To-Do List

Updated May 1st, 2009

Just a small list of things that we have completed on the VW bug before it was rallied.  Hopefully we won’t wreck it

Frame & Pans

  • Pans – Remove old pans
  • Pans – Weld in new pans
  • Frame – Clean center frame
  • Frame – Clean front frame head (top & bottom)
  • Frame – Seam weld front frame head
  • Frame – Paint with Eastwood Rust-Preventer (top & bottom)
  • Pans – Paint with Eastwood Rust-Preventer (top & bottom)

Front Suspension Beam

  • Beam – Remove old axle beam
  • Beam – Disassemble axle beam & clean
  • Beam – Cut beam in half and weld in adjusters
  • Beam – Seam weld beam around shock tower – Izzy
  • Torsion arms – Clean
  • Torsion arms – Paint torsion arms
  • Torsion arms – Press out old ball joints from old arms
  • Torsion arms – Press new ball joints in torsion arms
  • Spindles – Clean spindles
  • Spindles – Paint spindles
  • Pitman arm – Clean
  • Pitman arm – Paint
  • Beam – Pre-Assemble with urethane bushings, ball joints, torsion arms & measure travel
  • Beam – prevent over extending suspension – Limit straps (length / mounting)
  • Install stock sway bar
  • Check wheel bearing play
  • Install metal grease caps
  • Clearance beam for shock hose boss
  • Beam – Paint with Eastwood Rust-Preventer
  • Beam – Assemble with old leaf springs, new urethane bushings, torsion arms, etc.
  • Beam - Place on front frame head
  • Steering box – Paint new box
  • Steering box – place on beam
  • Steering damper – place on beam
  • Tie rods – place on steering box & spindles (measure old rods & center steering wheel!)
  • Front disc brake kit (bearings, seals, rotor, caliper, and bracket)
  • Shocks – Install Bilstein front shocks

Rear Suspension Area

  • Remove old drums – clean backing plates, micro stub, etc…
  • Control arms – disassemble & clean (wire wheel & prep for seam welding)
  • Spring plates – disassemble & clean
  • Torsion bars & housing – disassemble & clean
  • Control arms – Reinforce with small gusset – Izzy
  • Rear frame horns – clean
  • Rear frame horns – repair crappy weld job
  • Spring plates – Clearance spring plates for longer suspension travel & measure travel
  • Frame horns – paint with Eastwood Rust-Preventer
  • Control arms – paint with Eastwood Rust-Preventer
  • Torsion bar housing – paint with Eastwood Rust-Preventer
  • Rear disc brake kit – mount brackets, gaskets & seals, wheel bearings, rotors
  • Check right side wobble
  • Torque wheel nuts & install cotter pins
  • Increase ride height

Engine & Transmission

  • Remove old engine
  • Remove old transmission & CV half shafts
  • Shifter – install new shifter, bushings, urethane connection…
  • Transmission – Install new solid mount kit (only with new transmission!)
  • Transmission – Install new tranny (NOS ZF Clutch Type LSD – VW rally team used this)
  • Engine – Build new engine
  • Engine – Install new racing engine
  • Engine – Install junk engine to test car
  • Mount Setrab Oil cooler
  • Mount Oil Tank
  • Install CV joints & Axles
  • Fuel line – run inside.
  • Mount gas tank, fuel pump,fuel regulator & fuel filter.

Body work

  • Clean heater channels/sills – Top & Bottom (wire wheel with grinder)
  • Clean inside body – foot well, rear deck, roof (wire wheel)
  • Repair holes in body
  • Paint heater channels & where body meets pan with Eastwood Rust-Preventer
  • Lower body on pan (new seal & clean old bolts)
  • Clean outside – wheel wells, rubber trim areas, other rusty areas
  • Paint outside – wheel wells, etc., with bed liner &/or Rust-Preventer
  • Roll Cage (Tuxedo Park Racing)
  • Clean – hood, deck lid, fenders
  • Paint inside of fenders with bed liner &/or Rust-Preventer
  • Install hood, deck lid, fenders
  • Sand body for painting
  • Paint Body & Fenders
  • Rubber seals - doors, hood, deck lid, fenders, etc…
  • Bumpers - Install new or used
  • Cut aluminum inner door panels & install
  • Front windshield - install with new seal
  • Windows - Lexan
  • Cut NACA vent holes for oil cooler / engine fan inlet?

Steering wheel

  • Remove old wheel
  • Install new bearing & bushing
  • Wheel adapter plate – install between column & wheel
  • New steering wheel – install
  • Urethane steering column coupler – install

Pedals & brake lines

  • Run new brake hard lines (Rear)
  • Run new brake hard lines (Front)
  • Run new clutch hard line
  • Install clutch slave cylinder
  • Fabricate new mounting plate for pedals
  • Install brake, clutch, & gas pedals
  • Fab heal support
  • Mount new gas cable & swage ends
  • Bleed brakes & clutch
  • Mount hard line to center tunnel with clamps

Other

  • Seats - Ordered – Installed
  • Moust Harness – 5pt
  • Electrical wiring – Main Harness, Engine Harness, & Front Harness
  • Lights - Plug in headlights, turn signals, brake lights
  • Fab Optima Battery support
  • Wire & Mount Horn
  • Gauges
  • Remove Terratrip from Mark’s car
  • Remove aux lights - relays from Mark’s car
  • Trip computer – Mount & wire
  • Trip computer sensor – Mount
  • Map light – Mount & wire
  • Fire bottles – Mount metal brackets
  • Fab spare tire mount
  • Underbody protection (Plastic & Metal skid plates)
  • Missouri safety inspection & plates
  • Get Alignment