|
New
for 2010!
Larry's Off Road
Center
Buy a new buggy chassis and let us help you get it rolling!
|
Larry wishes
to thank his sons, Joe and Tony for working on the buggy from start to
finish. And special thanks to Joe for overseeing the project. We'd also
like to thank our friend Tom Triplett for his devotion to the project and
his sharing of his many years of knowledge in the VW hobby. We want to
thank our brother Ron for his help with getting the clutch installed. We
also want to thank our local guys, Sean and Justin for stopping by right
in time to solve our brake issue. We couldn't have pulled it off
without you guys! |
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|
 
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| Spring
is in full swing here at Larry's Off Road Center. For over thirty years,
Larry himself has fully welded frames for loads of people. Now,
Larry turns his 30 year experience to customizing your
buggy for you! Here you can see three Berrien Buggy 4 Seat Sand Fox Pickup
frames. The two against the wall are standard height, and the one on the
cart is plus 3 inches height. The buggy on the cart belongs to Paul
from Texas. The two against the wall belong to Jeff and Richard from Ohio.
Jeff and Richard had other buggy projects going, and happened to come in
the shop and see Paul's buggy. They then decided to have Larry build them
each a Sand Fox 4 seater. Each one is being customized to fit each
guy's individual needs. Check out some of the cool modifications
below! The below pictures are all from Paul's buggy. |
 
Paul and Larry
(seated)
Paul tries out his new buggy
|
|
Welding on the
frame |
|
Seat Mounts
(Click pictures to
enlarge) |
 1. |
 2. |
 3. |
 4. |
| Pedal
Plate Mount
(Click pictures to enlarge)
|
 5. |
 6. |
 7. |
|
|
Cable Tubes and
Mount Brackets
(Click pictures to
enlarge)
|
 8. |
 9. |
 10. |
 11. |
|
Shifter and E-brake
(Click pictures to
enlarge) |
 12. |
 13. |
 14. |
 15. |
|
Oil Cooler and
Filter Mount
(Click pictures to
enlarge) |
 16. |
 17. |
 18. |
|
|
Fuel Pump and
Regulator
(Click pictures to
enlarge) |
 19. |
 20. |
|
Headlights,
Taillights
and Turnsignals
(Click pictures to
enlarge)
 23.
|
 21. |
 22. |
 24. |
 25. |
|
Windshield Bar
Console
(Click pictures to
enlarge) |
 26. |
 27. |
|
Roof Tabs, Upper
Console
and Off Road Light Tabs
(Click pictures to
enlarge) |
 28. |
 29. |
 30. |
|
|
Brake Hose Tabs
(Click pictures to
enlarge) |
 31. |
 32. |
|
Steering Bearing
(Click pictures to
enlarge) |
 33. |
|
| Adjustable
Steering Stops
(Click pictures to enlarge) |
 34. |
 35. |
 36. |
|
Steering
Stop to be removed
to clear clamps
(Click pictures to enlarge) |
 37. |
|
| Painting
the Frame |
| Picking
the frame up from the powder coater.
(Click pictures to
enlarge)
|
 38. |
 39. |
| Getting
the Buggy back on it's wheels. |
| First
we installed a new stock front end. It's best to have two people hold it
in place while a third attaches the clamps to hold it on.
(Click pictures to
enlarge)
|
 40. |
 41. |
 42. |
 43. |
| We
then rebuilt the backing plates from Paul's old buggy and installed both
them and the drums.
(Click pictures to
enlarge)
(Click pictures to
enlarge)
|
 44. |
 45. |
 46. |
|
| Installing
the trailing arm bushings.
(Click pictures to
enlarge)
|
 47. |
 48. |
| We
had Paul's old trailing arms sand blasted. Then we sprayed two coats of a
self etching primer. Followed by another two coats of a gloss black enamel
paint.
(Click pictures to
enlarge)
|
 49. |
 50. |
| We
also used the rear backing plates from the old buggy as well.
(Click pictures to
enlarge)
|
 51. |
 52. |
 53. |
|
| No,
Tony it's not done yet.
|
 54. |
| Once
the front and rear suspension was installed it was time to get it back on
wheels.
(Click pictures to
enlarge)
|
 55. |
 56. |
 57. |
 58. |
 59. |
 60. |
| Transmission
and Brakes |
| With
the trailing arms installed we then placed the transmission in and
strapped it down.
(Click pictures to
enlarge)
|
 61. |
 62. |
 63. |
 64. |
| Next
we installed the emergency brake and ran the cable lines.
(Click pictures to
enlarge)
|
 65. |
 66. |
 67. |
|
| Once
the emergency brake was in place we installed the shifter, the shifter
bushing and ran the shifter rod to the transmission.
(Click pictures to
enlarge)
|
 68. |
 69. |
 70. |
 71. |
| While
the master cylinder was being painted, we installed the pedal assembly to
get ready to run the brake lines.
(Click pictures to
enlarge)
|
 72. |
 73. |
| Now
that the master cylinder was installed it was time to run the brake lines.
While Larry was taking care of that, Joe and Tom installed the aluminum console
and the coil over shocks.
(Click pictures to
enlarge)
|
 74. |
 75. |
 76. |
 77. |
 78. |
 79. |
 80. |
 81. |
| With
the brake lines in place we drilled and tapped holes to attached some
chrome brackets to hold them in place.
(Click pictures to
enlarge)
|
 82. |
 83. |
| The
Engine |
| When
we decided it was time to put the engine in we noticed the the clutch
pressure plate was no good. After we replaced that, Tony and Tom installed the engine.
(Click pictures to
enlarge) |
 84. |
 85. |
 86. |
 87. |
 88. |
 89. |
| The
Final Touches |
| With
the engine, transmission, brakes, and the rear suspension done it was time
to cut the diamond plate to fit the pickup add on. So first we made a
template to ensure that it would be cut right.
(Click pictures to
enlarge) |
 90. |
 91. |
| While
we took a break and checked in an Empi order, Justin and Sean figured out
our brake problem that we where having earlier.
(Click pictures to
enlarge) |
 92. |
 93. |
 94. |
 95. |
| Larry
installed the the bracket to hold the seat slider, while Tom attached the
seat slider to the seats themselves.
(Click pictures to
enlarge) |
 96. |
 97. |
 98. |
 99. |
| Paul
and his brother showed up to install their turn signals and head lights.
(Click pictures to
enlarge) |
 100. |
 101. |
 102. |
 103. |
| We
had waited to install the steering shaft so that we could cut it to best
fit Paul. Larry cut it down and welded the piece to attach the removable
steering wheel.
(Click pictures to
enlarge) |
 104. |
 105. |
 106. |
 107. |
 108. |
|
| The
only thing left to do was adjust the steering and then it was finished.
(Click pictures to
enlarge) |
 109. |
 110. |
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 112. |
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