VeeDub ReDub platform (new project from the DF Goblin guys)

In reply to nocones :

I think you are talking about replacing the two rectangular tubes with a bent up sheet metal structure? It is definitely hard to picture things like this from text though. 

One thing to note in this version of the platform is that much like the original VW, we are relying on the body of the Beetle as a structural element but we are connecting to the body in a new place compared to the original car.

Normally the furthest back mounting points between the chassis and body are the bolts on the rear shock towers. We are bolting in those same locations but we also have plates on each side of the rear subframe that will mount to the body where the rear luggage tray and engine compartment used to be (you can see the side plates between the upper control arm mounts in the rear view rendering). 

We also have a tentative plan to run a bolt in support from the rear cage forward through the cabin to the channels to the left and right of the seats. We'd rather not run these because it could encroach on rear seat room but this prototype will give us enough data to figure out if it is necessary.

I like the idea ,  are you leaving the floors flat or adding ribs etc ?

californiamilleghia said:

I like the idea ,  are you leaving the floors flat or adding ribs etc ?

I was thinking the same. If it's flat, maybe the option of central seating, McLaren F1 style?

I can't be the only one looking at those nice, flat floor pans and thinking DIY Ultium skateboard.  Batteries-as-floorpans, figure out how to swap a Tesla Model S motor (or see what EV West has on the shelf), and wrap it in a Beetle/Ghia/Manx/356/Mini Cooper body (with wheelbase adjusted as needed).  Of course, if someone took molds off the new Porsche 963 GTP, I wouldn't kick that out of my garage either.  :)

I don't know how far along DIY EV stuff is, but it looks like AEM is doing some neat things.

Our prototype is using off-the-shelf replacement pans from the local Bug shop. We left them flat in the model just because it wasn't necessary to model every detail. 

All three floor pans we got our hands on leave a lot to be desired (one had to be swapped out because it was so bad). We definitely don't want to fight low quality floor pans in the future so we are leaning toward making floor pans of our own. They will either be completely flat or they will have indentations similar to the Beetle pans but without the seat mounting brackets or the deeper pockets in the rear.

As for going EV, we actually did help one customer install a Tesla drive unit with Chevy Volt batteries into a Goblin so don't be surprised to see something similar in one of our Beetles. There is a good chance I'll be commuting pretty often in my Beetle so I wouldn't mind it being electric like my current daily driver.

The first piece we tackled after plasma cutting parts on the CNC table was the tunnel. The screenshot below shows the three main pieces: the tunnel on top and the two floor pieces below.

Since we don't have an 8 foot sheet metal brake, we drew in slots along the bend lines of the tunnel (top piece). The lower pieces have slots of their own but they are for the tunnel to fit into after bending it.

The bend line slots made it easier to hand bend the tunnel but we were still struggling. So to make things easier, we took a cut-off wheel and cut every other tab.

With the number of tabs cut in half, we were able to muscle the tunnel into shape. We used an angle finder to set each side and then put the floor sections of the tunnel in place. It was a satisfying moment seeing the floor slots lining up with the tabs.

We tacked each tab along the floor and had ourselves a tunnel for our prototype.

Great job ,

The best VW floorpans seem to be sold by Wolfsburg West , 

But if you had a way to make them you could sell  them too

In reply to californiamilleghia :

I've seen them mentioned a couple of times online. We are leaning more toward our own flat pans now (along with many other changes that we've figured out as we've built this prototype) but if we do end up using off the shelf pans, I think we'll go with Wolfsburg West.

So for the delay on updates. We were in between shops for the last week.

On a classic Beetle, the front bulkhead of the body is mated to a structure that stretches across the front of the pan and goes up and over the tunnel. We will call this structure the front bulkhead seat.

We decided to replicate the front bulkhead seat by layering CNC cut sheet metal pieces, a steel bar and a bent steel strap.

First we welded doublers on the underside of our tunnel structure. These add a little more rigidity for bolting up the body but more importantly, they double up the material underneath the crossmember that the lower control arms will bolt to. This crossmember was welded in after finishing the front bulkhead seat.

On top we welded a steel bar that goes through the tunnel and spans all the way across to the sets of bolt holes on each side. The steel bar was capped with 1/4 inch thick plates and a bent piece of 1/4 thick steel strap. At the same time, 3/16 thick panels are welded between the steel bar and the steel strap.

Next we moved forward to build up the front suspension structure. Where the Beetle used a torsion beam front end with trailing arms, we are using coilovers with short and long control arms.

Our structure is made of 1x2 rectangular steel tubing and various thicknesses of CNC cut sheet metal. The 1x2 tubing is used to make three crossmembers and two upper control arm mount tubes.

In the following photo you can see temporary tools that were CNC cut to help align the control arm mounting points. At each mounting a point, a rod end was bolted to the tool along with the mounting plates that needed to be welded to the frame.

Some of the CNC cut sheet metal pieces act as braces to support the crossmembers. The rest of the pieces are mounts for control arms, shocks and the anti-roll bar.

One piece still missing from the front end is the tube that the front of the Beetle body will bolt to. We will install this after our first test fit. But next up will be the rear suspension structure.

I'm interested to see how you handle the radiator. I am building a Subaru powered Super Beetle. I'd like to keep some usable trunk space that most conversions give up. My plan is to use an aftermarket Honda "Tucked" radiator. https://privatelabelmfg.com/products/private-label-mfg-power-driven-radiator-tucked

In reply to vdblu1 :

We have some ideas but we'll probably be one of those conversions that lose storage space up front. Coming from our Goblins, we would definitely appreciate having storage space.

We're going to get the body on the platform and then design the cooling system. Shouldn't be too long before we're at that point.

Hopefully it will fit under this.....

Are you making it to fit a stock 94 inch Wheelbase and the outer edge so you can bolt a VW body on it ,  and also a fiberglass kit car body that was made for a stock VW floor pan ?

Obviously, I decided not to depend on the bug body for ridgidity.  LOL

I applaud your effort!  Keep up the great work!  I concur with NoCones comments above.

Another cool project from you guys! Loved seeing the Goblin and I can imagine this will be awesome as well.

I am surprised there havent been many more ideas/kits like this over the years.  I feel like a modern underpinning with classic VW body would have been a hot seller for decades. Glad you guys are taking it on!

In reply to lrrs :

I think that is a Kelmark GT? It looks like guys squeezed old V8s into those so I bet our setup will work. The clearance between the top of the GTI engine and the fiberglass body will most likely be the tightest area. I don't know the height difference between the V8s they used and our engine so I can't be sure.

Sorry for not keeping you guys updated. I was posting regularly to our blog (doylemw.com/blog) but forgot to come fill you guys in. The biggest news is that we did get the platform down on its own tires. Here are some photos and summaries to get you caught up:

We welded the rear crossmember tubes to the tunnel along with the rear body mounts and the lower gusset plates that go from the lower crossmember to the tunnel.

Next we welded in the floor pans and the rest of the rear crossmember gussets (this included 1.5 inch DOM tubes on both sides to support the top crossmember, a top plate and two side plates). With the floor welded on, we did our first side by side comparison of the platform and the stock chassis.

Next we built up the rear subframe. It bolts onto the rear crossmembers and eventually will attach to the body of the car near our upper control arms. There will also be two forward supports that will go from the upper subframe tubes down to the floor pan. Originally we designed these supports to be bolt-on pieces but we've figured out a way to have welded supports going forward. This requires a little more trimming of the Beetle body than we originally planned to do but I'll elaborate more on this later when we add the supports. 

Our Goblin reused the stock Cobalt knuckles, struts and control arms. This was a decent arrangement but on the VeeDub ReDub project we wanted to swap to double wishbone suspension with coilovers at the rear. This meant machining our own aluminum uprights for all four corners.

On the prototype, we're using front GTI bearing hubs all the way around. These are pretty compact units and obviously will work with the GTI axles at the back.

Finally we were able to bolt on the brakes and throw on some tires. We didn't align anything so the toe and camber are definitely not right but no point in doing that right now.

We've already started redesigning many portions of the platform that aren't exactly how we would like them to be. Having to go back to the drawing board expected while prototyping something like this and we plan to iterate through 2-3 prototypes before we land on a production version. Here are some of the changes:

• bail on the Beetle floor pans and make our own pans
• simplify the rear area of the floor pan/tunnel
• change up the rear subframe where it mounts to the floor pan structure
• add welded in braces from the floor pan to the new subframe mount locations

 We still have a lot of work to do but we're hoping to do a first drive late this month or early next month.

I like the laser cut and fold chassis panels. And it looks like you are using thicker gauge metal than original which should be stronger.

Have you seen the Stealth V8 Beetle out of SA? Kind of the same cut and fold idea.

https://youtu.be/tAfCKmg2w0A

In reply to 78CobraII :

That is a very well done conversion. We did see that one shortly after we started on this project and we were impressed with what they've done.

I haven't been able to find recent prices but I saw that they were once offering build-it-yourself Stealth V8 Beetle kits for $18,500 (in 2018). We're planning for our assembled roller to be under that price (no engine or trans installed, no body included) so we're definitely going to be more affordable for the average guy looking to get a modernized Beetle in his garage.

Our price isn't set in stone yet since the project is still evolving but we plan to release a price estimate shortly after the first drive of our current prototype. It shouldn't be long now.

Any updates on this?

https://www.doylemw.com/blog

lots of updates. 

Thanks!

I love this idea.. even though I have neither a Beetle nor any particular love of VW, I'm tempted to build one of these.  Looking forward to testing data/video!

I'd love to see a shortened version that would fit under a Meyers Manx style fiberglass buggy.

Theoretically you can cut this the same way you cut a Manx, right? But yes, having it come the right length would be cool. My old boss had a Manta Ray body that I loved. It would be heckin cool on a real performance chassis like this!