only the portion in red from the lower half of the pan head, as well as the napolean top portion.

Then with some equal guage/thickness sheet metal, form it to the tunnel an path those area.. that need help..



Last one for tonight of the carnage


Its had to tell but if you look into the hole, there is rust where the top half of the pan head and the napolean top meet.. This may be tricky, but we will see..

At this point welcome ideas, suggestion.. or any comments.. I thought about getting a new chassis, but this doesn't seem to be fatal.. Once all buttoned up, I was planning on putting extra plating over this area, and welding it, to ensure its strong..
Take care
Alex

[bow]

well the only problem i see is that why not get a new front panhead because your gonna spend as much in just fixer pieces of metal

[Xellex]

nice to see a fresh project going on, as I always thought I was a few years late with my passion for Germanlookers.
Good luck with your project, I'm certain it will rock hard!

[Bug@5speed(US)]

Bow and X, thanks for the comments.

One of the main reasons that I am troubled by replacing the whole pan head, is messing up the suspension geometery.. due to misalignment..

I don't know of anyone locally that has a rack to do it right, and the cost of a framer to do the work..

Thought?
A

[wrenchnride247]

All REAL paint and body shops have a frame jig.

[Bug@5speed(US)]

Wrench,

True.. Well at least you all gave me another outlet.. Will try some shops around here, main concern is that they don't know VW's

Thanks
A

[wrenchnride247]

They really shouldn't need to know VW's. All there gonna do is level and square it on jig, and take some reference measurements. Then when putting new head on use the reference measurement's...