Author Topic: bug/audi project  (Read 15907 times)

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Offline Alisdair

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bug/audi project
« on: October 14, 2009, 05:50:21 PM »
Hi  ,  thanks for checkin out my  project.
Inspired by Volksrods and rally cars i thought id add my own twist and combine the two.
This started as a 55 oval window bug and an audi 5000 quattro  wagon or 100 QT Avante to our european friends .

The greatest rally car of all time ...in my opinion .. is the Audi S1 from the mid 80s .
 As well as the complete drivetrain change ill will add a few styling clues from the S1 without destroying the lines of the VW. 
 
 

okay lets get started ..take this  and this 
 
The bugs  chop was started a few years ago but came to a sudden halt  when i was involved in a logging truck accident in sept 06.
 The rusty body is not rotted out , just covered in surface rust all over after sitting under a tree for 30yrs , thats how it was when i found it .
The Audi  is an 86  2.3l 5 cyl 10v turbo, 5spd ,awd with vacc lock diffs front and rear (dash mounted control)

This is not a simple body swap as the audi 100/5000 is a unibodied car     
so  first thing i had to do was turn a unibody  into something that resembles a vw type 1 floorpan , then cut the "floorpan" to length .
After many hours cutting I was left with this...
..

I placed the body on to the floorpan to see how much needs removed from the length.






and cut up an old crumpled hood to see how much it needs stretched , didnt i just say without destroying the lines of the bug  ?  ye im friggin hilarious somedays.

  

After cutting 19'from the floorpan ...it sure looks short
 Thats where its at right now  . ill post pics as it comes together.
Although its not aircooled i figured it may still be worthy of airspeeds forum due to it being all vw/audi.  smite away yee purists, lol.
« Last Edit: December 21, 2012, 08:48:07 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Geoff

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Re: 55 oval + 86 audi quattro turbo= freakbug
« Reply #1 on: October 16, 2009, 12:10:49 PM »
Cool project! That thing will be crazy

Offline Alisdair

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Re: 55 oval + 86 audi quattro turbo
« Reply #2 on: October 24, 2009, 08:29:55 AM »
thanks Geoff .   this is the outcome  of reading  too many Volksworld and Street Machine magazines :o. it had to rub off one day .    
« Last Edit: February 08, 2011, 10:33:14 PM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Alisdair

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Re: new pics: 55 oval quattro .... update
« Reply #3 on: December 05, 2009, 09:28:46 AM »
its been a few weeks since i posted anything so ill post a few pics over the weekend.  plus i really need to tidy and clean the garage. hopefully the worst of the mess is over with as my garage is right off the livingroom of my house. fiance no likey!!   so now im done cutting , im going to re-organise the shop before i move on.

the "Bugaudi" or is it Bugoddy ?, has finally started  to come together after days and days of cutting the floor of the audi to accept the body of the 55.
 it now sits centred to the floorpans new  88 " wheelbase , shortened from the original 107.
2 frame rails added and floor finally back together, now fitting and welding cage that will be bring some much needed strength . just a few new pics until i clean up. more later today.

you get an idea of the 3 main pieces that will become one . the front engine and floor, the rear axle and floor , and of course the bug body.
    

slide all 3 together and you have this









« Last Edit: February 06, 2011, 06:39:01 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Bruce

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Re: new pics: 55 oval quattro .... update
« Reply #4 on: December 05, 2009, 11:20:41 AM »
... it now sits centred to the floorpans new  88 " wheelbase , shortened from the original 107.
88?  Why not 94" (stock for your 56 body)?

Offline Alisdair

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Re: new pics: 55 oval quattro
« Reply #5 on: December 05, 2009, 11:52:12 AM »
thanks Bruce, what i want to try do is stuff all the running gear inside the body and still try to appear as if its just a bug. i had to make it 88 in order to squeeze the engine under the hood. the rad and fan will be in the rear . it looked strange side on ,the hood was too long. i moved the body forwards,(actually i moved the audi front end back ) to hide as much of the engine as possible, but it still sticks out .




« Last Edit: October 26, 2010, 09:34:21 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Alisdair

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Re: new pics: 55 oval quattro
« Reply #6 on: December 06, 2009, 08:04:34 AM »
 Very technical roof chop measuring device , if i chopped the roof any lower id have to give up my  XL .




this pic gives a good idea of whats involved in chopping a bug using a second roof skin to fill the gaps and add some of the strength needed after cutting.
« Last Edit: January 09, 2011, 10:33:32 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Alisdair

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Bugaudi .... gettin on with the roofchop
« Reply #7 on: December 09, 2009, 09:30:18 AM »
ive been looking forward to finishing the roofchop but had to hold off until i joined the floor halves  and added some frame rails for strength.  the floors are only tacked in place but the rails are fitted  front and rear. the rails are more like a subframe connector/roll cage floor bars. they are 2 1/2 "  mega thick 0.250 wall .
 then i can  complete the roofchop once the body is in place.  
 more soon









« Last Edit: January 09, 2011, 10:39:42 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline somevwguy

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Re: update: 55 oval quattro ...Bugaudi
« Reply #8 on: December 09, 2009, 03:06:19 PM »
Do I see a spoiler back there?   

Offline Alisdair

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Re: update: 55 oval quattro ...Bugaudi
« Reply #9 on: December 09, 2009, 08:23:19 PM »
yes its an old one from the flat black 74 out back . i just had to try it out for size, stuck an old running board on and  dropped the hood in place .kinda  ;D
« Last Edit: January 23, 2010, 07:51:34 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline somevwguy

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Re: update: 55 oval quattro ...Bugaudi
« Reply #10 on: December 10, 2009, 05:58:35 PM »
I thought you were going for somthing a little more Audi?  A spoiler like this:

« Last Edit: December 10, 2009, 06:02:26 PM by somevwguy »

Offline Alisdair

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Re: update: 55 oval quattro ...Bugaudi
« Reply #11 on: December 10, 2009, 08:29:59 PM »
when i first started this project it was my intent to leave the body with the patina mother nature supplied ,ie rust. however the fact is im removing more and more of the surface rust so i can weld it all back together. today i decided  to the rusty patina has to go
and once again my shop is a disaster and  has a nice orange hue to it. or is that just the thin layer of rust coating my eyes? .



 
« Last Edit: December 27, 2010, 12:55:27 PM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Alisdair

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Re: update: 55 oval quattro ...Bugaudi
« Reply #12 on: December 15, 2009, 02:53:13 PM »
its been like workin in a deepfreeze this  weekend , -34c . i still managed to get out there thanks to the woodstove and new chimney i installed , but  i sure hate the mess firewood causes .anyway  i moved on to the other side of the roofchop . It has been held in place with clecos and a few  welds.  spot/stitch  welding may be the way to do the welds but it sure takes a long time to weld 5000  spots. I  also done a little cutting to the hood around the strut towers .   im still trying to figure out what to do with the nose of the car. but i have a plan that combines the bug hood and a modern audi/vw  grille, its that or simply mould around the engine to form the shape to the hood. time will tell .
more soon  

 


 






« Last Edit: December 27, 2010, 12:57:33 PM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Alisdair

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Re: update: 55 oval quattro ...Bugaudi
« Reply #13 on: December 17, 2009, 10:20:39 AM »
thanks for all  the advice  on the layout  and stuff , i finally managed to figure out how to resize pics  etc, my apologies to you all for the mix match of pictures.  its all been a learning curve  for me on the computer , or as i call it  "ukin puter".
im sure its been hard or even comical  to those of you who host web sites  /  forums etc.  thanks again. Al
« Last Edit: December 26, 2009, 10:49:57 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Geoff

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Re: update: 55 oval quattro ...Bugaudi
« Reply #14 on: December 18, 2009, 06:48:55 PM »
Lookin good! all those welds suck to do but grinding them is worse >:(

Offline Alisdair

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Re: update: 55 oval quattro ...Bugaudi
« Reply #15 on: December 26, 2009, 10:19:31 AM »
 iagree   , sux big time,  but hey!!   now its got some shiney bits, even if it is just grinder marks.     :D
« Last Edit: January 13, 2010, 12:31:10 PM by Alisdair »
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Offline Alisdair

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Re: update: 55 oval ...Bugaudi
« Reply #16 on: January 13, 2010, 10:16:52 PM »
not much has been done to the bug in the last few weeks thanks to  christmas and new year and perhaps the odd hangover, so i was glad to get things back to normal and spend the weekend in the shop and get on with the hood .
i ve had to use pieces from 3 hoods to make 1 longer and narrower hood . it is now about  10 inches longer and 6 inches narrower .

here you get an idea how much longer it needed to be . the raised area for the vw crest has to go , no need for 2




and fill the hole


 




« Last Edit: January 26, 2010, 09:56:52 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Alisdair

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Re: update: 55 oval ...Bugaudi
« Reply #17 on: January 23, 2010, 08:34:55 AM »
ive often wondered why my pics all have a tint to them , i tried different cameras and settings but still no change
i now realise from the pics above that its my shop lights and the color of the ceiling reflecting on the car.
 lesson is , take pics during the day

okay time to get serious . so far ive been playin around with the hood and roofchop , however  ive only figured out 'how' im going to join the 2 cars together . i havent actually joined anything solid yet. that changes as of now . no turning back as they say.
  this week i have spent a few days making sure the floorpan was perfectly square, and the body then squared to the floor. As much as it looks like its joined, the reality is the body is sitting in place and the floors in the right position awaiting welding .  i wanted to get welding , but, i knew i had to hold off , take some measurements  and then............................................................... go get someone to  help me .
my neighbour steve is a math wiz , so i called on his help, and im glad i did  . by the time he left , my shop floor  looked like a math class blackboard . i felt like a kid in class, but at least learned  a few lessons along the way .  and not nearly as complicated as i have made it in the past.   my lesson for the day.  a2+b2=c2.
first thing to do was put get the wheels on the car and add some weight . steve had a better idea.  raise the car ,set the weight on the axles and remove the wheels , that way we can use the brakes and suspension as refernce points when measuring. like i said, im glad i got some help.
after lots of measuring, checkin and double cheking , the only thing that needed adjusted was the right  rear corner . a few small adjustments with the hydraulic power pack and it sat square.  to be honest i was surprised that it was as close to square as it was.
i trusted my scribe marks when i cut it and when i rejoined it . i dont expect it to be perfect , but i do want it to be as close as possible.

more later

   




and so the welding of the pieces begins
« Last Edit: January 20, 2011, 08:28:53 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Alisdair

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Re: update: 55 oval ...Bugaudi
« Reply #18 on: January 23, 2010, 09:43:42 AM »
.
« Last Edit: January 30, 2011, 07:46:24 AM by Alisdair »
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Offline bugbuzz

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Re: 55 oval ...Bugaudi
« Reply #19 on: January 25, 2010, 08:44:18 PM »
Loo.kin good Al..... Holy crap what a project Good on ya....

Offline Alisdair

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Re: 55 oval ...Bugaudi
« Reply #20 on: January 27, 2010, 07:29:55 AM »
thanx  bugbuzz.   its coming together nicely  ,  but its  watercooled  :-\, now  if i could  just figure a way to fit an aircooled  up front  :cool:
« Last Edit: February 05, 2010, 08:34:25 AM by Alisdair »
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Offline Alisdair

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Re: 55 oval ...Bugaudi
« Reply #21 on: February 05, 2010, 10:02:16 AM »
im glad to say that i have gotten over the biggest hurdle with this build.
it has been no easy task measuring and cutting  both the floor and the body , especially with the roofchop the way it was.  Im glad i stuck it out as it has been a lot of work ,with very little reward until now .  
ive had to keep jumping from one thing to the next in order to bring it all together . some days it feels like im going nowhere ,but by day 2 things come together as planned.  finally the body  and floor are  one , the frame rails connected front to back , the rear frame half attached to the rails , and now on to the front . (remember i said this build would be bass ackward).
 



having done the right side , i simply followed the same process on the left
 
finally the rear end is attached to the bug body .
 now moving  on to the front.


the pics before now of this area shows only the inner wheel arch and door post.  after it is all sealed up ill finish it off with this






things should move along now that the peices are coming together. more sooon.
« Last Edit: February 06, 2011, 07:00:32 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline Alisdair

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Re: 55 oval ...Bugaudi
« Reply #22 on: February 05, 2010, 01:00:49 PM »
sometimes you just have to sacrifice .  ive been using 16 ga sheet to make the peices needed to join the 2 cars together . however its not the easiest gauge sheet to shape with handtools. a simple but effective way to overcome this (and to my girlfriends amusement ) was to cut a ball pein  hammer in 2 and make this handy little attachment for my air chisel.



i guess my girlfriend thought this was going to be a quieter way than hammering . think its gonna be a noisy weekend around here.......EHHH??
« Last Edit: February 09, 2010, 09:27:07 AM by Alisdair »
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline silas

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Re: 55 oval ...Bugaudi
« Reply #23 on: February 05, 2010, 09:08:48 PM »
.....and to my girlfriends amusement...

:o :D ;)

Offline somevwguy

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Re: 55 oval ...Bugaudi
« Reply #24 on: February 05, 2010, 10:15:05 PM »
.....and to my girlfriends amusement...

:o :D ;)


LOL, AL only one fiberglass front clip made it up, but my body is in WL now!!!

Offline Alisdair

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Re: 55 oval ...Bugaudi
« Reply #25 on: February 06, 2010, 09:05:56 AM »
silas , ye shes kinda hard to please.  :P   lol_hitting

jeff drop by over the weekend sometime



i think im building the most unphotogenic car ever  >:( :o
« Last Edit: February 06, 2010, 12:24:36 PM by Alisdair »
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Offline somevwguy

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Re: 55 oval ...Bugaudi
« Reply #26 on: February 06, 2010, 11:08:50 AM »
next week, I'm in sunpeaks all weekend

Offline Geoff

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Re: 55 oval ...Bugaudi
« Reply #27 on: February 06, 2010, 12:41:15 PM »
Keep the updates comin! This is one crazy build

Offline Alisdair

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Re: 55 oval ...Bugaudi
« Reply #28 on: February 07, 2010, 09:10:45 PM »
you bet !!!! 
 crazy's a good thing right ?  lol_hitting
66 ragtop bug, 55 Bugaudi 33 dodge 6

Offline somevwguy

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Re: 55 oval ...Bugaudi
« Reply #29 on: February 18, 2010, 08:15:44 AM »
11 days and no updates? whats going on?