V8 Volksrod - aka 'Lexibug'

Posted: Tue Jan 20, 2009 9:53 pm

A new year...so a new Project!!! Laughing

Not your normal Kit-car but a self-build job all the same with many crossover techniques and materials. Wink

I've always had the urge to built a Volksrod, but not just any Volksrod...it has to have a V8!

My plan is to chop, channell and shorten the Beetle body which will mount onto a homemade chassis with Independent Suspension all round. I want to mount the V8 up front and use a Ford Model 'B' grille and bonnet instead of the Beetle bonnet.

Here's what I've being doing over the last few days:

1 unused and forgotten Beetle

We aren't the best when it comes to safety!
Honestly we had to work quick as the bar holding the rear up was slowly bending!

No need to even take the car off the trailer!

Posted: Tue Jan 20, 2009 9:55 pm

Once I had the majority of body parts cuts away I mocked up some wheels, squinted my eyes and said...Yes...i'm heading in the right direction!

From this moment on I am now dedicated to this Project!

Posted: Tue Jan 20, 2009 10:04 pm

The next step was too Mock-up the Body over a Ford Model 'A' chassis I had out back. The chassis uses all running gear from a Ford Granada Scorpio. Because I want to run the body close to the ground I originally thought about modifying this chassis but instead I've opted to make a new chassis following the same principles but with 'Z'ed chassis rails and a slight alteration to the rear end.

Sitting NICE!!! Cool

Can't wait to chop it! Wink

You can see in the next picture the height of the Chassis rails are too high and would result in a floor level that after I chop the roof I would need to be lying down inside the car!

Posted: Tue Jan 20, 2009 11:00 pm

Once I was truly happy with the way the Body sat on the Model 'A' chassis I then set about making up my new chassis rails from 100x50 box section. I also decided that in order to get the side proportions correct as in engine compartment versus Beetle Body, I would make my new chassis rails about 200mm longer than the Model 'A' rails. I figured it was better to add a little now than later! Wink

Front Crossmember cut out

Posted: Tue Jan 20, 2009 11:11 pm

Basic chassis rails sitting at my preferred ride height, 5 inches at the front and 6 inches to the rear. Just enough to give a slight rake.

Posted: Tue Jan 20, 2009 11:31 pm

Granada Rear Axle laid out on floor with chassis rails

You can see in the next picture that my initial mounts for the rear axle are too low. The axle is currently sitting at the correct height with the wheels I am going to use so I'll have to modify my plans to keep the body sitting at the height I prefer.

Engine mocked up in place to gauge difference in height between rear diff and centre of flywheel. (No gearbox available at this point unfortunately)

At this stage I always think its best to work out my sitting position and bulk head position. I'm planning to use a Bench seat rather than two individual seats. At this point i'm glad I extended the rails a little as it seems to be working out just nicely.

Posted: Tue Jan 20, 2009 11:38 pm

Did a quick Photoshop just to give you all an idea of what i want to achieve. Cool

I want to shorten the length of the body in order to give a kind of Coupe look with a smaller rear quarter window. I'm going to remove about 4inches from the roof, not excessive by any means but I think it will look proportion and not too flat. I plan on removing the 'B' pillar completely and installing a retractable window frame so I can have both front and rear side windows working on electric motors. Also, my sitting position is going to be a little back than normal as i'm going to lose the front bulk head so in effect i'll probably be looking out the rear side window more than usual! Laughing

Posted: Wed Jan 21, 2009 12:27 am

C'mon the Stoneleigh................! Razz

Joined: 06 Mar 2008 Posts: 100 1955 Volkswagen Beetle

great plans and even better work so far John, I'll be keeping a close eye on this one!!

best of luck with it Smile

Posted: Wed Jan 21, 2009 10:23 pm

Altered the rear mounting points for the rear axle so the chassis rails sit just were I want them and gives a slight camber in the wheels unlike most cars lowered too exessive which have too much camber for my liking! Very Happy

Posted: Wed Jan 21, 2009 10:43 pm

Once I had the rear axle mounting points sorted I began trying to get the Chassis square so it wouldn't crab down the road! Best way was to make a JIG using an 8ftx4ft 18mm MDF sheet which I marked out the exact shape required to be 100% sure the finished chassis would be square.

Once I had the chassis rails in the JIG I tack welded some temporary cross bars to keep it square. Then I took the jig of the stands and back on the floor with the rear axle bolted to it. The plan is to leave the JIG in place as long as possible and add to it as the chassis is being built. This way I can build another chassis again quickly from scratch if desired! Wink

Posted: Wed Jan 21, 2009 11:06 pm

With two of the three rear axle points sorted, the third point, the Diff mounting point will have to wait a while as I ran out of 100x50 box section!

So, I moved onto the front Crossmember and installed the fixing points for the lower 'A' Arm.

Drilled out a 26mm hole completely through the Crossmember on both sides.

26mm Solid Bar cut into 4 lengths, 2 long and 2 short. The longer ones will support the lower 'A' Arm while the shorter 2 will support the upper 'A' Arms.

Tapered the ends slightly to take away the sharp finish

Drilled out the centre to 11.5mm bit with a depth of around 45mm

1/2 inch Imperial Tap

Finshed bars installed into Crossmember

Crossmember installed into position in JIG and tack welded.

Joined: 06 Mar 2008 Posts: 100 1955 Volkswagen Beetle

you're making it look easy!! Smile

Posted: Thu Jan 22, 2009 11:56 am

Brilliant thread John , great pictures and progress , best of luck with the new creation .

Posted: Thu Jan 22, 2009 12:47 pm

Fair play john looks good can't wait to see it finished Very Happy

Posted: Thu Jan 22, 2009 1:19 pm

Cheers for the comments guys! Smile

Always easy to make good progress in the beginning...the problem is keeping it up!!! Wink

Trying to get the Rover V8 to turn over on the floor at the moment but the starter seems a bit knackered and not enough torque left in it to turn over the engine decently! Sad

Good news is that our very own Chairman aka Grafter has a spare "Brand New" starter which he has kindly donated to the project so with a bit of luck I'll fit it later this evening and see if it makes a difference. Twisted Evil

Club Member Joined: 20 Aug 2008 Posts: 10

hi John ,
Thats a class project never seen a bug turn into that before , it really will stand out , best off luck with it .......................

all the best Gerard

Posted: Mon Jan 26, 2009 12:58 am

Started work on the front mounting brackets for the Upper 'A' Arms and the Shock fixing point.

Firstly I did a drawing of my desired shape

Then plasma cut the shape out 4 times from 6mm plate steel, 2 for either side

Tack welded the first bracket in place...

Then the second...

Next, I tack welded the short 26mm steel rod which I drilled and taped earlier to hold the Upper 'A' Arm in place.

Bolted up the lower 'A' Arm with ball joint

Upper 'A' arm installed with the Granada Hub and Disc also in place

Coil-over Shock fixed in place

Finished front passenger side mocked up and looking good

Gotta repeat the procedure now for the other side. Wink

Posted: Mon Jan 26, 2009 9:31 pm

Looks great. Keep the work going.

Posted: Tue Jan 27, 2009 5:28 pm

Almost a Rolling Chassis now! Twisted Evil

Next, I gotta finish off the rear Diff mounting point and then start fabricating engine and gearbox mounts.