The Build

Chassis Painting and Assembly
Underside of chassis painted. We lost photos due to camera glitch on detailed work. Forks Pans Top side ready for prime.
Chassis completely painted using 2 part epoxy paint to insure durability. After paint I wanted to seam seal the top side with brushable seam sealer to prevent any water infiltration. Normally this is done before paint but I rather have had the metal etching primer due it's job first. I will paint over the seam sealer when it is cured. Gathering parts for the assembly.
I am using a level to get a reading on the chassis so that I can install the spring plates. I am installing the spring plate at 15 degrees. Normally they would be installed at 17 degrees but due to the fact that the buggy fiberglass body is lighter I wanted to soften it up a bit. Yes I even make my own tools. I am compressing springs for install.
I will be using all brand new rubber products for assembly.
Sometimes you will need to use a little extra help installing spring plate covers, infact note the extra long bolt in the upper right hand corner. This is a method that VW manuals suggest that you use. The bolt will be replaced with proper size. Transmission mount in place. You will note there are no photos of the tranny being installed, which is realtively easy . It requires two people to prevent scratching the paint so my photographer could not take any photos since he was helping me. I strongly recommend using new rubber and hardware when available.
Buttoning up with new bolts.
It will keep your break line safe by keeping it away from any rubbing metal. I replaced boden tube and trottle seal as well as the tranny cone grommet. Axel boots ready for install.
Transmission is in without photos. Once again I must use my spring compressor to align axels to the spring.
Brand new steering box. Brand new spindle and control arms. Drop arm media blasted. Have been painted.
Rear shock bolt. Shock installed. Brand new shift cuppling. Cuppling installed. I used stainless steel, safety wire to hold blocking screw wihich is not in the photo.
All done. Control arms ready for install. Liberal amounts of grease.
We tumble the parts for 12 hours using coarse grit.
Installing control arms.
Tightening bolts Other side, don't forget the control arm seals. Tightening front end.
Installing down arm to steering box. I use Permatex threadlocker red which is permanent. Heat must be applied to remove. Drop down arm bolt. Align drop down arm with stops. Make sure the arm will strike both stops and then tighten.
This one will be painted. Installed.
Tom found the photos of the stainless steel shift cuppling safety wire installation.
Gas line grommet is a must.
Note: Brand new hardware. These are metric and hardened. They will not be tightened until alignment.
I used anti-seize on shock bolts and anywhere else services required.
Sometimes you have to use original bolts and hardware. This is how I deal with that.
Greasing spring plates.
Don't forget the locking nut.
Tie rods installed.

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