Chirco is building a Baja Bug! Many of the air - cooled VW parts and procedures used can also be used on Dune Buggies, Sand Rails. These pages feature links to the Chirco online parts catalog.

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PART 19- Putting the front end together

Now that the body is back on we need to bolt every thing back on.

First we replaced the KYB Bus shocks that we did have in the front with a brand new shock that Bilstein just put out, the new Bilsteins 5150's .These shocks have a small reservoir attached to them called the cross flow system. What this does is expands the oil capacity and help keep the shock from getting hot.
The top and bottom bushing turn so you can line up your reservoir any direction your car needs them. They come with a steel sleeve that sits inside of the rubber bushing that needs a squirt of DW40 to slide in. 
I know this kind of sounds like a commercial for Bilstein, but really we are just excited about have a good mid-travel shock. These shock also look very good. Bilstein also has a stock travel  (6.5") shock that will fit stock link pin front ends and all rear suspension.
We finally put our front end puzzle back together. It consists of upper support tubes, lower support tubes, limiting straps, and much more all going every which way. It was almost humorous thinking how it all goes back together with out bumping or banging into one another. Well believe it or not it all fits and is functional. One thing we did find out was the Warrior beam suspension does need the extra support. We noticed that the pan was under stress when we lifted it up on the lift. 

If you have any questions or comments about Project Baja please e-mail don@chirco.com we sure would like to hear from you.