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Bugzilla - The never ending project

Old 04-17-2018, 04:11 PM
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Default Bugzilla - The never ending project

Well guys, I figured I would start a thread on here for my Bug. The VW forum I am on kinda sucks and it really sucks to post pictures on. This is not going to be a build thread from the beginning since I am already 5 years into it and the car is built. So here we go! Even though the Bug is currently in a good driving condition, I still have a lot more to do to make it exactly how I want and to make it more reliable while racing. That is where this thread is going to start. Here is what I am working with.



Over the next few weeks, I will be installing a custom front air splitter. I have already designed the parts on Autocad and sent the files off to get CNC cut. Should be here next week some time and then the real fun begins.

Last edited by 5-Speed; 04-17-2018 at 04:40 PM.
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Old 04-17-2018, 08:25 PM
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I have hoped for this thread after every time you mentioned your Bug

i vote that you just dump 20 or 30 pics and say whatever you want about them.

in other words. MOAR
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Old 04-17-2018, 09:18 PM
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Honestly, I would post up older pictures, cause I have a couple hundred, but they are all when it was multicolored and beater looking. I know, its a project and all projects start like that... Maybe I'll pick and choose a few that were from the "nicer" part of the build and post them. Got to fire up the ol dinosaur computer for that. We shall see.
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Old 04-17-2018, 09:30 PM
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A few recent pictures, how about that? Ya its a bit dusty. I need to clean it.









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Old 04-18-2018, 05:26 PM
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I got confirmation that my splitter has popped out of the CNC machine and is all boxed up ready to ship! Should get it mid next week and mounted on the Bug by the end of the week. I still need to order some carbon fiber adjusters but I have to get everything mounted before I know what length I need.
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Old 04-18-2018, 06:15 PM
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Know what? I am about to do some work on my Bug too. I need it to make a lot of trips back and forth from home base to get Dad settled over there and need it for gas mileage and taking off road "Shortcuts" to cut off some miles and the Jeep is broke.

I am looking for an inexpensive source for a new ring and pinion set. The set in it now is way too tall. They obviously had an engine with a lot more horsepower than this one has now and built it for top speed off road.

I need to lower the ratio for a good compromise on/off road. 4:11 maybe? I'm not for sure what a good ratio would be if anyone has any suggestions? I would be happy with a comfortable top cruising speed of 65 on the highway with 235-15's in the rear.

Done cluttering your thread man. Just jumping on the Bug topic.

Last edited by Bugout4x4; 04-19-2018 at 11:16 AM.
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Old 04-19-2018, 11:14 AM
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I was kidding about off topic... Want me to clean that up?

Never mind. Done.
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Old 04-19-2018, 11:41 AM
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Sorry Bug! I was busy working on the Bug last night and never replied. No worries on ruining my perfect thread haha! How big in diameter are your tires and what engine you got in that thing? Air cooled engines are some picky suckers that need to be geared near perfect to not over heat on the highway, especially out your way in the heat.
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Old 04-19-2018, 12:01 PM
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Originally Posted by 5-Speed View Post
Sorry Bug! I was busy working on the Bug last night and never replied. No worries on ruining my perfect thread haha! How big in diameter are your tires and what engine you got in that thing? Air cooled engines are some picky suckers that need to be geared near perfect to not over heat on the highway, especially out your way in the heat.
I figured you were probably busy. Please don't let me bother you when you are busy, never anything that can't wait.

I have and like the single port that is in it now, fuel mileage and carb trouble free if you know what I mean, and it has plenty of power for my needs if it was actually geared right. What they did was swap engines before they sold it and it has become apparent they had a 200 horse power engine in it to pull these aftermarket taller gears and get a better top speed.

But with this single port they are just too tall. Too tall in low crawling and even too tall on the highway. With the 29" 235-15's (which I want to keep) It is doing 65 in 3rd before it feels like the right RPM to grab 4th. Obviously way too tall for the pulling power of this little single port. Like I mentioned below I would be absolutely fine with a "comfortable" pulling RPM and top cruising speed of 65. I never plan to pass anyone anyhow. lol

But this would also be an advantage off road crawling because I am working the clutch way too much in first as it is. But I'm not sure what the formula would be to find this ratio compromise I am looking for to choose the right ratio gear set. Owned a lot of bugs but never got into the details of fine tuning gear ratios like this and could use some expert Bug help.

In no way obligated, but If you can help point me the right direction it would be great my friend!

Last edited by Bugout4x4; 04-19-2018 at 12:08 PM.
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Old 04-19-2018, 12:37 PM
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I am going to say that you need to go more toward 4.56 gears. Thats what the 091 trans in the bus came with factory. They had about a 29" tire. The later buses with the 002 trans actually came with 4.86 gears! Your bug probably has 3.88 in it right now if its a late IRS trans.
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Old 04-19-2018, 01:14 PM
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Originally Posted by 5-Speed View Post
I am going to say that you need to go more toward 4.56 gears. Thats what the 091 trans in the bus came with factory. They had about a 29" tire. The later buses with the 002 trans actually came with 4.86 gears! Your bug probably has 3.88 in it right now if its a late IRS trans.
Super! I honestly think these are even taller aftermarket gears they put in this thing, ever since I got it this has been a pain but I learned to deal with it. It is a swingarm transaxle. I was leaning to about that ratio range as being the compromise I was looking for. And I think the 4.86 ratio would be even better for my needs? I will be doing more backroad travel than freeway travel with it. Would the 4:56 be better for my 65 MPH goal though? I don't want to get ran over either. lol

Thank you Sir!
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Old 04-19-2018, 01:46 PM
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4.56 and call it a day. It would be a good all around combo.

Now to the other Bugs updates. Here is my splitter progress so far.



Started off with cardboard



Then switched over to thick paper for the final template



Change up the skirts to make it look better



Nice 2.5" lip all the way around



Transfer the paper template onto Autocad and send the file out to be CNC cut



Take the skirt template and copy it on to some metal



Cut the metal out

At this point, I am waiting for the splitter to show up. I got confirmation that it shipped out today so it should be here next week to install. Not shown - I primed the skirts last night.
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Old 04-19-2018, 02:03 PM
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Originally Posted by 5-Speed View Post
4.56 and call it a day. It would be a good all around combo.

Now to the other Bugs updates. Here is my splitter progress so far.

At this point, I am waiting for the splitter to show up. I got confirmation that it shipped out today so it should be here next week to install. Not shown - I primed the skirts last night.
Done... Sounds good to me man! Wish I could just find a JY Bus Axle with those, but they are now rarer than hen's teeth no matter where you look. So I am stuck with buying gears and tearing it down.

Can't wait to see what it looks like when put together! I have a feeling I know where you are going with this... Do you think this might help suck the front end down for you to help in the turns?

Know what? I am in the works of adding quick fastener removable rubber fender air dams to mine so that I can prevent the front open Baja fenders from turning into parachutes catching too much air on the road.
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Old 04-19-2018, 02:40 PM
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Yes this should solve my front end lift. You can feel it start lifting at high speeds. The entire bottom of the Bug is flat so there is not much I can do to help there. Its about as good as it can be. With the addition of the splitter, the front end aero should be done. I am most likely going to move on to rear aero next. The rear fenders need to be filled in a little on the inside to help with lift and I need to put something like a skid plate below the engine. I will probably end up switching over to a real GT style wing since the one I have now is not really functional. Moar down force = moar betters! You are going to see the Bug on TV racing next year and that is a promise!

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Old 04-19-2018, 02:59 PM
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Originally Posted by 5-Speed View Post
Yes this should solve my front end lift. You can feel it start lifting at high speeds. The entire bottom of the Bug is flat so there is not much I can do to help there. Its about as good as it can be. With the addition of the splitter, the front end aero should be done. I am most likely going to move on to rear aero next. The rear fenders need to be filled in a little on the inside to help with lift and I need to put something like a skid plate below the engine. I will probably end up switching over to a real GT style wing since the one I have now is not really functional. Moar down force = moar betters! You are going to see the Bug on TV racing next year and that is a promise!

I honestly never thought about all that subframe and engine space you have under there. Man... that could be acting like a high pressure bubble build up area in it's self right?

I did think about the possibility of a front wing though... But didn't suggest it because it would look funky as hell and block some vision on that and didn't think you would consider it. lol

I hope you can get it recognized man... That would be cool as hell!
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