Please print these articles out. I wanted to update some of the things that we have done to Project Baja. We have started to install the one piece front end, we have installed the brake lines and have hooked up the shifter and shift rod. We have also started the rear storage area that is where the back seat used to be. First I want to tell you that a one piece front end does not fit perfect out of the box. We when set our front end on the car it did not follow the curve by the front windshield. Well no big deal, we just needed to make a paper template that did match the curves. We then found the center and taped our template on to the one piece front end.   With an angle grinder we sanded away all the extra fiberglass on the front end.   It took a few times setting it on the car and checking the fit and sanding more until it fit properly.   The same thing needed to be done to both sides. Soon we will fab up some hood pin holders and some light brackets for our driving lights. Then we can totally secure the front end to the car. We are also going to trim up the fenders so we won't have any problem running a much taller front tire.   I finally got around to painting the nerf bars on each side.      For the front brakes we had to install longer stainless steel brakes lines because of the wider beam. We also put in a billet master cylinder reservoir on a VW bus master cylinder. This reservoir will last the life time of the car, where a stock plastic reservoir can get brittle and crack in with the hot Arizona summers. With my luck it would be in the middle of the desert somewhere.    The rear brakes were also extended to accommodate the addition downward travel we created. You can see in the above photos the clips we used to secure the break lines to the boxed trailing arms.   We also shinned up the door handles and replaced the door handle seals with new black ones.    The T-Handle shifter was installed. This shifter has a button on the side to allow you to go into reverse with out having to push the shifter down like a stock shifter. It also feels very comfortable in your hand. We also installed a new heavy duty shift coupler and set screw to connect the shift rod to the transmission.    Where the back seat used to be, we are building a platform with a hinged door to access the battery and the other side can be tool storage. To do any type of work now back there, we will have to remove the passenger seat. At least Donnie will be able to have a place to put his back pack behind the front seats.  In the next update I promise to have more completed.  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. Previous Page             Next Page