MANXTER #54
Manxter #54 is being built for a customer in Texas. The #54 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 Red is a really nice color and will make for a really great looking buggy. 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 the rust free So. California pan that will be the basis for #54 has also arrived. The pans will now be stripped down, every part removed and made ready for our pan restoration process.
Here you can see that we have started to strip the rolling chassis down to the basic pan. Each piece will be cleaned and anything that is damaged will be replaced with a new part. Things like wheel bearings and seals are all tossed at this stage to make way for new parts that will be coming shortly.
Once the pans are stripped down we make the needed modifications so that they will fit the Manxter. The seat braces are removed, as are the controls for the old Beetle heater set up. We also repair any damage at this time and install new battery pans to assure long buggy life. When all this is done, as seen above, it is time to media blast the pans to get rid of the dirt and surface rust.
Next, with the pans now in clean white metal, we will paint the pans in numerous coats of PPG epoxy primer and paint so that rust won't be a factor once the Manxters are built.
To cover the longer Type IV engine in the Manxter we need to make a new engine cover. Here you can see we have sprayed in the clear, metal flake and backing color into our extended engine cover mold.
Next we lay in the fiberglass to make it an exact match to the original red Manxter body, but our custom part will better cover the longer type 4 engine set up. In the background of this image you can also see the pan for #54 after primer. It will soon be going back into our spray booth for the 3 coats of top color.
Here you can see the 2 Type IV engines from ACT. Both cooling systems have been removed so that we can metal-flake them, but they will soon be mating up to the restored pans and ready to hook up.
Here you can see the engine nearly back together with the custom metal-flake work done to match the buggy body. Once tucked under the body of the Manxter this will be one good looking set up.
Now that the engine is nearly set up we need to get the pans ready for their new suspensions. Here you can see we have made all the needed modifications to the pan and then given it 3 coats of PPG epoxy primer top and bottom. We then top coated that with 3 coats of PPG Concept 9300 black to give the pans maximum corrosion resistance and a tough good looking finish.
On the bottom of the pan we then applied a truck bed liner in order to keep any rust or corrosion from happening to the buggy in the future. The bed liner also gives a nice side benefit of reducing some of the road noise transmitted through the pan.
Now that the pan preparations are complete we can begin to assemble the buggy on a backbone that we know will last a good long time. Here you can see we have assembled the front suspension and steering. New steering boxes and all new tie rod ends and such are used to make sure the steering feels tight and is trouble free. We have also added an adjustable front beam so that the ride height can be set just right. You can also see the hydraulic clutch system starting to take shape. The master is installed and the stainless steel pipes have been run for both the clutch system and the brakes.
Out back, the rear suspension is also being set up. The new Sway-a-Way adjustable trailing arms have been installed and everything has been built up with new urethane bushings, all new bearings and all new seals. The freshly rebuilt Rancho transaxle has also been installed in #54 and the CNC clutch slave has been installed. Next the T2 CVs and heavy duty drive shafts will go on and then the new rear disc brakes will be ready to be installed. The brake rotors are currently being machined with a 5 on 4.5 bolt pattern so that more wheel and tire options are available. Once those are done we'll install the new Weld Racing wheels and BFG tires to get the buggy on its feet.
Here you can see the completed T4 engine cover that covers the larger T4 engine used in these Manxters. Once it is trimmed and installed it will look stock, but in reality it is a very trick custom piece that gives the installation of the T4 engine a nice subtle look.
Now that all the suspension is done, the brakes and clutch system have been installed and leak tested, its time for the fun stuff to begin. We have now mounted the Manxter body to the restored and updated pan making this project actually look like the cool buggy it will be.
Inside the body tub we have finished up all the foot pedals, capped off with a new alloy throttle and fully restored linkages in the brake and clutch for a nice tight feel to all the controls. We also have installed a new Berg locking shift for both security and better shifting. The shift rod bushings and couplers have all been replaced with new as well to make sure a shift is never missed. All this combined with the new hydraulic clutch system makes for a buggy that drives far better than most. These are all small items, but when combined they are the reason an ECR buggy is better than the average buggy build.
Here you can see the new wheels and tires have been added and everything in the brakes and rolling gear has been double checked. Next up we'll make the radio mounts for the top support bars and then get the support system installed.
This image shows the buggy a little further along. The top support cage has been installed along with the fuel tank, fuel pump and the lower dash assembly.
Inside the cockpit is coming together as well. The gauges have been installed along with all the vehicle controls and even the locking glove box, a nice touch in an open buggy, has been installed.
Here you can see the engine has been installed and things are starting to be hooked up. The oil cooler and remote filter mounts are in place and will be plumbed up shortly.
Up front the hood has been installed and everything has been mocked up for the front bumper assembly.
This image shows the rear bumper set up being fabricated. The stock Manxter parts do not work with a Type 4 power-plant, so all these parts are fabricated here at ECR. You will also notice that the new stainless steel exhaust has been installed along with small details like the rear lamp housings.
To protect the engine and the exhaust we have fabricated an alloy skid plate that covered the bottom of the motor and keeps in from harm just in case.
If you have been following this page you'll know that there have not been any updates for a long time. The buggies are done and now with their owners in Texas, and sadly due to various reasons we are no longer building Manxters, but to give a little "closure" to this project, below you will find a small photo essay of the completed project. Enjoy.
Lockable cubby box
10" subwoofer
Roll cage mounted Alpine radio.
iPod hook up lockable in glove box.
JL Audio marine speakers and custom fit snap in marine grade carpets.
Ready to head to Texas for fun in the sun!
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East Coast Rover Co.
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