The offroad rail project

[MacUser]

Thanks. I just hope this doesn't get on anyones nerves as I keep randomly updating it with new info. I appreciate everyone letting me share.

Details are everything and my main goal at this state isn't a complete restoration.. but a complete functional running restoration. Meaning if I drive it with my family... I want it to GO and STOP AND be SAFE. At the same time.. I don't want to have to come back and redo anything later.. so as I break it down I fix it back right with added future protection.

Then at some future point.. I may strip down and repaint the chassis, add extreme offroad goodies, if it proves itself a useful fun summer vehicle.

Rahab, your brother and BIL sound like talented guys. I love to take something old and left for dead and breath new life back into it. Restoration is part of my nature and this is just a way to express it.

[MacUser]

Right rear brakes refurbished with extra por15 protection from the elements.

[MacUser]

Wheel on...



The wheel was sanded and painted inside and out with an Aluminum Coating.


Very similar to what you see on ATV wheels.

[MacUser]

Update on the left drivers rear side:

The entire assembly was taken down and cleaned.


The parts were cleaned completely to metal!


Por15 was applied to all the parts after cleaning and the assembly was put back together with new parts and new seals.


Por15 applied to the new hub inside and out.


It looks great.

[Susie Hamilton]

I really admire your work. Can't wait to see the before and after pics. Keep us updated, please.

[MacUser]

The seats finally installed. The Stainless Steel Bolts used to secure etc.



Seat pad was needed.. so I used some dense carpet pad and test fit.



Then after the carpet pad was test fit I covered it in a durable trash bag so it would not soak up any water that gets in the seat.


Finally the cover is installed over the newly padded and secured seats


I relocated the regulator to below to underneath the rear seat bracket for a more clean look. I'm slowly cleaning up the crazy wiring.


A picture of installed seats.



The pedals were installed and temporarily hooked up so I could test the engine and seats etc. Replacing out with hard lines soon and fabricating another bracket to hold the pedal stronger.



Now onto the last 2008 VW project done. Engine Swap!

Out with the old tired single port


Looks sad, eh?


The old tired single port rail engine was retired for a fresh chrome dual port and weber powered upgrade!


My son helped me out.


The old tired engine out. Rebuilding later.


We reused the bazooka style exhaust except revamped them.


My son attempts to light the New Year fireworks with the VW bazooka style exhaust


My son instead awaits fire from the exhaust to ignite the pack of New Year Bottle Rockets


That's it for now. Happy New Year. See you next year.

[MacUser]

Per a specific text request.. here is the side view as we tested it today.



We attempted to get the "bugs" out in this cold weather. Yes, I did say it..

[MacUser]

Added some brand new 6" lights to the project.



Installed and working!



Looks like a brighter 2009 already.

[beckrl]

Looks Great, MacUser

I like the lights

[RamboPreacher]

looks too dangerous for my taste. but it is pretty.

[MacUser]

Thanks Beckrl. We've been having fun wrenching on it.

Rambo, it's what modern Spartans drive.

[MacUser]

We put some beefy tires on the front and boy did that make a huge difference! Take a look.









Need some black center caps. Anyone have a source?

[MacUser]

Parts arrived. New brake lines, New Pedal Mount, New Billet Brake Fluid Bottle, New Steering shock.. plus some other goodies.


So it was time to tinker.

New Hard Lines were installed onto the Offroad Rail Project front pedal assembly. I also installed a billet reservoir




New Hard & Rubber Brake Lines were installed onto the Offroad Rail Project.



I installed the hard brake lines and kept the sand brake. This is how I snaked them around the parts.



Few busted knuckles.. but it's done and much safer.

[beckrl]

It's looking really good, I can remember when I road around in a converted offroad corvair. It was alot of fun.

Some good tube bending

[Susie Hamilton]

Looking real good. Love the pics of your son as well. Hope your knuckles are feeling better. Keep up the good work.