Manxter #169 / 170 Custom Red and Orange

Manxter 2+2 Build Threads
Brad Connell
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Manxter #169 / 170 Custom Red and Orange

Postby Brad Connell » Mon Nov 28, 2016 3:48 pm

This build thread will be a little bit different as it is going to cover two Manxter 2+2 Builds as opposed to one. The reason for this is that we are building two Manxter 2+2's at the same time and both will be the same specification

These Manxter 2+2's will be built on a custom Type 1 VW Floor pan and have a number of very custom features to suit the owners requirements. These builds are based on a Manxter 2+2 Kit with the following Specifications:

• Manxter 2+2 - Custom Colours, Hard Top, 6 Point Roof Support, Side Pods
• Manxter Stainless Front and Rear Bars
• Meyers Manx IRS / BJ Floor Pan, custom 2" lift kit, custom tunnel and outrigers.
• Custom SS Mustang Seats from a 2015 Car ( leather and electric), Covered Manx Buckets in Rear
• SubaruGears 5 Speed Transmission
• SubiWorks EJ 25 SOHC Subaru Engine with factory ECU
• Air Con and Heating

Brad Connell
Manx Admin
Posts: 364
Joined: Sun May 29, 2011 9:54 pm
Contact:

Re: Manxter #169 / 170 Custom Red and Orange

Postby Brad Connell » Mon Nov 28, 2016 3:55 pm

Like all our builds once the order is taken we fill out the Meyers Manx Purchase agreement and hand it over to Winnie or Paige to get the kit onto the schedule.

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Once the kit has been ordered the search begins for a donor beetle and Subaru. In most vases we try and use a pre 75 VW Bug to avoid any issues with smog.

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The Engines and transmissions come from a later model Subaru. In this case they will be an early 2001 Subaru Outback

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The engines and transmissions are then pulled and fully rebuilt by Chris at SubiWorks.

Brad Connell
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Posts: 364
Joined: Sun May 29, 2011 9:54 pm
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Re: Manxter #169 / 170 Custom Red and Orange

Postby Brad Connell » Mon Nov 28, 2016 3:59 pm

With the donors found we start by stripping down the VW Bug to bare floor pans.

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All the suspension components are pulled down, sand blasted and rebuilt to factory specifications.

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Brad Connell
Manx Admin
Posts: 364
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Re: Manxter #169 / 170 Custom Red and Orange

Postby Brad Connell » Mon Nov 28, 2016 4:15 pm

One of the big difference with these builds is that they will be getting custom seats from a 2015 SS Mustang. This is not usual fitments and is being done to fill the customers needs. The issue you run into with any factory seat is that you have limitations as they are designed to fit into factory cars which are often not square and are much larger than the Manxter will be.

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By track measurements they should just fit but once we received them we soon realised that the track width would fit but all the electric controls and gears would not, added to that the height of the seat base in stock configuration was to high to fit in the Manxter 2+2.

This meant that we were going to have to do modifications to the tunnel as well as the lift kit IOT make it work. For this we would need to get the body so we could do a dry assembly.

After we did this it was back into the Chassis Jig so that it would not suffer any heat issues as we did all the modifications.

The fixture we use weighs in at several hundred pounds and is welded onto a flat table. It allows no movement off center and ensure that the tunnel and beam alignment is correct.

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Once we had done the modifications we did what we hoped would be one last test fit, this showed we need to modify the body as well

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Then the moment of truth, the fitting of the seat

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Bam it all works, from there we put her back in the fixture, add some gussets, sleeves and other mods to support the reduced cross section of the tunnel and weld it all out. This is then repeated on the 2nd pan.

To put this into prospective it sounds much simpler when you say it quickly but these simple modifications added around 40hrs onto the builds and several weeks of delay while we waited for the body to arrive etc. We usually have the pan built before the body arrives.

As we find out later in the build ... thing the pans like this ... live and learn.

Brad Connell
Manx Admin
Posts: 364
Joined: Sun May 29, 2011 9:54 pm
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Re: Manxter #169 / 170 Custom Red and Orange

Postby Brad Connell » Mon Nov 28, 2016 4:20 pm

While all this is going on the Roll Cages are made from 1020 DOM and full Tig Welded.

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They are then sent out to Powder Coating

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Once they get back from Powder Coating we cab do one more final mock up to confirm the pans are good to go to paint and seal.

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With the green light from QC they are fed through the spray booth and get the usually full prep and sealing treatment.

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