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
2 comments on “To-Do List
  1. fitzpata says:

    – Are you planning to run heat in the car?
    – How big of an alternator are you planning to run for all the lights and electronics?
    – I wondered why you were running the “wide 5” hubs but I have been reading through the site and saw your comment on the off road wheels.
    – I like the baja class 11 cars and much of what they build seems like it would transfer to rally but I am not sure about what the rally rules allow.
    Take care guys! -Al

  2. johnhuebbe says:

    No heat in the car. Shouldn’t be a problem.

    Yes, the Wide5 wheels work very good for off-road. Should hold up very well for rally.

    Many of the Baja modifications transfer over to rally. The biggest difference is safety. The cage and other items are all to FIA specs. A lot of the rally modifications that we are making to the car were done back in the 70’s by the VW team. Pretty cool.

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