Building a Dune Buggy - the Essential Manual

Paul initially trained as an aircraft technician with The British Aircraft Corporation. This was followed with a job at a company who specialised in preparing Chrysler cars and engines for rally, race, and speed hill climbs. He then retrained in illustration, working for publishers and popular magazines. This led to successful study for a Masters degree at the Royal College of Art, London, England. Since the mid eighties, Paul has taught full and part time in Illustration and Graphic Design in the UK, with guest lectureships in the USA and Sweden. He still manages to engage in his love and fascination of the motorcar.

Foreword Acknowledgements Introduction Part One: The Big Plan Our approach Optional approach Somewhere to Work Sourcing Parts Donor vehicles the Options Suspension and Brakes Wheels stud configurations and their implications Styling Part Two: Getting Started Tools and Techniques Safety Jacking Using stands Rear hub nut Cutting, tools, safety equipment Removing rusty components safely and efficiently Drive shaft CV joint tools Fibre-glass Repair Materials Wiring joints Rust removal paint prep Materials The processes and options Rust prevention Removing the body stripping the necessary parts Lifting Removing the engine Removing the gearbox Cleaning repairing the chassis Bolster burning Preparing the chassis Floorpans Shortening options Three methods: straight cut chevron volkswagenworks Measuring/marking out, alignment Supporting Cutting Alignment Handbrake options and tip Cable routing: Checking and making the join Welding processes Filling saddle gap Finished floor Strengthening Fitting master cylinder Front suspension Front beams Lowering front suspension Removing leaves Lowered ball joints Camber compensation Castor shims Camber compensation Bump steer kit Steering tie rods Rear suspension Rear lowering sequences Spring plates Wide 5 discs Extra struts What else is needed Cable shortening methods Master cylinder pedal assy Brake pipes and hoses Gear linkage Gear change options Transmission mtgs Brake-clutch master cylinder Anti roll bar CV s gaiters Steering Shock absorbers Frame head change Irs brackets The build Mounting the body Lowering body Drilling holes Mounting points Stainless plates. Fitting the dashboard Fitting the nosecone Fitting the screen Steering column Wiper assembly and options Seat belt mounting Roll cage Seat mounting Lights front Rear lights Turn signals (indicators) Fuel system/options Tank, filler Pump Filter Fuel lines Wiring diagram Wiring process and options Battery Instrumentation Nudge bars fitting Front Rear Engine A look at those areas that are specific to a dune buggy. Carburettors and air cleaners Fan and belt guards. Remote filter Transmission Strengthening for off-road and competition Completing the project (what it takes to see the project through to the finish) Getting it on the road Anecdotes There are a huge and fascinating variety of stories from people who have successfully built a buggy. Interviews, advice, timescale, hindsight, 10 pages - 10 interviewees