Buggy Project

Buggy Project

March 7, 2006
Tom has taken on a new project, rebuilding a dune buggy. Over the next couple of days Tom will inventory the buggy and identify it’s origin. Plans will be designed and then the fun will begin.  Watch the dune buggy’s new life unfold over the weeks to come.

buggy chassis

Roll over all pictures to get a step by step detailed description of the work at hand.
buggy body

Chassis evaluated and determined that it is a hunk-o-junk but an excellent opportunity to show how to rebuild a chassis from next to nothing.
Rust at its best brake line Under coating is evil.

The front end and engine will be completely replaced and the transaxle will be reconditioned.
Boat anchor Trashed front end.
transaxle

It has been decided to keep the vintage chrome rims with its original patina.
old rims

Relax, it’s only an early April Fool’s joke.

Tools of the Trade
The tools.

After removing the front end, engine and transaxle, I determined the extent of rust that had to be removed.  The chassis that is being worked on is technically scrap. Due to this project the opportunity to demonstrate some repair methods and most importantly at the customer’s request, I will be salvaging the upper tunnel.
Worlds best sawzall blade!

The two primary tools for this job are a reciprocating saw and a air chisel.  This is the only method that I strongly recommend.  The blade to the right, known as the Torch, is the best blade that I have ever used in any sheet metal application.

The Operation
Floors cut out

After using the reciprocating saw to remove the floor pans and the lower section of the tunnel, (not in photo), which took a whole five minutes, I proceeded to use the air chisel to remove the spot welds that were holding the floor pans in place. The air chisel makes fast work of it.  This took about ten minutes.
Air chisel at work

Clean As You Go!
Clean up

Ready for blasting and the build.
ready for media blasting Chassis and body on dolly

Note: Normally I would not remove the rear most part of the floor pan but this one was so bad that I had no choice. The part is supplied with new floor pans.  You will see that I have left the bulk head wall attached.  This will be replaced after I make sure everything is aligned correctly.

Chassis and body are sitting upon a custom made dolly for easy transportation.

www.tijuanakustoms.com