‘Build a buggy in your backyard’ part #4; Driveshafts, cooling system & driving


Hey folks, great your watching again Welcome at a new part of ‘build a buggy in your backyard’ Last video you’ve seen I’ve almost finished all of the controls I’m running out of time, the idea is to have it finished this weekend So I have today and tomorrow and then it should be finished more or less It should be drivable at least I need it next week for a tv shooting I think I shouldn’t talk too much and get started That seems a better idea I’m going to start with the shifter mechanism Here are the cables I installed last time See the stick over there The invisible driver What do we have here; This one is to set it into gear That’s this movement on the lever That’s simple, I’m going to attach this cable parallel to it This one is harder That’s the sideways movement And overhere it’s this; a rotating movement I have to make an additional lever for that A challenge, but it will get all right I made a hinge, it used to be a bolt It exactly fit this And this one fits that See; that’s good Here an extra lever That’s moving in neutral That’s reverse That’s 1st That second Third, Fourth And fith The clutch is also a challenge! Because; the pedal is over here That’s it But; there Is the clutch lever Yeah Diesel.. Diesel has a stick Hey Diesel; seek! So we have to go from the front all the way to the rear Therefore I have this original clutch cable It goes from the pedal to the front under the bonnet It’s not that long.. That is not good enough But! An extra long cable It came from a parking brake But it will work for the clutch as well I think it will be all right Yeah Diesel, give me that Seek! Here’s the clutch pedal It used to be hydraulic There was a cylinder with a tube That’s perfect, it would have been very good for me as well But I don’t have that cylinder and I do have a very long cable Normally the cable will go from here to there But I’m going to attach it over here And let it point toward the rear Over here we have the gearbox This one is the clutch lever Over here was the cable Through here and then; And then you have to eat a lot of spinach And then you can compress this by hand too That has to go with a cable to the pedal This is 100 points; look Yeah, one cable wasn’t enough So I have the original cable overhere and here the parking brake cable Made two supports and a connection over here Baked it together I have an important issue overhere and that are the driveshafts These are the original Opel driveshafts and on the opposite side are the beetle drive shafts Hey Diesel, you’re coming to take a look as well Give me that Seek No we can proceed without getting disturbed What I’m going to do; weld these together If I just weld them like this then it wouldn’t last long Therefore I have; Therefore I made a pair of tubes That’s not Diesel barking, it’s the neighbour’s dog Because Diesel is here He can’t bark, he allways has a piece of wood is his mouth It’s not perfect straight I think it’s getting in unbalance at speeds above 200 But I think it’s excellent for an offroad buggy and that’s number 2 All controls have been connected, gear shifter works throttle works, clutch works Drive shafts have been connected Now it’s time to fix the cooling system I have my toolbox overhere; ‘connect your own cooling system at home’ a pile of hoses a reservoir a radiator oh, it fits so nice It looks like it’s made for it it is.. How works the cooling system of car In the engine block there are several channels coolang runs through there a waterpump pumps it around It runs through a radiator See; the connections The warm coolant enters at the top and the cold coolant exits at the bottom Important to connect it in the right direction the warm coolant comes from the top channel of the engine and that should be connected to the top of the radiator that’s easy for the rest it’s just putting some hoses in between more hoses.. that’s about it on the highest point we put the reservoir I think there That goes with a hose to the highest point of the engine and you can fill it through there It’s important to put this high and that hose doesn’t make all kind of strange corners and that it should not come from a lower connection because air has the habit to travel up and we don’t want any air in our cooling system because that doesn’t work as coolant at least not for this engine it does if you have an aircooled engine but we don’t have that, so.. okay, let’s put it together First I will fixate the radiator This one has those handy pins on the bottom I thought to fix it like this I’ve cut a few pieces of square tube that fits those nicely put it in position where I want it to be I remove the radiator immediately That’s aluminium and aluminium does not like welding drips that’s important, otherwise it might get leak and that would be a shame It doesn’t look too good.. I hope it isn’t leaking allready that would be a disaster I don’t have another one Now I need a support on the top side Let’s see if I have a tube which fits overhere by accident Like it was made for it! Now a few supports here I made this I weld the lower part to that tube This one can be disassembled Maybe that radiator has to be removed some day Since the radiator is in position; we can start puzzling with hoses This one gets overhere I cut these hoses in the right corners so they will fit nice and then I connect them with pieces of tube and this is an important tip put a few welds on there the hoseclamp sits behind it so the hose won’t pop off the cooling system can build up pressure The last thing you want is a hose with comes off in your neck The front channel has been finished as well it was a bit more work than the rear one Look It enters the engine overthere I had to make a long tube It runs from there to here and there to the radiator with a long hose below here I have this huge tube I could weld it to the frame But that’s not a very good idea If anything moves there the weld can be torn out of that tube and it will start leaking So I have another solution overhere I have this bent piece of flat I made that extra bent to prevent the hose clamp from slipping off and then I do it like this Proper fixated, but it can move a little if needed Moment of truth; check if the water will poor out somewhere at the bottom I hope not Good, the water stays in Now I will connect the brakes In the rear it’s allready connected From both wheels a tube comes to a T and that one comes to the front and that’s this tube, so that one should go to the pump I have welded all other connections there’s one connection left I’m going to fix that tube I’m going to cut the first part, there’s a burr This is a nice cutting tool Very handy, no deburring needed. Good in one handling Very straight; nice! The nipple on there first Don’t forget, afterward it can’t be put on And now I’m going to make a flare, for which I have this nice tool I fixate the tube and now this 100 points! We have a flare now and that nipple will compress that flare and because the copper is soft the cylinder and the nipple will deform the copper in a good seal another tip if you work on brakes sometimes; get a few of these open wrenches Normal wrenches doesn’t work well on these I hope no brake fluid will leak somewhere Hey folks, there’s somehow a part missing in my story.. One moment ago we were building this buggy and then it got very late and more later and it really needed to be finished… Because we needed that buggy today for some filming I was asked to participate on a tv show and if I had a suitable vehicle to drive the presenter on the set They wanted to have that 4×4 buggy I didn’t have that anymore so I needed another one I was planning to build one anyway I had the engine, I had the idea I only had to build it Therefore I gave this project priority worked hard to get it finished in the end it’s allways more work last open point.. terrible last night.. I tried at 1:30h to get those brakes working misery yeah.. but the important part; here it is and it drives take a look it’s not completely finished yet I want to put some isolation in between For now it’s good Nice seats If we’re going into the mud I want some other seats there Steering works fine Superior fuel tank The last thing I did yesterday at 2:00h Look, welded a bracket Put a jerrycan in there punched a few holes in there Perfect It costed 8 days to build I don’t think that’s bad there are a few points I need new brake cylinders in at the back it doesn’t brake very well I need to adjust the front suspension The wheels are not aligned correctly But I think we need to test it tough soon Unfortunately we have to wait for that The vehicle stays here This tv show will cost 6 or 7 weeks to be finished But that we can test it serious later.. Won’t say we can’t do a small test right now! Ignition switch is scrimped away by the tight schedule Great folks! Now.. I’m going home The buggy stays here I can’t show much more about this buggy right now but of course it will come home later and look onto the bright side.. or should I say the rainy side? Autumn is coming, weather is getting worse I think we can expect a video soon where I’m getting wed clothes in that buggy on an offroad trial Hey folks! Thanks for watching and till next time!

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