Tim's Green Bug...

[TimS]

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[TimS]

Aha! I see why round tube and tab is easier than square.

Passenger seat mount took away any fun I was having today. I designed it all wrong. I had square tube and was trying to use a welded in nut inside the tube. But now there is absolutely no play in any of the bolts, so I stripped one of the nuts partially and had a heck of a time. It was a very poor design choice. It is fixed now, but that is my only progress today. Well, except for the rear bar. I drilled it out, shaped it, and put it in place. Tacked it in for now. I want to get it driving again, then i will seal up that area.

[BAJA-IT]

Aha! I see why round tube and tab is easier than square.

Passenger seat mount took away any fun I was having today. I designed it all wrong. I had square tube and was trying to use a welded in nut inside the tube. But now there is absolutely no play in any of the bolts, so I stripped one of the nuts partially and had a heck of a time. It was a very poor design choice. It is fixed now, but that is my only progress today. Well, except for the rear bar. I drilled it out, shaped it, and put it in place. Tacked it in for now. I want to get it driving again, then i will seal up that area.

I need to seal up the shock holes on mine before the trip.

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[TimS]

Passenger seat mount is painted and passenger seat Installed for good.

Dust free is nice, Cameron. If I get time, I want to do a positive pressure cabin.

[dustymojave]

Be sure to allow for flow-through ventilation so you don't suffocate or experience CO poisoning. SOME outside air is a good thing even in freezing cold or severe dust. I expect I'm preaching at the Deacon, but others on here might not understand this issue up front. That issue is why 1971 and later Bugs have a vent in the back edge of the front hood and that funky air box and little ducting under it, and the outhouse vents behind the 1/4 windows.

[dustymojave]

New battery mount cuts into cargo area some, but protects the battery much better. I've had the batteries off the floor in my Baja Bugs since 1974. Needs a box to keep anything form touching acid or shorting the terminals and cable ends.

That battery pic also shows the cage tube through the floor much more clearly than before too. The issue is that there needs to be a larger area of connection that just welding the sheet around the tube as it passes through. A gusset from the side of the tube to the side of the rear wheel well would help. So would a piece of plate welded around the tube as a flange with another flange piece bolted to it on the other side of the sheet metal. A little caulk would seal it.

[TimS]

Getting it out of the blood is easy, getting it to let go of ribosomes is a far more complex process involving people in a high pressure 100% oxygen environment. In this environment you have enough time to see a spark and realize it is a spark before your body is consumed by fire. I remember a night way back when when a fairly local hotel had a CO problem. They scattered their guests around the mountain region to all the available spots with a hyperbaric chamber. We had oxygen by the ton scattered around the ER in 2200psi vessels and I was going from patient to patient changing tanks and drawing blood.

I got about 8' of sheet metal welds today.

[TimS]

That battery pic also shows the cage tube through the floor much more clearly than before too. The issue is that there needs to be a larger area of connection that just welding the sheet around the tube as it passes through. A gusset from the side of the tube to the side of the rear wheel well would help. So would a piece of plate welded around the tube as a flange with another flange piece bolted to it on the other side of the sheet metal. A little caulk would seal it.

So for the visual learners, I will translate that into a picture.

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[TimS]

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[TimS]

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[TimS]

Came out okay but by the end of it I was getting frustrated. Should be strong. Will be dustproof after seam sealer. Found a crack in my tunnel down 1/2 way both sides. Threw more metal at it. It seems to have stuck.

[CentralWAbaja]

GO Tim Go!
I'm Loving it!
Got sh!t to to and places to be!

[bajaherbie]

Mikey likes it!

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[TimS]

And for the engineer types, I am really banking on the strength of that beam and catilevering the loads back to the rear suspension and past the seats in the other direction. Eventually I hope to tie this in up front, but for now I will load it tail heavy front light.

I got a massive forhead burn from doing my spot welding on the tube joint between the cage and he body. My helmet wouldn't fit.

Battery is mounted. Im running out of steam, but hope to get the seat mount done today. That will be the end of this stage's welding and i can be drivable with quick and clean efforts scattered sporadically through next week. Maybe even Sunday, but household chores need done.

[TimS]

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