I thought I would start a thread showing the progress on my Speedster. It's slow because I tend to get bogged down in the details, and always need more time and money! Questions, comments and suggestions are always welcome.
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To begin, I did a few small jobs while the body was still on the pan. During this time I also evaluated the project and made a list of things to be done. This is when I fixed the butt sag and added additional rear supports, test fit the windshield assembly, cut-out and installed the steering column, mounted the engine deck lid which included making the inner hinge brackets, and reworked the door latches for smooth operation.
I made the inner hinge brackets and modified the hinges in order to swing the lid up far enough to keep from hitting the body. I used 5/8" diameter aluminum round bar for the new door latch mechanisms. They are much better aligned and have a much smoother operation than the originals from CMC.
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Steering column:
The metal VW steering tube slips snugly into the PVC that I glassed thru the firewall. I made the aluminum adapter for the steering wheel and will have an ivory colored column with an authentic looking signal indicator switch.
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New sheet metal floor pans and 1x2 tubing support rails had been installed and the pan was blasted when I got the project. I did a few additional weld repairs and wiped the entire chassis down with Ospho. The front beam has been removed and will be replaced with a new, adjustable front beam and CB Performance Wide 5 discs.
Then I painted the pan with POR-15. The rear trailing arms, torsion bars, spring plates, etc. were removed and reworked as needed. I was anxious to get the pan painted before the freshly blasted surface could begin rusting.
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Body removed from pan:
Reworking front beam assembly. Cleaning, inspecting front torsion leafs (a handy trick from the Samba forums - chamfer the ends of each leaf to help when inserting the bundle into the beam!) All new tie rod assemblies, ball joints, TRW steering box, steering damper, rag joint coupling and NOS ball joint drum spindles for the CB Performance disc brake kit. Caster shims added behind lower front beam tube with longer bolts. Waiting on parts from CB.
Assembling and pre-adjusting rear spring plates. Final adjustment will be after final assembly. Rear will have wide 5 drum brakes, using the IRS brake backing plate with early shoes and brake cylinders. Plenty of stopping power for this car, especially considering the weight and the front disc brakes!
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This cover was missing from the rear end of the tunnel on my pan. I made one out of aluminum and will pop rivet it to the tunnel. Bolts cleaned and inspected, I am using OG VW Kamax bolts everywhere possible.
The cutout for the shift coupling will have a curved portion fiberglassed in to close the back of the opening.
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More to come!!