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Volkdent
19-07-2013, 22:27
I really never saw this coming, but I'm starting a new build thread!!!

So, here's where we are at:

2004 Boxster S 85k miles purchased
Cutting out dented panels and generally cleaning stuff up and see what I have to work with.
Have made contact with a guy in Oregon who will sell me a '57 Oval Rag body and some later doors that I'll be fileting within an inch of it's life. Take heart that this body has already been stitched together at some point, so I'm not cutting up a complete car.

Here's some of the damage:

http://images.thesamba.com/vw/gallery/pix/954543.jpg

http://images.thesamba.com/vw/gallery/pix/954542.jpg

http://images.thesamba.com/vw/gallery/pix/954541.jpg

http://images.thesamba.com/vw/gallery/pix/954540.jpg

Some motivational reference:

http://images.thesamba.com/vw/gallery/pix/954539.jpg

The one with the red decklid is the one I've got my eye on, I'll be replacing all sheetmetal with fiberglass from CCC.

http://images.thesamba.com/vw/gallery/pix/954547.jpg

http://images.thesamba.com/vw/gallery/pix/954546.jpg

http://images.thesamba.com/vw/gallery/pix/954545.jpg



Jason

Volkdent
19-07-2013, 22:28
More pics of the victim, a little nicer than I really want to cut up actually...:(

http://images.thesamba.com/vw/gallery/pix/954694.jpg

http://images.thesamba.com/vw/gallery/pix/954695.jpg

http://images.thesamba.com/vw/gallery/pix/954696.jpg

http://images.thesamba.com/vw/gallery/pix/954697.jpg

http://images.thesamba.com/vw/gallery/pix/954698.jpg

http://images.thesamba.com/vw/gallery/pix/954699.jpg

http://images.thesamba.com/vw/gallery/pix/954700.jpg

http://images.thesamba.com/vw/gallery/pix/954701.jpg

http://images.thesamba.com/vw/gallery/pix/954702.jpg

Jason

Volkdent
19-07-2013, 22:29
Almost done, only took me 10 minutes;)

http://images.thesamba.com/vw/gallery/pix/965804.jpg

http://images.thesamba.com/vw/gallery/pix/965806.jpg

http://images.thesamba.com/vw/gallery/pix/965805.jpg

More motivation!

http://images.thesamba.com/vw/gallery/pix/965807.jpg

JASON

Volkdent
19-07-2013, 22:31
Car is back from the body shop, oddly the chassis ended up being in spec, so it was $380 of insurance I guess.

Some more big news, not very sexy, but really hot if you are a Californian car owner. This project is officially registered as a 1957 Bug!!!! For those of you in other parts of the world or country, in California you have to smog(emissions test) every car newer than '72 I believe. So, this car would have had to have been registered as a 2004 Porsche Boxster, having to be smogged every 2 years. Instead it will never get smogged, have lower insurance rates, and is all set for twin turbos!!!

Back to the juicy stuff, the boxster is completely stripped, very close to the deep cuts it will need to allow the bug to fit over it. Pics to come, sorry.

The whole area from the apron to under the dash is gone from the bug.

Today a set of KW V3 coilovers arrived so I can start to set up ride height.

Good to see you Panel, does this get your juices flowing?!!!

Jason

Volkdent
19-07-2013, 22:31
I purchased KW V3 coilovers for her. Did a lot of head scratching and the cost/value ratio was just too good to pass up compared to competitors.

http://images.thesamba.com/vw/gallery/pix/984629.jpg

Got the inner panels cut out of the bug, and got the whole thing ready to go onto the frame table

http://images.thesamba.com/vw/gallery/pix/984630.jpg

http://images.thesamba.com/vw/gallery/pix/984619.jpg

Unfortunately, the wheels on the frame table are not rated for enough weight, they are barely up for the weight of the table, let alone a 3000lb car. So that was a big waste of time. I'll get some better casters for the table and also I think the legs should be triangulated so they don't fold in if it hits a bump moving it from shop to shop.

http://images.thesamba.com/vw/gallery/pix/984618.jpg

Jason

Volkdent
19-07-2013, 22:32
I probably could write a little how-to now, getting very close. Still have some major hurdles to overcome like moving the steering column to the right a couple of inches...

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/479742_10151175640268310_1360788265_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/424783_10151175640333310_1780210791_n.jpg

Some more motivation...

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/67770_10151175784963310_2011078548_n.jpg

Jason

Volkdent
19-07-2013, 22:33
Some candy...

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc1/424841_10151179666263310_2086019461_n.jpg

Like a glove...

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/556871_10151177395403310_1733445471_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/66033_10151177395243310_424958658_n.jpg

Jason

Volkdent
19-07-2013, 22:34
Last shot of her before she goes next door to Nor Cal Sand & Off Road owned by Eric Jenkins. His forte is offroad, but he's a heck of a fabricator and I need a chassis, so that's a good mix.

Here's the last shot of her:

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/403768_10151196562703310_1401492147_n.jpg

I had to leave 1.5" between the bottom of the body and the chassis bottom, I simply didn't have any more room at the top of the fender for the strut tops. As it is I have some grinding to do before the fenders will be low enough:

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/528350_10151196562803310_149088719_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/406662_10151196562898310_1044024951_n.jpg

Jason

Volkdent
19-07-2013, 22:35
Random build shots:

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc1/600673_10151297588638310_990923579_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/163318_10151297588708310_358305117_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/48110_10151297588858310_1958678855_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/379361_10151297588928310_906809006_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/580685_10151297589018310_1954197965_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/549191_10151297589163310_1415768881_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/72681_10151297589273310_1202400505_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/549320_10151297589538310_1622300194_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-snc7/600887_10151297589793310_1743715652_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-snc7/481435_10151297589878310_2072799946_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/307336_10151297589983310_1291659419_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/541603_10151297590073310_1590187060_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-frc1/603938_10151297590203310_1918817441_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/426388_10151297590328310_1367962526_n.jpg

Thanks to Eric at Nor Cal Sand and Off Road (http://norcalsandandoffroad.com/) for his awesome fab skills and attention to detail!

Jason

Volkdent
19-07-2013, 22:35
https://sphotos-a.xx.fbcdn.net/hphotos-prn1/541659_10151331614378310_1758771530_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/67019_10151334314838310_812277241_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-snc6/268112_10151334315403310_1951016998_n.jpg

Jason

Volkdent
19-07-2013, 22:36
https://sphotos-b.xx.fbcdn.net/hphotos-ash3/562166_10151376053978310_2120575726_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/164198_10151376053943310_1611492502_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/602075_10151376053903310_648961109_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-frc3/480302_10151376053818310_234430615_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-snc6/221720_10151376053608310_598843602_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/527717_10151376053523310_2125278806_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/559275_10151376053488310_1803878837_n.jpg

Front and back are joined again.

Jason

Volkdent
19-07-2013, 22:37
This would be cool!

http://www.precisionchassisworks.com/uploads/2/5/1/9/2519425/647376_orig.jpg?334

http://www.precisionchassisworks.com/uploads/2/5/1/9/2519425/8491764_orig.jpg?336

Precision Chassis Works (http://www.precisionchassisworks.com/index.html)

Jason

Volkdent
19-07-2013, 22:37
This turned out to be one of the largest problems I didn't even realize I would face. Turns out the steering wheel needed to be moved to the centerline by 3.25". Well, also turns out the steering column and the pedals are one unit. Also turns out the steering shaft is sitting very near the gas tank. Also, the master and accompanying booster aren't really the moving-type. SOOOO

I took a wild guess and tried a step in the right direct by just moving the whole assembly over by the distance between the 2 main mounting studs, 1.75".

The hole on the right is the new one, the other 2 are backed by some sort of aluminum casting that transmits the load right to the MC. I figured half is better than none.

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/11879_10151412354893310_1026974595_n.jpg

Well, my decision turned out to be a good one, as the steering shaft just clears the gas tank by the width of a zip tie, the master cylinder extender arm just clears the steering column if you turn it 90 deg, and the heater/ac core just fits back in next to the assembly with less than a 1/4" to spare.


https://sphotos-b.xx.fbcdn.net/hphotos-ash3/537921_10151412354178310_1974422971_n.jpg

I had to hack open the hole for the steering shaft as it would have fouled now, and I have to figure out some sort of reasonably safe way of transmitting the brake pedal motion to the MC extension arm. This is what I'm most worried about, I'm taking a really well designed double-shear and perfectly centered brake pedal system and building a single shear and slightly side loaded force vector. I've got a couple of ideas, rod ends to be exact, but I will have to play it by ear and get the opinions of a couple of the engineer types on GLF when I get that far.

Jason

Volkdent
19-07-2013, 22:38
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/969142_10151449308523310_812519596_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/249059_10151449308733310_386927054_n.jpg

My first plan included using a male heim, but I just couldn't let myself feel comfortable with that in a single shear load. I'm not worried anymore, the pedal will break before this thing does.

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/934061_10151449309623310_454100357_n.jpg

This is my friend Michael who has done the beautiful lathe work. He's from the old school and can machine ANTHING! Thanks Michael!!!

https://sphotos-a.xx.fbcdn.net/hphotos-ash3/942082_10151449309688310_69125704_n.jpg

Volkdent
19-07-2013, 22:39
Roll cage nearing completion:

https://sphotos-a.xx.fbcdn.net/hphotos-prn1/941567_10151495049538310_1137852953_n.jpg

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/983968_10151495049383310_1514968821_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc3/993065_10151495049233310_498535981_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-ash3/1017086_10151495049143310_877569764_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/1011691_10151495049088310_182010115_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/184467_10151495049033310_1311597978_n.jpg

Not sure how "legal" the rear mounts are, but they seem stronger than a plating type so not sure why that would be a problem. I don't think this think will ever race but I try to follow FIA/NASA/SCCA rules as much as possible.

Jason

Volkdent
19-07-2013, 22:39
Starting to put her back together. Figured I'd just start at the front and work my way back!

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash4/1005971_10151513318753310_1181820695_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/931181_10151513318828310_1152787745_n.jpg

Notice the drivers side connection and the passengers side connection to the "bumper" bar are at different heights. The drivers side is where the impact occurred on the Boxster, so the height difference is about 3/8". I had thought about having the frame straightened here, but it was just more work/$ than it was worth as it affected a large area.

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/1002943_10151513318863310_1403604027_n.jpg

https://sphotos-b.xx.fbcdn.net/hphotos-ash3/1010928_10151513318913310_680488725_n.jpg

The holes filled in nicely, low so I can fill. The whole front apron has been tweaked so I was just looking for a seal and a low surface.

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/1002785_10151513318988310_235789823_n.jpg

Jason

Volkdent
19-07-2013, 22:40
Rad arrived. I might have overdone it, this thing is heavy and a bit bigger than I wanted, but I think bigger is better if a turbo is on the horizon.

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/1002779_10151542513213310_428199200_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/995701_10151542513113310_1372142156_n.jpg

Jason

Volkdent
19-07-2013, 22:41
This is the closest example of the color combo I'll have when I'm done, except in satin not gloss:

http://www.vwvortex.com/artman2/uploads/1/beetlers2.jpg

http://www.vwvortex.com/artman2/uploads/1/beetlers3.jpg

http://www.vwvortex.com/artman2/uploads/1/beetlers4.jpg

http://www.vwvortex.com/artman2/uploads/1/beetlers5.jpg

Jason

hajee
19-07-2013, 22:41
awesome project!
thanks for posting it here, and keep us posted here!!
cheers from the Netherlands!
:thumbup: :D

Tjaap
19-07-2013, 22:47
I just read all 8 pages from your link.
This thing is insane. In a VERY good way.

Keep it up and please keep us updated!!!

evilnyntje
19-07-2013, 22:58
Damn!

Tjeerd
19-07-2013, 23:19
Verry, verry nice poject!

Keep us posted

2sneaky bora
20-07-2013, 00:04
Perfect fit

Nice project

Van Limburg
20-07-2013, 03:07
Great welts! Cool project!

RobbieMK1
20-07-2013, 07:25
http://www.helloericritter.com/wp-content/uploads/2012/11/Borat-VeryNice.jpg

Keep up the good work, looking good!

Albert87
20-07-2013, 09:14
lol this is sick. *in a good way*(y) keep up the good work's!

dewieker
20-07-2013, 15:58
whow! verry nice project! :eek:

René
20-07-2013, 16:29
Cool project!

Wouter42
21-07-2013, 10:24
Best.
Project.
EVER!

Keep up the good work!

VW Johs
21-07-2013, 10:36
Awesome project

Jel Golf 2 GTI
21-07-2013, 11:09
love it, keep up the good work :thumbup: :thumbup:

Dokter D
21-07-2013, 13:19
"Vind ik leuk" otherwise: LIKE

Volkdent
25-07-2013, 17:59
Getting the radiator to fit has been a challenge. Working out airflow through the hood.

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1025915_10151566496803310_173459176_o.jpg

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash4/998210_10151566496958310_853546325_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-frc1/1006296_10151566497063310_1108111294_n.jpg

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/1078745_10151561711838310_1928887513_o.jpg

Walkaround (https://www.facebook.com/photo.php?v=10151562203233310&set=vb.735178309&type=2&theater)

Jason

Tjaap
25-07-2013, 23:46
Awesome

DÁ-BRT
26-07-2013, 07:02
Welkome to the forum. And I thought my mid engine V6 TDI project was nuts...

Keep the good work going!

steven16v
26-07-2013, 12:10
Wow! Very nice!

Volkdent
01-08-2013, 02:39
Picked this little guy up for the A/W intercooler rad. It's a stock 996/986 center rad, about $170 so I thought that was reasonable. Has about 3/4" inlet/outlet. Unfortunately I don't have any more room around the rad, so it's going to have to find a place somewhere else in the car...

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/972107_10151579593798310_907635871_n.jpg

Jason

Tjaap
01-08-2013, 19:51
So where are you gonna fit it then?

VeeDubber
01-08-2013, 21:54
Love this project. It's nice to see someone stepping out of the box and go radical with his car. Keep us updated!

Volkdent
05-08-2013, 02:49
So where are you gonna fit it then?

I'm a "build as you go" kinda guy, I try to have forethought, but it's not always as clear as I'd like. I may be cooling it through the roof oddly enough, we'll have to see. I might even not be able to use it, which would be really annoying, but it's the right size for the job I think.

Jason

Volkdent
20-08-2013, 21:34
Getting there, working on the A/C system and getting the stuff under the hood to work out nicely...

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/1184773_10151613490148310_483553186_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn2/1186232_10151613490253310_1599715771_n.jpg

https://sphotos-a-sjc.xx.fbcdn.net/hphotos-prn2/1185937_10151613491168310_279772951_n.jpg

https://sphotos-a-sjc.xx.fbcdn.net/hphotos-ash4/1013293_10151613491313310_1118394275_n.jpg

https://sphotos-a-sjc.xx.fbcdn.net/hphotos-prn2/1186220_10151613491973310_1591905898_n.jpg

https://sphotos-a-sjc.xx.fbcdn.net/hphotos-prn2/1185380_10151613492018310_1091275857_n.jpg

https://sphotos-b-sjc.xx.fbcdn.net/hphotos-ash4/1146615_10151613492088310_1691094240_n.jpg

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/1150361_10151613492163310_778222133_n.jpg

https://sphotos-a-sjc.xx.fbcdn.net/hphotos-ash3/1176240_10151613492233310_1608038409_n.jpg

Jason

Tjaap
20-08-2013, 22:02
so much awesomeness.....!

Dokter D
20-08-2013, 22:10
Damn! Respect! LIKE is an understatement over here :thumbup:

JR_berry
21-08-2013, 11:23
holy smokes :wow:

keep up the good work :thumbup:

Tjaap
24-08-2013, 22:20
Getting there, working on the A/C system and getting the stuff under the hood to work out nicely...

Jason
Also love you're keeping the modern creature comfort bits.

Volkdent
04-09-2013, 02:31
Back at it, just grinding through the details.

Fabbed up these steering column brackets, I now have a tilt AND telescoping steering wheel!!! This little bracket was a lot of work but now I can adjust the wheel for almost any seat or seating position. The nutsert tool is already paying for itself!

https://sphotos-a.xx.fbcdn.net/hphotos-prn2/1234865_10151638495198310_1426666443_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn2/971965_10151638495278310_2122532922_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn2/1234873_10151638494668310_911666522_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-frc3/1157638_10151638494743310_816528036_n.jpg

Finished up moving the clutch master over 1.75" as well. It's not what I would call pretty, but I'm working on my side under the dash so cut me a little slack. It is all sealed and if I ever do a renovation of this thing I can pretty it up then.

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/1004708_10151638495123310_589121094_n.jpg

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/1186242_10151638494983310_2055634056_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-prn2/1175146_10151638494868310_1004781063_n.jpg

Steering column back in and we have steering again!!!

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/1231208_10151642088188310_1608086189_n.jpg

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/1236742_10151642088278310_76254614_n.jpg

Finalized the angles, routing, and rotation of the tubes for the cooling system. I think Erik at norcalsandandoffroad (http://norcalsandandoffroad.com/) got them welded up for me today. I do all the fiddley work and I let the pros do the talent stuff!

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/1234222_10151642088458310_1754295149_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-frc3/1240634_10151642088418310_2029694179_n.jpg

These are the details I'm most proud of, I was able to utilize the stock coolant pipe bracket even though my pathway is totally different.

https://sphotos-a.xx.fbcdn.net/hphotos-ash3/1208995_10151642088388310_1360507800_n.jpg

Jason

Volkdent
09-09-2013, 07:29
More coolant work. Had to "massage" the area above the front lower control arm attachment point to allow space for the rad. Not pretty but necessary. Also welded a tunnel through two body layers for lower rad hose.

https://sphotos-a-lax.xx.fbcdn.net/hphotos-frc3/1235465_10151650922743310_1663258738_n.jpg

This is where the tunnel exits, then up and over the rack bellows. Tight fit.

https://sphotos-a-lax.xx.fbcdn.net/hphotos-frc3/1234528_10151650922923310_375101036_n.jpg

The top and bottom hoses join next to the gas tank. Also this is a high point for the lower tubing, so a bleed bung has been added that ties into the stock Boxster coolant bleeding system. Hopefully this makes for trouble free bleeding. Very excited to be able to use the factory coolant hose bracket!

https://sphotos-a-lax.xx.fbcdn.net/hphotos-ash3/1174978_10151650923063310_801701844_n.jpg

The previously dual rad system now only has one pathway. Both side bleed tubes can be seen and will be used. On a technical note, I am now aware that there are special hose clamps for silicon hoses. They have an additional internal sleeve that offers a smooth surface for the silicon to be squeezed by.

https://sphotos-b-lax.xx.fbcdn.net/hphotos-ash4/1209438_10151650303333310_2007621350_n.jpg

https://sphotos-b-lax.xx.fbcdn.net/hphotos-ash4/1174614_10151650923178310_1363077504_n.jpg

I've been able to just squeeze this monster in there, next up add the A/C condenser...

https://sphotos-b-lax.xx.fbcdn.net/hphotos-prn2/1174807_10151650922478310_1022741332_n.jpg

Jason

LRR
09-09-2013, 08:37
Stunning piece of work !!!

Tjaap
10-09-2013, 22:02
That ducting is very impressive

Dokter D
10-09-2013, 22:18
Respect! Nice piece of plumbing!

Volkdent
18-09-2013, 01:42
Small update, big progress.

I finally got the floor pan welded to the frame. It sounds simple enough, but the floor pan has a nice thick layer of German underbody sealer on it, and it all had to be ground back from the welded edge. A big mess. Then, to make it just a little more messy, I seam sealed the whole area. I forgot to get a pic, but I used a honey consistency seam sealer so I could really flow it into all the nooks and crannies. Trouble is I'm doing this upside down so I looked like I pigged out at the chocolate fountain...

Also got a jack point welded in, seen it the top part of this pic.

Anyway, here's a shot pre-sealer.

https://scontent-b.xx.fbcdn.net/hphotos-prn1/558184_10151665682153310_83792484_n.jpg

And a couple more of the rad area.

https://scontent-b.xx.fbcdn.net/hphotos-ash3/543923_10151665682393310_720646262_n.jpg

https://scontent-a.xx.fbcdn.net/hphotos-ash3/1237178_10151665682423310_442974796_n.jpg

Jason

gtipower
20-09-2013, 20:05
Nice Project, keep up the nice work.

En keep us posted :)

Dennis.

Volkdent
25-09-2013, 06:08
Big day, I finally came up with a structural solution that is also elegant in its design. It ties the inner and outer Boxster chassis, the new frame rails, and the roll cage together, all while allowing a nice edge to finish the bug/Boxster seam along.

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/q80/s720x720/1237123_10151680596473310_1284078532_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/q71/s720x720/1236541_10151680596583310_1977634780_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-prn2/q71/s720x720/954891_10151680596648310_1126126717_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-frc3/q73/s720x720/1236159_10151680596348310_768460668_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash3/1236864_10151680596228310_1611546750_n.jpg

Also finishing up a factory-like re-attachment of all the lines running back to front.

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash3/579085_10151680165018310_1319901253_n.jpg

Jason

Audi1981
29-09-2013, 11:34
Impressive! :thumbup:

Volkdent
01-10-2013, 06:36
Starting to get fun. Installed the stock Boxster trunk latch.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1383065_10151693878083310_1758562936_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1383518_10151693877978310_235928109_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/q87/s720x720/960004_10151693878258310_565200045_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/q77/s720x720/1186184_10151693878313310_1916288989_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/q86/s720x720/1013122_10151693878183310_151814064_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/q87/s720x720/558349_10151693877923310_1365873892_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/q72/s720x720/734111_10151693877823310_1655275867_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/q71/s720x720/1378846_10151693877538310_1762070908_n.jpg

Jason

Volkdent
01-10-2013, 06:45
Devil is in the details. There was a fatigue fracture through this area. Hope this makes it better and the decklid easier to seal against water.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/q74/s720x720/1385260_10151694548358310_862572045_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/q77/s720x720/1010970_10151694548303310_1796832355_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/q72/s720x720/1377496_10151694548043310_1870404975_n.jpg

Jason

Tjaap
01-10-2013, 23:55
Will the hood latch have a remote ?

Volkdent
02-10-2013, 07:08
Will the hood latch have a remote ?

The Boxster has a remote solenoid to pop it, then there is also a manual pull. I don't remember if my Porsche remote has anything but door locks, but I can add an aftermarket remote later that can handle the decklid latch if I want. Honestly, that little trunk is so small I don't think it will get used that often!

Jason

Volkdent
06-10-2013, 06:16
More body mods. Not too many things good about getting old, but a couple are patience and knowledge, so I scraped up as much of each as I could and this is what happened.

https://scontent-a-pao.xx.fbcdn.net/hphotos-frc1/q80/s720x720/1383909_10151703162818310_1171667986_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-frc3/q80/s720x720/1380701_10151703162678310_620922168_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/q77/s720x720/1381338_10151703162713310_991554547_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-prn2/q81/s720x720/1380445_10151703162748310_1210043420_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/q77/s720x720/1383148_10151703162633310_1234955743_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash4/q72/s720x720/1380587_10151703162368310_71598732_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/q71/s720x720/1378724_10151703162518310_931581513_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash3/q74/s720x720/541895_10151703162583310_972869743_n.jpg

vdWal.
19-10-2013, 18:54
really great project you have going on here :thumbup:

Volkdent
21-10-2013, 09:15
Slow, tedious progress, but progress nevertheless.

Built the template for the side storage pods, the drivers side will house the rear relay block.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1375707_10151705444598310_241137063_n.jpg

To close off the frame rails, I built a plug that also includes a nut to affix a bracket for the trailer hitch. I see myself building a trailer that I can haul track tires with and that is also a tent someday.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1378024_10151705445043310_1518620866_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1378878_10151705445083310_1944934077_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash4/1383090_10151705445013310_692682715_n.jpg

The inner fender seam between the Boxter and the bug is almost complete. Built a panel that merges the strut mount to body.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1381190_10151730333233310_554505894_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1391738_10151730333298310_633183846_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash4/1380731_10151730333503310_1944716544_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/1376494_10151730333648310_210552230_n.jpg

Jason

Volkdent
07-11-2013, 02:42
Little update:

Got these aluminum mufflers, yes, I said aluminum. Got a buddy that builds big HP cars and he swears by them, very, very light, no cracks yet for him. I'm doubtful, but they aren't that expensive and I could flange them to a stainless system if I wanted and still get big weight savings.

https://scontent-a.xx.fbcdn.net/hphotos-frc3/1382385_10151737660453310_1482146545_n.jpg

Ditto for cheap Chinese headers. They are supposed to be stainless, and they are except for the severely warped flange. Had to spend a bunch of time on them to get the flange flat and to open the bolt holes up. Really surprising how simple some of the mistakes are, but equally surprising how little a complete header setup was.

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/859837_10151737660538310_1492183244_o.jpg

Working on the fitment to the fenders, these will have to be widened ever so slightly unless I like the smell of burnt rubber around every corner. Looks kinda cool though...

https://scontent-b.xx.fbcdn.net/hphotos-ash4/1390626_10151756158063310_558302321_n.jpg

https://scontent-a.xx.fbcdn.net/hphotos-frc3/1394792_10151756157963310_1673219011_n.jpg

https://scontent-a.xx.fbcdn.net/hphotos-prn2/1383568_10151756157908310_1835340928_n.jpg

https://scontent-b.xx.fbcdn.net/hphotos-prn2/1452064_10151756157853310_733837085_n.jpg

Finally got the condenser attached to the rad, used aluminum spacers my wife uses for her business, re-threaded them for metric, and had Eric at NorCal Motorsportz weld them on for me.

https://scontent-a.xx.fbcdn.net/hphotos-ash3/1450885_10151768985053310_1466570364_n.jpg

https://scontent-b.xx.fbcdn.net/hphotos-frc1/1451353_10151768982628310_116145612_n.jpg

https://scontent-a.xx.fbcdn.net/hphotos-ash3/999723_10151768982358310_648473959_n.jpg

https://scontent-a.xx.fbcdn.net/hphotos-frc3/r90/1424379_10151768982138310_1063643835_n.jpg

A before shot of the area I need to fill between the Boxster chassis and the tubing.

https://scontent-b.xx.fbcdn.net/hphotos-prn2/1395348_10151768982953310_1715329369_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1461089_10151768983613310_1152902058_n.jpg

The mess I have yet to tackle...

https://scontent-a.xx.fbcdn.net/hphotos-frc3/379663_10151768986253310_130647322_n.jpg

Jason

Marco
07-11-2013, 11:04
Still going strong :)

Very impressive!

I'm very suprised that the wheelbase is almost the same, reffering to one of your first shots with the beetle body hanging over the porsche.

smeerpeer
07-11-2013, 11:19
OMFG...what a cool project!

Matheo
07-11-2013, 12:02
Great project!

SjorsMK2
19-11-2013, 12:47
waiting for an update on this awesome project,

Volkdent
21-11-2013, 07:25
The details continue - gauge cluster now.

Cut the stock speedo ring and moved it over 1.5". It was really tricky because I couldn't put the cluster in level, didn't flow with the curves, and it couldn't flow with the curve because it would look too tilted, I ended up with a compromise between the two.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash4/1462917_10151794708018310_869449247_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1463576_10151794708078310_230458955_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1452115_10151794708128310_541256817_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1465283_10151794708183310_130858452_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1460101_10151794708233310_441406731_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/q71/s720x720/62458_10151800914808310_2037121392_n.jpg

Jason

Volkdent
21-11-2013, 07:42
Front and rear latches will be controlled by stock solenoids. Deepest part of front latch aluminum will be embedded in fiberglass to bond it to inner hood surface.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1461030_10151779575313310_1004152730_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/1465215_10151779575213310_517804218_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/999777_10151779575148310_1724784218_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-frc3/1424304_10151779574853310_1277396155_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/994380_10151779574763310_1725698219_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1461488_10151779526988310_181382168_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/988752_10151779527288310_1254154908_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1394080_10151779528183310_466168637_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-frc3/1395340_10151779528458310_553976449_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/599406_10151779528738310_1973517595_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1460237_10151779528993310_100593643_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1441317_10151779531218310_752182829_n.jpg

Tjaap
21-11-2013, 08:01
Love the cluster!

SDBNL
22-11-2013, 14:50
MAN! That is awesome..! Keep u the work. Amazing..! :thumbup: :thumbup:

Jonne Feith
09-12-2013, 12:26
How's the progress on this awesome project?

Volkdent
05-02-2014, 07:05
Stopped at least for another month, bought a new house and need to build a new shop, I'll post again when momentum returns!

Jason

Spijky
03-03-2014, 19:40
Great project!!

Looking forward to see some more pictures.

:thumbup:

Tjaap
30-04-2014, 13:57
Any updates yet? Pics of the new shop are welcome too :)

Volkdent
06-07-2014, 20:58
Dirt is still being moved on our hillside, should have a flat spot to build a 26'x40' shop next week. 0 progress on this project, of course things take more time than you expect to get rolling.

Here's a shot of a Super/Boxster S from Sweden, hope to be doing this in my bug next year.

https://vimeo.com/m/99021642

Jason

Tjaap
30-10-2014, 23:57
Updates !

Volkdent
27-02-2015, 07:32
Nothing new to report, she just sitting there. A roller, yes, but no progress. May be done with engineering next week on the garage structure, but don't expect to be working on it again for at least a couple of months.

Jason

Tjaap
06-12-2015, 08:10
I read on germanlook your pics are dead because of hosting them on Facebook.
Did you know you can host them on here too!