MANXTER #55

Manxter #55 is being built for a customer in Texas. The #55 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". This is our second Blue flake buggy and we can't wait to get it on the road. 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 #55 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.

You'll notice in the image above that the rust free So. California IRS (Independent Rear Suspension) pan that will be the basis for #55 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 metal 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.

Once all the steel work is done on the pans they are media blasted back to like new white metal, shown above. Next we will paint the pans in numerous coats of PPG epoxy primer so that rust won't be a factor once the Manxters are built.

Here you can see the new heart of the Manxter. This is the Type IV engine built by Jake Raby at ACT. These engines push out upwards of 150 horsepower and do it long term and with reliability unlike a high horsepower Type I engine. These engines are set up with Weber carbs, Mallory distributors and even full stainless steel exhaust systems. At this stage the engine has already been bench tested and dyno-tuned at ACT.

The next step for us it so remove the cooling system and get it painted in blue metal-flake to match the buggy body, as you can see above. The color match is identical as we use the same metal flake as Meyers Manx does, so everything on this Canadian Blue metal flake buggy will look like it was all made at the same time and give the buggy a cool custom look.

As the restored pans are made ready for primer the small parts of the suspension are media blasted back to white metal and then hung on our spray racks so that they can get coated in numerous coats of epoxy primer and top coat. Above you can see the front and rear suspension arms being readied for a trip to our paint/bake booth.

To be able to cover the Type IV engine in the Manxter a new engine cover had to be created. The engine cover supplied with the kit is too shallow, so we have fabricated a new, deeper, engine cover in the correct blue metal flake that will reach back and cover the longer Type IV engine and its Bosch alternator. The new piece retains the same look as the original, but will cover the engine set up without cut outs for the alternator/fan pulley.

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.

This image shows the pan nearly ready for primer. We have made all the needed modifications and done any needed steel work to the pan before we apply the primer, that way we will not have to cut into the pan for any reason once the paint has been applied. We have removed the heater control tubes and factory seat mounts, and installed new seat mounts for the upcoming Beard Racing seats. Next the pan will get prep'd and ready for primer.

Here you can see the pan fresh out of our bake booth. It has had 3 coats of PPG epoxy primer laid on top and bottom. Once that cured we applied 3 coats of PPG Concept 9300 black to give the pan a tough, but beautiful finish, as you can see above. Too bad none of this will be seen, unless you are under the buggy. We then scuffed up the top coat and next we will apply a truck bed liner so that rust will never be a factor on this buggy, even after beach use.

Here you can see that the engine is back together and ready to mate to the new IRS transaxle from Rancho. The matching blue metal-flake give the engine the custom look the owner is going for and will make for one great looking Manxter.

Now that the engine and metal flake work is complete we can turn our attention to getting the pan built up into a rolling chassis. That means a new adjustable front beam, new rear suspension, shocks, urethane bushings and much more. We are running a CNC hydraulic clutch in this buggy for ease of operation and a smooth clutch feel, as well as adding 4 wheel disc brakes and much more. Above you can see the rear suspension set up and the new Sway-a-way adjustable spring plates. Next up the T2 CV joints and drive-shafts will go in and then wheels and tires so that the body can be installed. Also notices that all the brake and clutch tubing and fittings are stainless steel and will not have rust issues down the road.

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 rid 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. We also fully leak test all the pipes and fittings at this stage to make sure everything is 100%.

To make sure the shifts are smooth we have installed a new Berg locking shifter, replaced the shift bushing and coupler and made sure the shift rod is correct. All that is then mated to the newly rebuilt Ranch transaxle. All that combined with the new hydraulic clutch set up will make these buggies drive better than most, and you'll never have to concern yourself about getting stranded with a broken clutch cable.

Now that all the suspension, brakes and such are together it is time to start doing the fun stuff on the buggy. Here you can see wee have mated the Manxter body to the new restored rolling chassis with a new seal and marine grade adhesive for a secure and leak free bond. This work when combined with the Manxters tubing structure will make for a tight and flex free buggy that drives better than othert buggies. All these items are small, but once combined they make a buggy that drives and feels better than buggies built by other shops.

Here you can see the Manxter starting to look as cool as it should. The new wheels and tires have been installed and all the brakes and such tested and checked. Next up we will fabrciate the mounts for the radios into the top support system and then get them installed into the buggy body.
Keep watching as the buggy comes together.

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East Coast Rover Co.
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