Building a Dune Buggy - The Essential Manual: Everything You Need to Know to Build Any VW-based Dune Buggy Yourself!
There has been a huge resurgence of interest in Dune Buggies (Beach Buggies) - kit cars based on the chassis and running gear of fatally corroded VW Beetles. Here is the complete step-by-step practical guide to the equipment and building techniques needed to build a Buggy, as well as sound guidance on the choice of donor car and new components. With this manual in your workshop, you can build any VW-based Dune Buggy avoiding all the common pitfalls and money-sapping mistakes, and end up with a superb, roadworthy multi-purpose vehicle.
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Chassis shortening methods
Brake component options
A fuel system
The buggy engine and ancillaries
Mounting the body
Wiring the buggy
Rust removal and paint prep
The donor vehicle
Wheel stud configurations
Removing the body
Floor pan preparation and assessment
adjustment allow angle grinder assembly axle stands ball joint battery beam Beetle body bolts bracket brake fluid Bruce Meyers cables centre chassis circuit clamp clean cold chisel components disc drill dune buggy easy edge engine fibreglass filler flange floorpan front suspension fuel gel-coat halves handbrake hole hose inner inside join leaves look loom lower mark master cylinder measure metal method mounting neck nosecone Once options outer paint pans pedal piece pipe position problem rear end rear section rear suspension remove rust screws shaft shortening side slave cylinder socket splines spot welds spring plate steering strip stud supply surface swing axle switch tack tank tape there’s thread tool torsion bar torsion bar tube trailing arms transaxle tunnel section underside vehicle Volkswagen washers wheels whilst wire workshop