Berrien Nostalgia Dune Buggy - berriennostalgiadunebuggy

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Z Bar Beam to Fiberglass to bottom of Tank Support
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Rear Engine Cage Tack, Weld and Paint018
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Cherry Picker Front End Loader
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Rear Engine Cage Tack, Weld and Paint001
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Main Cage001
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Main Cage002
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Main Cage014
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Main Cage004
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Main Cage005
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Main Cage006
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Fiberglass Floor Cut Outs008
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Fiberglass Floor Cut Outs007
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Battery Box009
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Battery Box012
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Battery Box011
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Main Cage012
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Battery Box010
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Battery Box013
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Rear Engine Cage Tack, Weld and Paint006
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Main Cage013
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Rear Engine Cage Tack, Weld and Paint009
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Rear Engine Cage Tack, Weld and Paint010
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Rear Engine Cage Tack, Weld and Paint011
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Rear Engine Cage Tack, Weld and Paint012
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Rear Engine Cage Tack, Weld and Paint013
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Rear Engine Cage Tack, Weld and Paint014
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Rear Engine Cage Tack, Weld and Paint015
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Rear Engine Cage Tack, Weld and Paint016
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Fiberglass Floor Cut Outs001
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Fiberglass Floor Cut Outs002
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Fiberglass Floor Cut Outs003
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Fiberglass Floor Cut Outs006
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Rear Engine Cage Tack, Weld and Paint017
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Welded nut on Frame to attach wiring etc...001
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Welded nut on Frame to attach wiring etc...002
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Welded nut on Frame to attach wiring etc...003
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Welded nut on Frame to attach wiring etc...004
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005
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Picking the Buggy from Dave and Sue at Berrien Buggy!!001
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Picking the Buggy from Dave and Sue at Berrien Buggy!!003
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Picking the Buggy from Dave and Sue at Berrien Buggy!!002
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Picking the Buggy from Dave and Sue at Berrien Buggy!!005
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Picking the Buggy from Dave and Sue at Berrien Buggy!!004
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Picking the Buggy from Dave and Sue at Berrien Buggy!!006
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Picking the Buggy from Dave and Sue at Berrien Buggy!!007
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Picking the Buggy from Dave and Sue at Berrien Buggy!!008
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Picking the Buggy from Dave and Sue at Berrien Buggy!!009
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Picking the Buggy from Dave and Sue at Berrien Buggy!!010
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Picking the Buggy from Dave and Sue at Berrien Buggy!!011
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Picking the Buggy from Dave and Sue at Berrien Buggy!!012
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Picking the Buggy from Dave and Sue at Berrien Buggy!!013
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Picking the Buggy from Dave and Sue at Berrien Buggy!!014
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Picking the Buggy from Dave and Sue at Berrien Buggy!!015
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Picking the Buggy from Dave and Sue at Berrien Buggy!!016
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Sitting it on the chassis for an inital fit.001
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Sitting it on the chassis for an inital fit.002
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Checking fit for Battery Box and top clearance.001
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Checking fit for Battery Box and top clearance.002
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Rear Engine Cage. Inital Fit.001
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Rear Engine Cage. Inital Fit.002
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Rear Engine Cage. Inital Fit.003
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Rear Engine Cage. Inital Fit.004
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Rear Engine Cage. Inital Fit.005
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Rear Engine Cage. Inital Fit.006
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Rear Engine Cage. Inital Fit.007
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Rear Engine Cage. Inital Fit.008
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Rear Engine Cage. Inital Fit.009
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Rear Engine Cage. Inital Fit.010
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Rear Engine Cage. Inital Fit.011
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Berrien Cage. I will have 3 front to back bars, gussets, etc..001
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Berrien Cage. I will have 3 front to back bars, gussets, etc..002
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Berrien Cage. I will have 3 front to back bars, gussets, etc..003
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Berrien Cage. I will have 3 front to back bars, gussets, etc..004
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Moved the body and side pods to another garage for safe keeping!!001
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Moved the body and side pods to another garage for safe keeping!!002
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Moved the body and side pods to another garage for safe keeping!!003
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Berrien Cage. I will have 3 front to back bars, gussets, etc..006
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Berrien Cage. I will have 3 front to back bars, gussets, etc..005
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I am planning on tying the rear motor cage into the rear roll bar down tubes. DSC03254.JPG 2008-10-21

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I am planning on tying the rear motor cage into the rear roll bar down tubes. DSC03255.JPG 2008-10-21

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I am planning on tying the rear motor cage into the rear roll bar down tubes. DSC03256.JPG 2008-10-21

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I am planning on tying the rear motor cage into the rear roll bar down tubes. DSC03257.JPG 2008-10-21

Moved the body and side pods to another garage for safe keeping!!004
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7/16/2009 8:08:25 PM - 000062812610
Still wiring. Started back on 06-14 after getting all my parts together. I have at least a full week working on it. Weekends and Nights and some day time effort.

7/2/2009 1:00:34 AM - 000062812610
What a slow process for me. It finally makes sense. I told Cindy we would push it outside when I finally put a battery in place and try to see if it is working. We better have a fire extinguisher ready - just in case.

6/15/2009 2:25:23 AM - 000062812610
Stared wiring the DB today after hours and hours on line. I had to work out diagrams for the gauges and the front to rear wiring.

6/7/2009 5:52:21 PM - 000062812610
Greased the CV Joints and installed them along with new hardware. Torqued them to 25#. Put on the rear cage to check the fit after powder-coating. Added a new convex mirror to both side so now you can actually see out the back from the drivers seat.

3/20/2009 9:50:48 PM - 000062812610
Jerry made me a little tool that looks like a crack pipe to install insterts into my roll cage tubing. I used them to install the side mirrors and rear view mirror. They are the pictures for 3-20. I also installed my side pods. 2 man job that I did by myself. Where are my 3 boys when you need them? One was a pain and the other went on easy as pie.

2/27/2009 2:16:45 AM - 000062812610
There is nothing that goes easy. I was under the impression that the ball joints on the front end were new. I think the guy that sold them to me certainly believed it to be true. I went to replace the boots and found out that the ball joints were used and bone dry. They were ruined. I went to have new ones pressed in and of course this is not that simple. They had to be put in a lath and turned down to fit. Seems there has been a problem for years with replacement joints. Mine were from Germany but they were not any better than the China crap. Installed new seals on the torsion arms. This was before the final coat of paint on all the items.

2/2/2009 2:29:24 PM - 000062812610

Roll Cage, Push Bar and Engine Cage were powder-coated. I finished up during Superbowl Weekend most of the front suspension, the pan gasket, emergency brake tubing, and fitted the push bar.

1/20/2009 10:55:10 PM - 000062812610
I took the Dune Buggy to Brett Hamiltons Race Car Shop. He always has been great about letting me bring a project and work on until it is done. I can tell you that most projects like this take months to get done because he is so busy. Brett always does my jobs himself and it is greatly appreciated. We added extra bars to the cage and tied the downbars into the rear motor cage. The front push bar is a very simple attachment and quick release when needed. He will do the final weld on the gas tank when I take it to him later this week. (Now this may take months to get back.) I have to have Caison and Patrick help me remove the cage so he can do a final weld on all the joints.

1/3/2009 8:20:05 PM - 000062812610
It was great over Christmas and New Years to have time to work on the Dune Buggy. A lot was done not much shows in the pictures. The big deal was to get the hole for the gas tank and hod done as well as get the steering figured out. Cindy's brother Jerry was a big help and is going to machine down a connector for the steering column so I can finish bolting it in place. It is rolling and can now make a trip to Richmond to go to a fab shop for the rest of the cage that did not come in the kit.

12/11/2008 10:14:55 PM - 000062812610

I mounted the body on the chassis. I also fitted the roll bar to check clearances with the body and to get it ready for additional bars. The trailing arms are installed. (I need to bolt it together with all the hardware, but I need to check mm-bolt sizes.) I cut the hole for the steering column. Just a note on my black paint. I cannot stand bare metal. From day one it starts to rust. I always clean, prep, primer and give a light final spray coat. (This is for those who see my brown primer poking out.) I know it will have to be done over many times before it is done, but it makes things much easier to work with even if you have to grind it down for more welds. The only real change I am going to make is to enlarge the roll cage bolt holes. They are a pain to line up and it took way to long to bolt it onto the frame. I think over Christmas I can get the front steering installed and the gas tank drilled for a new inlet.

I bought new transmission mounts, but for the life of me I don't see how they are going to work with the set up I have installed for the rear cage. The rear cage slides on/off the transmission mount on stubs that are welded to it.

12/6/2008 5:06:26 AM - 000062812610

I bought a stock 1600cc motor to start with in the dune buggy before I try and rebuild the original motor with a little more pep. It seems that it is pretty solid. It was suppose to be freshened up, but I have my doubts. Ut has a new clutch and pressure plate and it is somewhat shinny (from 10'). Trailing arms now have urethane bushings installed and are ready to go in chassis.

12/1/2008 3:10:40 AM - 000062812610

11/28/2008 4:51:45 AM - 000062812610
I had the IRS trailing arms and drum brake backer plates sand blasted. I degreased, painted, repacked the bearings and added new seals. This is a major pain in the ass to do as well as being super messy. I have installed the backer plates four times and tomarrow I will do them again hoping to get them turned the right direction for the last time. This is the transmission from Geno Boyd in Pittsburgh. Geno and his buddy met me in MD and delivered the transmission. I will add the details on what he did during the rebuild. It is a standard 3.88 R and P.

11/15/2008 5:28:33 PM - 000062812610

I fit the front beam. The chassis is a little wider for the beam mounts. The steering stop was in the way so it had to come off. I will have to fabricate a stop after it goes together with the body.

I also covered the fiberglass with 3M paint tape to protect it from bumps and scratches. 

Last items are the IRS trailing arms. I had bought some off of Samba in the used parts area. I am stripping them and will have them sandblasted this week. The bearings seem to be fine so that will be one of the few things that will not be replaced.

I am bidding on some wheel adapters for 4 lug to chev 5 x 4.75. I am the high bidder, but now I find out they don't work with front disc brakes. Someone told me that this can be solved, but he cannot remember what he did?????? I cannot remove my high bid so I have to pray that I lose this one.

 

10/28/2008 8:04:56 PM - 000062812610

I had 3 days in the mountains to do what I wanted. Cindy, Caison and the girls were going to head up and spend a long weekend, but it was raining so they cancelled. It work out great for me. I was able to tack, weld, prime and paint the cage for the body and engine. I still have several bars to add to the cage, but it is easier and cleaner to touch up areas. I also pulled the motor from the donner bug. I have unbolted the body on the bug and will use the front end loader to pull it off the pan. I also have the gas tank out so I can weld in a new gas outlet and seal up several vents holes and the original filler location.

10/22/2008 1:51:39 AM - 000062812610
Picked up the body on Sunday. Dave and Sue came down from Berrien Michigan. It was fun to see the birth of my orange buggy. They were faternal twins (yellow Citation and orange Nostalgia). Mine must be the oldest since it came out first. I had ordered the Berrien "Show Cage". It was 1.5" mandrel bent tubing. I am not sure of the wall, but it looks like .095? The matching rear motor cage is something they don't show on their web site. I can tell you it is well engineered. It is not 100% welded but it will be very easy to finish.  I also picked up the seats on Monday down in Oneida TN, long story to save $100. Should have got them from Berrien, in the end it would have been about the same cost..