12/2001
After dreaming of owning a buggy for years and spurred on by some cash burning a hole in my pocket and a willing(-ish) boyfriend who just happens to be an aircooled VW mechanic, I took the plunge and called to enquire about a Bounty Hunter body.
A couple of weeks later, the bank account was emptied and Ian was roped into driving up to collect the body.

 

01/2002
It was bloomin' freezing but I had a brand new Buggy, Ian had bought me a donor Beetle and Andy had agreed to let us strip it at The Farnborough VW Centre. So, wrapped up in arctic survival gear, we stripped the poor little 1972 Beetle down to a big pile of greasy and gungy parts.
The next few weekends were spent in the kitchen of the flat (oops!) wire brushing years of grease off parts before overhauling and painting them all with gallons of black Hammerite.

 

02/2002
The phonecall from Tony at Sports Leisure and Commercial Trailers came that the subframe was ready. (This box and tube section frame fits between the body and pan and makes for a very light yet strong basis for the buggy). So, we set off to pick it up from the Southern Dune Buggy Club meet in Reigate.
New parts were being fitted to the donor running gear where necessary, or where fitting whilst on the car would be a nightmare. All replacement parts used were either genuine VW or top quality (usually German) aftermarket. For example; brake shoes, wheel cylinders, axle gaiters, gearbox mounts, etc.etc.

 

03/2002
It was time for Ian to drag the welder out and weld the subframe to the shortened floorpan. Once this was done and the welds dressed, I cracked open the seam sealer and prettied it all up with another dose of black hammerite. While we were at it, Andy supplied a new adjustable front axle beam and Ian converted it from left to right hand drive. Then the whole load of freshly painted and serviced parts were chucked in the back of the trusty old T25 and dumped at-----I mean delivered to---my parents house, who had kindly/unwittingly offered the use of their drive.
Andy was persuaded that the Wolfrace slotmag wheels on one of his Beetles were just crying out to be fitted to my buggy, and after a wad of cash was waved at him, he agreed. Armed with some Scotchbrite pads, some metal polish and a big tub of elbow grease we soon had the wheels gleaming.

 

04/2002
It was finally time to start putting some bits together. Hoorah!! A pair of tyres were sourced for the rear in 275/60/15 and squeezed onto the 6" rims much to our amazement. The beam was fitted to the pan/subframe unit, along with the front brake assemblies. The gearbox was chucked in complete with rear brakes, and then the wheels were fitted. At last, we could move it without involving any heavy lifting. A good days work, made even better by dropping the body on to get an idea of how it'd look.
The next few weekends were spent sorting out the fiddly stuff; pedal cluster, all new metal and flexi brake hoses, wheel bearing and brake adjustment etc. One of the most daunting tasks was trial fitting cables and measuring how much to have them shortened by. With crossed fingers, the cables and measurements were despatched, only to be lost by the cable company's couriers. Thanks, back to square one. Speedy Cables in London came to the rescue-even managing to fit the correct M7 end to the clutch cable. And they fit. PHEW!
Work was temporarily postponed at the end of April due to Ian's Birthday weekender-how inconsiderate!

 

05/2002
With the rolling pan well under way, we took some some measurements and headed off to the scrapyard to source some seats....hmmm! Easier said than done. With the subframe and the low seating position, there's not much room between the central tunnel and the subframe, particularly if you have a large behind, like myself. We did, however source some headlight units at a bargain price. All we need to do with them is cut two great big holes in the as yet untouched body....AAAARGH!

 

06/2002
What with moving home, weeks of rain and getting the lurgy, we didn't have much chance to do a lot with the buggy. Although Pa bravely cut out the holes for the headlight bowls, and Ian sourced a big pile of greasy parts which apparently will form the basis of the buggy's engine. Ian helped degrease all the parts, rebuilt the carb, lapped in the valves into the heads and generally checked things over to make sure all was well. Andy helped re-install the distributor drive which had tried to escape from the bottom end of the engine. We managed to source some seats eventually, very old school looking and at a bargain price courtesy of George. They fit in with almost a fag papers clearance, and that's more than enough!

 

 

07/2002
Again, not much progress this month. But, we've made up some new excuses; funds were low, I had some job interviews (which might solve the first one-fingers crossed), and my Beetle needed an MOT, so good old Ian spent his spare time (What's "spare time"?- Ian) sorting out the bits that required attention: brakes, bearings, and general service stuff . Plus the pub called us in a few times and we were too weak to resist. The engine should start going together next month. Once its in, we'll start making lotsa holes in the body and see what happens.

 

08, 09/2002
August and September saw a break in proceedings, mainly due to a lack of funds and a much needed fortnights holiday in the South of France. However, we had a chance to amass those vital bits needed to complete the engine, which is still in bits...although, with the help of a few cans of paint, the bits are now clean, shiny and looking very presentable. (Powder coating can wait until we decide on the final colour).

 

 

10/2002
At last, some progress! After our well earned rest it was time to get stuck in, even though the days are getting shorter and the weather is getting progressively worse... (arse). Tinware, heat exchangers, exhaust etc were scrubbed down and painted. New 1641 barrels and pistons were bought and fitted to give a bit of xtra 'oomph'. All the freshly painted bits were re-fitted along with a 009 dizzy, new plugs and leads etc. The new clutch kit was fitted and the lovely shiny engine was born. BUGGY NOW HAS A HEART! HOOORAGH! I know... I know it was 2 months late, but its done now.
Next job is to modify and fit the mass of exhaust bits we have accumulated from shows over the summer months. (What we had of summer anyway...)
The screen and side posts have also been ordered from Mel (should be coming through December time).
Many brain cells were burned out trying to decide upon whether to have a tinted or clear screen. A clear one was chosen because of the rake of the screen being so steep, fears were of constantly looking through the top of the tint.
We're off now to fit a fuel tank and to drill lots of lovely holes! Wish us luck!

 

11/2002
Well, we just fitted the engine to the rolling pan, which proved very easy with the body off. Ian connected and adjusted all the relevant cables, fitted new fuel lines etc. and then decided to annoy the neighbours by attaching some wires and a fuel can and firing it up....with no exhaust! A big smile spread across everyone's faces as it burst into life and ran sweetly, if a touch noisy without the exhaust. Pleased with ourselves we dropped the body back onto the pan/subframe only to find it fouled the top of the fanshroud.....aaaaaagh. Still, it was only a cardboard hoop that Mel had 'glassed in to remove the body from the moulds, and after hacksawing it off, the body cleared the fanhousing....hoorah!.....but the rear number plate housing fouled the dynamo pulley.....boo! Still, we have a cunning plan to rectify this, and will tell more if it works out ok. I must add that the problem doesn't seem to be with the bodyshell but the subframe, which seems to be around an inch too shallow, and as no one had tried body on frame with an engine fitted nobody would have known...oh well, just a minor hiccup.

 

 

12/2002
Well, having a Birthday and Christmas in the same month is probably a pain for my friends and family, but it suits me just fine. Especially when there's bits I need for the Buggy. So, December was Buggy shopping month and thanks to Ma & Pa, Ian, Sue & John, Tracy & Karl, I managed to amass some more much needed parts to aid completion of the Buggy. I now have a set of sidepods, a windscreen, and lots of pretty shiny things for finishing touches like switches, license plates etc.
It wasn't just a month for shopping, though, we did get some more work done in between the rain and cold. We cut a hole for the fuel tank to sit in, and Ian bravely welded a filler neck into the centre of the tank and made sure it didn't leak. Ian suggested we trial fit the tank to make sure he'd got the filler neck in the right place and that it would fit ok.....it didn't!!! Grrrrr! Panic overcame us for a while, and there were frantic calls to Mel and lots of head scratching(especially after last month's clearance issues).However after whipping the tank from my Beetle and measuring a few datums, we realised that the angle of the panel the tank sits on was too steep and the tank just needed raising up slightly at the front to clear the steering gear....PHEW! It would appear that we are doing a whole lot of Research & Development along the way with this project, being the first in the UK, but we are taking notes should anyone else need them.

 

 

 

01/2003
Well, it's a new year and the Buggy is still unfinished. We've spent absolutely ages messing about attempting to overcome the clearance issues. However as soon as we compromise something in order for it to fit, we create another problem...it's like a domino effect! So after weighing up all the options we've gone for an easy life and we are adding 40mm to the subframe. We've mocked it up and its going to work (Hallelulah!!) Which means everything fits where its supposed to and we may have some chance of getting it on the road before this summer. We have trial fitted everything possible and measured, re-measured and measured again before making notes, before removing it all again, which should speed the build up from here on in. ( It's amazing how long this has taken, but it beats going round in circles trying to overcome the problem.) Next job is to construct the new top part of the subframe, attach it and then start heading for that light at the end of the tunnel.
( I thought it was a light at the end of the tunnel. but it was just some ****er with a torch bringing me more work!!-Ian)

 

02/2003
Well, hope has been restored at last! Pa bought some 25x40 mm box section, and cut it to size and shape for the subframe. Ian came along and welded it all together and I dressed it all up, sealed and painted it all. While we were at it, we trial fitted the body, and then the steering column before knocking up a steering column support bar and welding that in too. Now, there are no clearance issues and everything should start to move along a bit more smoothly from here on in. Happy that all was well, we finally drilled the body ready to bolt to the subframe and inserted 'Riv-nuts' to the top tube of the frame. A fair bit of wedging, tweaking and clamping was in order to ensure the body sat central and flush with the frame. Since we now had a fixed point we measured up and plotted the hole in the dash for the column and gingerly drilled it. We had to lose the factory mounting bracket, but Pa constructed a clamp to attach the column to the support bar. Aaaah, the satisfaction of making progress again. Enthusiasm returns.

 

03/2003
Inspired by the progress of last month, we were really keen to get some more work done, despite the wet and windy weather. We trial fitted the fuel tank again, which fitted beautifully, missing everything its supposed to. This was a major step forward, so I ordered up a flush fitting aero style fuel filler cap (much to my bank balance's disgust!) We fitted rubber mounted support brackets from the top of the front axle beam to the body, and bolted the tank down with body gasket beneath it. Then came the scary bit...plotting and drilling the first hole smack bang in the middle of the bonnet. Bullseye! We trimmed down some genuine VW fuel hose to join the filler and the tank and fitted the cap to the bonnet.
We set up the driver's seat and runners and used various bits of wood to ascertain the correct position and height, ready to make up some subframes to suit, from scratch. We've still got to tweak the steering column position through the dash and enlarge the hole to accept the ignition and switchgear housing, but we were rained off!
Well, we've been hard at it and have got the steering column through the dash. We also visited the Volksworld show and I spent a small fortune on yet more bits for the buggy. Street Style and Power supplied a dual zoom buggy exhaust, steering wheel boss for the woodrim wheel that Pa donated to the project, and various small but important parts. Bernard Newbury persuaded us that a pair of his Empi bucket seats were the answer to our seating problems and was very helpful.
Ian donated a pair of Empi polished rocker covers and detailed them to suit the buggy.
Pa supplied the aluminium sheets and folded the return into the top edge, before Ian trimmed, folded and drilled them to fit the subframe. We fitted M6 Riv-nuts to the subframe and stainless screws to attach these side panels.

 

04/2003
With the side panels completed, we could move on a step further towards getting the body bolted down once and for all. Margnor supplied the stainless bolts/ screws/ washers etc, and Pa supplied some 25x5mm aluminium strip which Ian cut to length and shape to act as a big washer/ retaining strip for the body. It works well and looks good too!
After crawling around under the rear of the buggy, tape measure in hand, Ian plotted and cut out another great hole in the rear seat area to accept the fibreglass battery box.
We finally have a pair of screenposts, but they need polishing, drilling and tapping and trimming to fit the body and screen.
With the body bolted down, we were able to mount the brake reservoir on the front bulkhead and plumb it into the master cylinder, before adjusting the brakes and bleeding the system. We also fitted up the switchgear to the steering column, fitted the twin speed wiper motor to the bonnet and mounted the standard VW fusebox to the steering column support bar.
We visited Wheels Day Hot Rod show and sourced the gorgeous rear lights for the buggy.
Ian also unravelled th Beetle wiring loom, stripped off the old sleeving and removed all the unnecessary wires, ready to re-sleeve it and start the big re-wire next month.

05/2003
More progress again, this month, Andy lent us his camber and tracking guages so we could set up the steering geometry after adjusting the front ride height. After test running the engine again, we found an idle fault, so Ian stripped the carb down to a big pile of tiny bits, cleared all the jets and airways through and replaced the accelerator pump and gaskets. Once refitted, the engine ran real sweet.
Now that the steering system was all set up as it should be, it was safe to bolt and plumb the fuel tank in, using body gasket around the edge.
We ordered up a load of wiring products, such as sleeving, heat shrink and connectors and started the joy of wiring the buggy's electrical system. With very handy colour coded wiring diagram in one hand and a big bundle of wires in the other, Ian trial fitted, then shortened or lengthened each wire to suit, before soldering new connectors onto each one. Then, we re-sleeved, routed and connected the wires to the relevant fuses, switches etc.
Ian plotted and cut the hole in the centre of the dash for the speedo and we spent ages trying to work out the best positions for the light and hazard switches. Once we'd settled on a position, we drilled and fitted them to the dash. Pa is machining up some longer bezels as the fibreglass is so thick, and some trick adaptors to fit the Moon piston knobs to the switches in place of the dull originals.
Ian also bought the front and rear indicators for the buggy and after lots of trying out different positions for the lights we commited to drilling the holes and fitting them in...WOW, what a difference the lights make to the look of the buggy.
With everything connected as it should be, it was time to cross fingers and fit and connect up the battery. Well, nothing exploded, so we tested each switch, light etc and everything worked (except one front sidelight, but that was a blown bulb which came from the donor Marina). Feeling confident, Ian turned the key and the engine burst into life....HOORAH!! This meant there was no need to push the buggy back up the drive as Ian drove it there instead, even getting wheelspin on it's maiden voyage....which he claims was due to the bit of wood he was sat on, sliding about....yeah, right!

 

 

07/2003
Well. with just one day into the month, we cracked into the buggy and trimmed the screen posts and bonnet to fit. Then we fiited the screen and posts to the bonnet, before fitting the whole lot to the car. We've still got to bolt the bonnet up in place, but we were able to plot the holes to attach bonnet and body securely to each other, using 40mm threaded plates, for extra strength and less rattles. We also messed around with various wiper arms, and blades in order to get a wide enough sweep of the screen. This is due to the screen angle and curve as opposed to the flatter, more upright Beetle screen.
More to do, but getting close to being roadworthy...and then we'll think about paint jobs, side pods, hoods etc. etc......
Well, we went mad and spent two ten hour days on the buggy, getting it MOT test worthy. Ma helped me cut and fit the bright red carpets to the interior of the subframe, the centre tunnel and the floor. We also carpeted the rear deck area in black. No wonder trimmers charge so much, it's back breaking and time consuming work!! While we did the interior, Ian made dash templates to cover the unused guage holes and recesses. This sounds easy, but the dash curves in three different directions, so took a fair bit of time to get right. Once happy with the template, Ian cut the shape from some diamond point patterned ali sheet and fitted it all up to the dash. This meant that the speedo and switches could be fitted up along with the security LED in the dash top.
The wheels came off again, and were given a coat of silver paint on the insides, before being re-polished, and the slots were treated to a splash of Signal red. Then the inner and outer tyre walls were dressed up before refitting the wheels.
Ian and Pa aligned and fitted the bonnet and the wing beading between it and the wings, before Ian dived head first under the bonnet to join the fuel filler neck and tank together...(which didn't look very comfy). Pa made up some adaptors which allowed the washer jets to fit through the extra thick fibreglass of the bonnet. Ian then fitted, and plumbed in the washer system which works real well.
Other little jobs covered include securing the battery, adjusting headlamp aims, plumbing in the fuel tank breather pipes and a brief engine tune/checkover. Then all that was left was a quick vac out and a wash over to remove the millions of handprints etc. and it was ready for it's first proper trip on the road.
Ian drove it home and checked all was well, before taking it for its first MOT at Farnborough Car Care. I'm very pleased to say that it sailed straight through.....HOORAH!!!!!!! and the guys were very impressed with the build quality. So, it's on the road at long last.....it's taken longer than we expected, but everything has been done as well as possible, with some bits possibly over engineered, but that can't hurt, can it?! It's by no means "finished", but it's roadworthy, looks good and is great fun to drive. Let's just hope the sunshine lasts long enough to enjoy it. BIG shouts of thanks to everyone involved!!(THANKYOU)

 

 

08/2003
Well, we've been on the road a couple of weeks now and the expected teething troubles have been very minor. The aftermarket air filter fell apart and disappeared somewhere on one of our trips out. We attended the SDBC annual show and the buggy was well recieved by most people who saw it...which was nice, but thats not why we built it, we built it 'cos we like it and it's a bit different from most buggies.
We've already clocked up 500 miles since getting him on the road, so it's time to service the buggy, and check everything is ok now it's had time to settle in. The service showed all was well and allowed us to open the throttle a bit more from now on.
The next day was the SDBC club cruise down to Club member Gregg's pub in deepest Dorset. We met up with 6 other buggies and their owners and raced down in convoy to the pub where we were met by the South West buggy club, resulting in a showing of 20 buggies in all, and a great bunch of guys and gals. And we came a close second (1 vote in it) in the " I want to take it home and put it in my garage award" . Which was a result as the Bounty Hunter is far from 'finished', was not built as a trophy hunting show buggy, and the winner was a V8 powered Jas Buggy. ( Thanks to those who voted for us! It's nice for all the effort to be appreciated by others!)
The buggy ran well, although we were a bit wary of opening it up too much due to the heat and the low mileage on the engine. Big grins all round!

 

09/2003
We've been putting some miles on the buggy recently, joining the SDBC club cruise and meeting up with the South West Buggy Club in Dorset. Then we loaded up and whizzed down to Cornwall for a fortnight. The buggy behaved itself despite some off road action and a lot of use. See some pics here! PICS!

01/2004
Well, despite having no roof for the buggy and the winter weather being wet every time we go out, we've still managed to use the buggy a bit. I took it up to the Slough swapmeet and got soaked on the way back! I took it to the Dub Addicts VW meet/cruise and got soaked en route, which was only made bearable by the standing ovation I got when we got back to the pub! :-) Roll on Spring and Summer!!! Oh, and we also bought a set of FAT slotmags for the rear, which are soon to be fitted!