MANXTER #27
Manxter #27 is being built for a customer on Nantucket. The #27 buggy kit arrived at ECR the usual way, via the guys at Stewart Transport in their specially designed rig. The basic kit was looking good as it was removed form the truck and moved inside the ECR facility to begin its assembly. The metal flake Blue is a really nice color. The depth of the shine makes it look almost like a "black light". The look of a metal flake buggy hasn't lost any of its luster over time.
Once inside the ECR facility we inspect and catalog the entire kit. If anything needs attention or if parts have been left out of your kit, we take care of all that at this early stage so that it can be handled quickly and easily. You'll notice in the image above that #27 has been checked over and will now be taken apart from its transport stage to get ready for assembly. We also cover all the edges of the buggies with special material so that no scratches or dings happen to your buggy while we are building it. This is the same material used by new car companies when they ship your new car to the dealership, and we feel it is well worth our investment, to help protect yours.
As we get the parts together for the pan and suspension, the engine for #27 is made ready. The engine for this buggy will be a Type IV monster. In the image above you can see the nearly completed engine getting ready for a dyno pass at the A.C.T shop. The Type IV engine is being used in this project so that we can have a roughly 2300 cc engine, that has all kinds of power, but one that also will last long term and is daily driver friendly. This buggy will also be getting an automatic transmission from a VW 412. We are currently rebuilding the entire transmission with new everything in our shop. We know we'll loose some power going through the full automatic so that was another reason for the Type IV, to keep as much power, with longevity and durability in mind, as we could. We have also gone with a full stainless steel free flow exhaust system and a Mallory Uni-Lite distributor for long term trouble free performance. Our Type IV engines are built by Jake Raby of Air Cooled Technologies.
Why do we have Jake build our Type IV engines? Take a look at these dyno pass results in the image above and you'll have your answer! Reliable, long term power that has over 160 foot pounds of torque and over 155 horsepower. Keep in mind this will all be built into a buggy that will weight very little. The end result should be one amazing package.
Now that the engine has been dyno-tuned and shipped to us, it is ready to be detailed. The engine shroud you see in the image above as black has now been removed and is being painted in metal-flake blue to match by our in house paint department. We have a 1,000,000 BTU cross draft spray / bake booth to handle any custom paint idea you can imagine. The rest of the engine is being tricked out as well, right down to its new stainless steel, twin exit exhaust.
Here you can see we have moved the body to our rolling jig and rolled it to the fabrication department of our shop. Here we will test fit everything and assemble as much as possible while the pan and suspension are being set up and while the detail the paint work is done to the engine parts.
At the rear of the body we have installed the engine cover and lights so that we can clearance check the engine, exhausts and carbs before we lower the body onto the pan.
We also reverse mounted the engine cover hinges so that you can't see the hinge for a cleaner look to the rear end.
Up front we have started to lay in the wiring harness and set up the dash. The next step will be to mate the engine and the gearbox to the pan (or frame if you will) so that the seats rails can be installed and custom items such as the radio mount can be welded in place before the top support cage goes to our paint department.
In this image you can see the Type IV engine being set up with the detail work it needs. The ACT shroud has been removed and painted in the same Canadian Blue metal-flake as the body for a complete custom look. Once the detail work is done on the engine it will be ready for install into the buggy.
To fit the Type IV, or even a Type I engine with an alternator, into the Manxter, a new engine cover had to be made. The image above shows the difference in the Meyers supplied engine cover that is too short to even fit a stock 1600cc engine, and the ECR corrected engine cover that will allow the Type I, Type IV or even a wild 4 bbl intake system to be covered and nice looking. Our piece is on the left (obviously) and it is purposely left long so you can trim it to fit your application (better too long than too short like the kit piece). Once installed it will cover the Type IV engine nicely and will look more finished than just leaving the engine cover off the buggy.
The lower end of the buggy will be this T1 VW pan that we sourced from So. Cal so it is rust and rot free. As this buggy will have a the T4 engine and that will be mated to the automatic we will need to heavily modify the rear section of the pan to accommodate the set up.
The full automatic transaxle for this buggy has been fully rebuilt, including reconditioning of the torque convertor, and now it is time to match it up to the pan. The 412 automatic does not bolt into the T1 pan, so we'll need to remove parts and the engine mount horns and replace the steel with a new tube design, so that all the strength is retained, but it will allow the automatic to work in the T1 pan and the buggy. ECR is all about making your dreams come true. Do you want a 4 seater buggy that has nearly 160 hp and has a full automatic? Other places may say, No. We say, Yes. Our only limitation is your imagination. Once the new mounts and such are done we will remove the suspension from the pan and get those pieces blasted, primed, painted and ready for new bearings, seal and bushings.
The front end of the buggy has been stripped down, prep'd, epoxy primed and painted. Now we will install all new bearings, seals and ball joints along with upgrades Sway Way front leaves into the adjustable from beam for a nice set up that will handle the buggies needs.
Here you can see we have completed the fabrication of the pan. We then blasted the pan back to white metal and have applied numerous coats of PPG epoxy primer for rust preventive measures. The pan is sprayed on a rotating jig so that all areas, from top to bottom, side to side, are covered to combat any rust. This buggy is bound for the beaches of Nantucket, so rust resistance is a major focus in this build up. Above you can also see our tube framework that will hold the 412 full automatic. The standard pickle fork is gone, and the pan is now fully customized from the suspension back.
This image shows the pan now covered in multiple coast of DCC 9300 black paint. This will keep rust away and make the areas of the pan that you can see look great as well. You can also our custom engine/ transaxle mount, now fully painted and ready for assembly and Rhino-Lining.
The side bars for the buggy have also been epoxy primed and painted in this cycle of the bake booth. We had to shorten these bars to fit the buggy, but the welds have been ground down so that they will not be noticed and we sleeved the interior of the pipe for added strength. Once the pan fully cures we will spray on the Rhino-Lining on the bottom and then start installing the suspension and all stainless brake pipes.
Now that the restored and modified pan has been primed, painted and the bottom coated with Rhino-Lining, it is time to start the true assembly process of the buggy. The pan is moved to the assembly side of our shop where the systems will now start to be installed.
Here you can see the suspension and other systems being installed onto the restored pan. The new adjustable front beam has been installed along with the Manxter front bumper mount, and a set of our recovery points just in case the buggy needs a tug out of the sand. We have also installed a new steering box, with all new tie rod ends. ball joints, steering stabilizer and KYB shocks to assure smooth handling. You'll also notice that we have installed the CB performance spindles for the front disc brakes.
In the rear of the pan we have now installed the 25mm torsion bars and the Sway Away adjustable spring plates. All the suspension pieces are fully restored with epoxy primers and PPG paint, then set up with full urethane bushings for long life and great road manners. KYB shocks also control the rear end of the buggy. Rear braking will be handled by a set of CB Performance disc brakes with emergency brakes. To makes sure the over 150 hp motor can get to the street without issues we have installed a set of Empi conversion stub axles so that we can run Type 2 CV joints with heavy duty custom axle shafts from Chirco. As with all our builds, every seal and bearing is also replaced with new German parts. Our buggies are built for a lifetime, we don't cut corners on seals or any other parts. Next we will get ready to Rhino-Line the inside of the pan.
Here you can see that we have installed the full auto transaxle along with T2 CV joints, new torque convertor and custom shafts. The drive flanges on the full auto are slightly offset from center, so this meant custom shafts needed to be made for the different length L and R shafts. You can also see that the tape lines are set up so that the inside of the pan can be Rhino-Lined for long life.
As the rolling chassis is coming together we are also doing the modifications to the cage. The cage needs to have the radio mounts welded in place and the mounting bracket for the XM radio antenna installed prior to paint. Once these mods are complete the cage will be media blasted back to white metal then epoxy primed and painted in DCC 9300 black.
This images shows the new foot controls for the buggy. As is is a full automatic, it no longer needs a clutch pedal, so we fabricated a nice wide brake pedal and installed a CB Performance roller gas pedal for smooth throttle control. You can also see that the inside of the pan has been coated with bed liner and the stainless steel brake tubes have been custom made and installed.
Here you can see the engine has been mated to the transaxle and the systems are being hooked up. Everything from the fuel lines (all stainless steel) to the throttle cable are installed at this time, as well as some other modifications to allow for the automatic transaxle's. Now that as many systems that can be installed without the body are, it is time to mount the body with a new pan seal and urethane for a strong leak free bond.
In this image you can see that we have mated the buggy body to the restored pan. At this point it starts to look like a Manxter and now we can begin to hook up all the systems and get ready for the cage install.
In the front of the body we have finished up the brake system with all new stainless steel flex lines, as well as stainless steel brake pipes. This will allow for years of beach use before any rusted parts become an issue. We have also installed the new electric fuel pump with all stainless hardware and lines. Next we will install the cage and set up the steering system and finalize the brakes.
Here you can see that we have installed the freshly painted cage system and have also finished up the new 4 wheel disc brake system.
At the rear we have installed the stainless steel exhaust and we have started to wire up the buggy. We are also test fitting the Center Line Wheels and BFG tires at this point to make sure there are no clearance problems, and to make sure the tires are under the body to stay legal in MA.
In the front we have installed the lower dash tray, steering column and the front bumper. The wiring is just roughed in at this point until we get the location of all the electrical parts confirmed, then we will wire up the systems.
Here the wiring looks like a rat's nest, but once the rough in is complete we will tidy everything up to make it look ship shape. At this point we are also installing the secondary system such as the handbrake lever and cables and much more.
Looking good, and getting there!
As work continues on the body of the buggy, we take time to build up the rear seat. We have fabricated a cross bar and simple mounts and painted everything with epoxy primer and paint. Then we install the foam kit from Bear for the rear seat cover and glue it in place. Once the glue dries the foam will be trimmed to fit and the new Beard EBS black seat cover installed.
Here you can see that the gauges and dash panel have been installed. The VDO Vision gauges cover everything from fuel level to cylinder head temps to keep an eye on the Massive T4 engine out back. Indicator lights for signals, alt, oil pressure and high beam are also located on the dash, as well as sand sealed switched for the lights.
The wiring for the dash is now nearly complete and looks a far cry from that earlier rats nest. We installed a 12 volt power point on the lower dash for the customer's cell phone or other 12 v needs, and we also make sure to leave a few fused circuits in place (the neatly wrapped up white wire) just in case the owner wants to add some equipment later on. That way he does not have to cut into any wiring, the fused circuit is already there waiting. You can also see that the brake fluid reservoir has been installed as well and the Maxi-Fuse link. This fuse protects every electrical system in the buggy, so in case of a "worst case" this fuse blows, and the buggy harness does not go through a melt down.
To make a super slick and simple fuel fill we removed all the factory VW fuel fill items from the Beetle fuel tank and welded them shut, We then made and welded in our own backing plate that accepts a standard sand rail vented flip cap. This is not only easier to fill at the pump, it gets rid of al those unsightly hoses and such under the hood.
This image shows the back of the buggy coming together. The engine now has all its systems from an Empi breather box, to a Mallory ignition system. The wiring for the engine and the light is complete and the engine has been tested and is running great.
To keep everything running great we have installed an oil cooler and a remote oil filter, see RH yellow arrow. Everything in the oil system of this buggy is plumbed with stainless steel lines and Earls fittings for not only a great look, but a long lasting system. The LH yellow arrow points to something you don't see in a buggy much, a micro switch on the throttle for the kick down control of the automatic transaxle. Now that most of the engine and transaxle systems are in place it it time to turn our attention to the small details and the interior.
Here you can see that we have started to install the cage padding and Beard cage covers. We have also install the Alpine speakers in the body and the handbrake boot and trim.
This image shows the Beard EBS seats installed on their sliding tracks. The RH seat also tilts for ease of entry into the rear seat. The seat offer a low stance, but are very comfortable.
the owner of this buggy wanted XM radio installed, so we have set the Manxter up with an XM ready Alpine CD player and installed a mount for the marine XM antenna on the back of the cage system. The wires are hidden inside the cage for a clean look to the radio install. You can also see in this image that the rest of the roll cage covers are being installed, and the rear seat is now in place.
In the front of the buggy things are really taking shape. The windshield wipers, rear view mirrors and the top have all now been installed. Short of the side pods and some testing the buggy is nearly complete.
Here you can see that the interior is nearly complete. The glove box and dash top have now been installed, and the shifter for the automatic is in place, as are the Alpine stereo speakers.
This images show the mascot for the buggy, a chrome skull shifter handle for the automatic. In the background you can also see the 12 volt power point we installed in the lower dash for a cell phone or whatever takes 12 volts.
At this stage we will set the ride heights on the buggy and then do a full front end, and 4 wheel laser alignment so that the buggy drives straight and true. Next we will fabricate a rear bumper and skid plate for the buggy, install the new ECR engine cover and get it ready for testing.
Here you can see we have installed the side pods and the roof lift system. The next step is to start the road tests of the buggy to make sure everything is 100%.
This image shows the rear bumper system installed on the buggy. The placement of the engine for the automatic transaxle meant that this had to be custom made, but it is made to resemble the original Manxter pieces for a nice clean look. You can also see the new ECR extended engine cover that allows the use of the T4 engine and the license plate all in the stock location, without goofy cuts. The engine cover still opens on a hinge for easy access to the top of the engine.
Under that T4 engine and automatic transaxle we have installed a heavy gauge alloy skid plate to protect the oil pan of the transaxle and the exhaust. The skid plate will take a substantial hit, but it is also easy to remove if need be for service. This image is also a good look at an ECR built buggy underneath. If you are having your buggy built at another shop, can you eat off the bottom of it? You can with an ECR built buggy.
Overview of the rear end with new ECR engine cover and custom rear bumper system.
Here is the completed ECR built Manxter 2 plus 2 #27, finished up and ready for delivery. This Manxter sports everything from over 150 horsepower to a full automatic, XM satellite radio to stainless steel exhaust. If you have a desire for a top of the line dual sport buggy contact ECR. We'll be happy to make your buggy dreams come true, just like we did for this customer!
For an image gallery of this ECR built Manxter 2 plus 2 go here!
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ECR
21 Tolman Road
Warren, ME 04864
ph: 207-594-8086
fax 207-594-8120
email: ecrover@midcoast.com