My first ever build thread: Thunderbug Dune Buggy

[ANSAracingb]

Hi everyone, I've been on here off and on for years but have never created a build thread for any of my Volkswagens. I finally own a unique enough vehicle that (imho) deserves its own thread. Updates to this thread will most likely be at random times since, admittedly, I have my 1969 Beetle on the plate first. However, I have already started working on this and would like to do as much as I can this year before it becomes winter time. So here's what I'm working with:

Thunderbug Dune Buggy (year unknown)

http://www.dunebuggyarchives.com/ThunderBug

According to the chassis number stamped in the tunnel on the pan, the chassis came from a Beetle made in March of 1958. I don't know what year the buggy mold was made and the car itself was put together, but the chassis welds are very nice and professional and the car was last on the road in the late eighties (I have the license plate in the garage). According to the archives, these cars were put together by a couple guys who later started Bugformance (which I think was in the late sixties?). My girlfriend's dad and I found this car on Craigslist a couple years ago and were going to rebuild it together. We have already rebuilt a 1979 Corvette that turned out nicely. The kid we picked it up from had spent a lot of time and money with some mechanic on trying to sort out the wiring, but they didn't get far. It has a 1300cc engine in it (according to the serial number).

We were able to get it running but the engine smoked really bad from the #3, #4 side of the engine, and that bank got really hot in a short amount of run time. We decided that the engine would be swapped out in favor of a nice simple 1500sp or 1600dp when the time came. Fast forward about one year and my girlfriend's dad found a 5yr-old buggy that is already road-ready, just needs an engine. He picked up a 1641 for that vehicle and now the Thunderbug was sitting in the back pasture. He had no interest in it and always wanted my 1961 IH Scout project, so a deal was made and we swapped. The Thunderbug is now mine.


I have always loved Dune Buggies but have never owned one. This is only the second aircooled I have owned (the first being my 1969 Beetle). The other day my friend and I moved the buggy from our side pasture to the slab on the side of our house. I would put it in the driveway but that's where my Beetle and Golf II reside. I noticed when I pulled my hand off the Thunderbug that my fingers were covered in that crappy chalky green paint. At some point somebody had painted over the original glitter green paint job, and although I'm sure they had a good reason to make it look worse, I haven't the foggiest what it was.

So, the other day I decided to see if I could get down to the original paint. I carefully used some 0000 steel wool and lots of water, and sure enough the ugly green started coming right off, exposing the original glitter-type paint underneath! I have so far done most of the passenger side, and will continue to work on it after I get home from work whenever I can. Once that part is done, I will apply some polish and try to make that old paint sparkle some more!

Plans are:
*new engine
*refresh braking system
*swing-axle transmission seems to work and shift smooth, although it hasn't been driven yet, so no work needed there I hope
*new wiring
*new lights
*new wheels (but I wish to retain the wide-five setup and want nostalgic wheels)
*get rid of the yellow on the roll bar and change to black
*new seats
*no radio, no wipers (want to keep this thing simple)

Here's the pics I have so far:












This is what I found after removing the ugly green paint (picture doesn't do it justice):



Comments, advice (especially from you dune buggy owners), and general thumbs ups are greatly appreciated. If you don't have anything nice to say, keep your comments to yourself. As I get farther along with this project, I will update you with pics and progress. Thanks for reading!

[zzzdanz]

Nice man.I've always wanted 1 of those buggys....Look'n forward to this build,good luck to ya man.

[spasticone]

That's my favorite buggy body. I love it!

[zzzdanz]

was thinking the same thing...there's some ugly bodies out there.

[JDII]

Nice buggy. I think a set of speedwell wheels from moon eyes.com would look good on that and they are nostalgic + cool!

[ANSAracingb]

Thanks everyone.

This past Sunday I bought an instrument cluster at the swap meet. From what I've found on the internet about these buggies, they used mostly stock Volkswagen parts. The giant round hole in the dash accepts the guage cluster perfectly...I'll just have to wire it up properly when doing all the wiring work on the car.

The one huge worry I have about this project is taking care of the DMV stuff at the end. When purchased, this car did not come with a pink slip. The previous owner had a bill of sale and the license plate, and said the car hasn't been registered since 1987 (iirc). So, it is out of the system. I think that when I go to re-register it, DMV will make me take it to the CHP for inspection. Since I don't want to install wipers, I'd rather not do that. As time goes on and the end of the project draws closer I'll have to look into that a bit more.

Heck, at the very least, I can still build the car and trailer it wherever I want to take it to have some off-road fun!

[zzzdanz]

I dont know how the whole title thing works in Ca. but it's a pain in the bag in Ma...I'ld find a $200 junk Bug with a title and just toss the bug VIN on the buggy.

It almost looks like someone painted that buggy with a brush.

[JDII]

any updates? bump

[ANSAracingb]

Unfortunately, not too much has happened of late. I have removed more of the green paint but I'm not done yet.

I have a three day weekend coming up this weekend and I hope to be able to spend one day with the buggy, one day with my Golf/Beetle/motorcycle, and of course one day with the girlfriend (not in any particular order).

[zzzdanz]

Man, give the girlfriend some paper towels and windex and she can *help* ya with the cars...It's win/win..you get to spend 3 days with ya rides and the GF thinks you care enough to have her around cuz you want to spend *quality* time with her.

[ANSAracingb]

Finally got to spend some serious time today with the project. I have been trying to clean up the paint but whoever re-sprayed it that ugly green did a half-ass job...some areas are really thin and I can get to the original green glitter stuff easily. Other areas are coated so thick that even after I use oven cleaner I either can't get down to the original coat, OR it goes right thru it to the blue color of the tub.

So, I have decided to remove the tub, and I'll take it to a body shop where someone who knows what they're doing can re-paint it for me. In the meantime, I'll do what I know best: mechanical stuff. While the tub is off getting taken care of, I'll be able to do an engine swap, re-do the brakes, lines, electrical, suspension, etc. When the tub comes back I should be ready to bolt it on and install lighting and away we go!

Below are some pics of today's work. I started by removing the front section of the body which covers the fuel tank and front apron area. I removed all front lights and electrical items, and sprayed some PB Blaster on the steering column base (where the splines are) to help loosen that up. Removed the steering column and started removing all the bolts that held the tub to the pan. I'd say about 30% of the bolts didn't even have nuts on them, and those that did...well, some had washers; some didn't. It's kind of sad when you have a nice little project like this and all you find is evidence that the previous owner didn't really give a sh*t to do the job right the first time. I'm sure the job was done right at Bugformance in the 60s (when it was built originally) but at some point this body has been separated from the pan by somebody else, and not too long ago at that.

Anyway, on to the pics!









You can really see the difference in the old glitter paint vs. the gross color sprayed over it. This was found when I removed the front section that covers the fuel tank:

[ANSAracingb]

The past week and a half or so has been really weird weather out here...I mean, I can't remember the last time it rained here in June?! Today I didn't do much but I did get the wheels off and the pan is secure on jackstands. I have been making a list of replacement parts I'll need so far. I also have a question about the transaxle that I'll post below, with pics.

The pan as it sits now, without wheels:



Old link-and-king-pin front beam (going to keep but I'll "freshen up"):



Here is the question I have. Is this a split case transaxle? I would like to know if that's the case because I'm getting ready to purchase replacement parts. The only transaxle type I've ever messed with is the IRS setup like on my '69 Beetle. I don't have any experience with swing-axle rear ends as of yet:





I have read that the split case transaxles are extremely strong and can take a ton of power and abuse. I'm not planning on having more than 70 or 75hp in this buggy but I just want to make sure I get brake and suspension parts correct. Next major thing will be removing the engine/transaxle from the pan, and the front beam after that.

Thanks in advance for any insight to this transaxle!

[cfvwtuner]

Not a splitcase trans. From a 58 it would be a regular swingaxle, non syncro first gear.

[ANSAracingb]

Not a splitcase trans.

Thanks. I know the case itself doesn't split in half like an engine block, but the huge flanges on the sides led me to belive that it was technically that type of trans. I know the pan is from a 1958 but considering this thing was converted to buggy status in the mid or late sixties I didn't know what trans what used. I have an extra swing axle from a 1968 parts car, so I may have a spare for this setup in case this one doesn't work properly.

Thanks again

[ANSAracingb]

The buggy pooped out its engine!




This engine is a 1300cc which is not going back in. For now, it is on a pallet next to the 1500 (that came out of my 1969 Beetle) inside the shed sitting on the side of my house. I haven't decided quite yet which engine I will put in this buggy...I have a few options to think about:

(1) rebuild 1500
(2) rebuild an extra 1776 my dad has that came out of his TypeII singlecab
or
(3) get something else entirely and keep the other two engines around as spares for cars we already own

Meh, I have lots of time to think about it...

[ANSAracingb]

Today I helped my friend install some roof rack base bars to his BMW 5-series, so in return he helped me remove the transaxle before he had to leave. After he left, I removed the front beam assembly. Pics!






On the driver's side rear spring plate, I found this tag on the inside:



I can't make it out super easy but it looks identical to this one (on the pan):

[ANSAracingb]

I haven't had much time lately to devote to working on this project. But this last weekend my friend helped me move my 1500cc from the shed into the garage so I can start working on it.

This engine came from my 1969 Beetle and is stock with the Solex 30 series carb. It ran pretty good in my car but was burning and leaking some oil, so I replaced it with a 1600dp. In the meantime this has been sitting so it is time to clean it up, rebuild the top end and use it as the "period correct" engine for the buggy. I'm not looking to win awards with this combination at car shows but I think having a simple, reliable, basic single port engine in the chassis would be cool. Plus, I can change the barrels and pistons so it will now be a 1600cc.

Tonight I was able to strip most of the stuff from it, excluding the flywheel. Once that is off I can put it in the engine stand and tear it down the rest of the way. Although I didn't use the flywheel thrust endplay tool tonight, I did check end play and it is barely noticeable. I will use feeler gauges later to make sure everything is in spec. This engine (if it is the original one for the car which I belive it is) didn't have many miles on it so I'm hoping internals are good.

Before:


After:


Before "before" (when the 1500 was in the car, pic taken right after I bought it):

[ANSAracingb]

Work has been extremely busy and really stressful lately...all I want to do when I get home is just relax. Working outside in the heat on this project after a hard day at work just doesn't appeal to me.

I did get some parts ordered for my engine, and they came in yesterday. New cylinders, pistons, pushrod tubes, valve springs, head studs, and some other misc. things. I need to get some more pieces but will have to wait two weeks for my next paycheck. I was able to get the block really clean today:

[cz_kid]

I think i have a Thunder Bug too, based on your pictures. Do you have any more info on company. brochures? manual? Mine is silver, on a 62 chassis. I bought it in the early 80's. mike in cupertino

[ANSAracingb]

I think i have a Thunder Bug too, based on your pictures. Do you have any more info on company. brochures? manual? Mine is silver, on a 62 chassis. I bought it in the early 80's. mike in cupertino

Hi Mike, it has been awhile since I have done anything to this car because my other cars have been taking up my time. This is the only good link I have found on the internet:
http://www.dunebuggyarchives.com/ThunderBug

I'm going to start working on this project again here real soon. I want to have it done by spring of next year.

[JUS_GT_EYEZ]

That's my favorite buggy body. I love it!

Always wanted one of those.