Project Baja Bug. These pages are about Don and his Son's project car. Most everything we have done here can also be done on a Dune Buggy. We knew this would be a fun project and we wanted to share it with our internet customers. To try and be helpful, we have linked the part numbers we used on this car to the parts in our web site. Part 1: Disassembly

For Donnie's 13th B-Day we got him an old Baja bug that had been parked for a long time, I told him it will also be his 16th B-Day present along with a set of keys. Notice the smile!!! We started the project on November 8th 2002, the first night the plan was to start tearing it apart. We fired up the air compressor and went to town. Donnie agreed that his little brother Ben should also help. All the fenders were removed and the inside was gutted. We removed 5 pounds!! of pack rat droppings from inside this car,....yuck! The next day the body had to come off, since it already a six point roll cage installed. The Body was very heavy. I recruited some muscle from the store. Joe Chirco came over to help and we started lifting. Joe & I wondered if we worked this hard at the store? With the body off we started to disassemble the front end and the rear suspension. The entire pan is being wire brush down to bare metal and the few stock parts that will be reused will be sand blasted, primed and painted. I hope you can follow along with our up dates. I will also include some "How To" articles through out this project. If you have any questions or comments about Chirco's Project Baja please e-mail don@chirco.com we sure would like to hear from you. Next Page