Bought an old BTF U4 buggy

Almost done with all new panes. Need to make a new grill and massage the existing hood back into shape. Cut out and replaced a few bent tubes and straightened a couple. The further I dig into this thing the more I know I need to touch every nut and bolt.

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Joe_U4 said:
Almost done with all new panes. Need to make a new grill and massage the existing hood back into shape. Cut out and replaced a few bent tubes and straightened a couple. The further I dig into this thing the more I know I need to touch every nut and bolt.

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I assume that is a bent tube replacement. With both ends fixed how so you get the tube in there with out it being an inch short? My mind can't see to see how you made it look that awesome.
 
Yes I replaced both the driver and passenger A-B connector tubing. I machined solid sleeves to fit inside the tubing. The B pillar was already sleeved where several joints came together so I made a stepped sleeve to fit the inner tubing diameter. The replacement tube is cut ~3/8" short so it can be welded to the sleeves and existing tubing. I slid the solid sleeves inside the replacement tube and used the plug weld holes to slide the sleeves into the existing tubes. The sleeves are plug welded on both sides of the new joint. Then weld up the tubing and sand smooth. You would never know the tubes were replaced.

I've still got to do a similar repair on one of the hood support tubes. I'll take better pictures of the process so it's clear.
 
Over the years I seem to have acquired quite the collection of grinders LOL. It does not fit my newer ones, but it did fit an older Makita.
 
Joe_U4 said:
Yes I replaced both the driver and passenger A-B connector tubing. I machined solid sleeves to fit inside the tubing. The B pillar was already sleeved where several joints came together so I made a stepped sleeve to fit the inner tubing diameter. The replacement tube is cut ~3/8" short so it can be welded to the sleeves and existing tubing. I slid the solid sleeves inside the replacement tube and used the plug weld holes to slide the sleeves into the existing tubes. The sleeves are plug welded on both sides of the new joint. Then weld up the tubing and sand smooth. You would never know the tubes were replaced.

I've still got to do a similar repair on one of the hood support tubes. I'll take better pictures of the process so it's clear.
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Ok that makes more sense. The sleeves in the picture were in the chassis and I could not figure out how you got the tube in there. thanks for clarifying that process.

Joe_U4 said:
This makes finishing the tubing easy:

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I've seen tools like that used in videos I've watch and thought about getting one.
 
ghost said:
I've seen tools like that used in videos I've watch and thought about getting one
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Works ok for a cheap Chinese tool. Down side is it only fits an older Makita I have which is not variable speed so it's wide ass open šŸ˜† Figured down the road I'll modify one to fit one of my DeWalt cordless grinders. It would be much more useful if it were variable speed
 
Started on the grill tonight. Removed the old grill and salvaged the BTF emblem.
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Cut off the existing fairlead mount. I think they used a rat to gnaw out the cable slot šŸ˜†

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Made a cardboard pattern for the new mount and imported it into AutoCAD. Used the CNC plasma to cut out the mount and then bead blasted it. Mocked it up for fit and tacked it in place.
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Tomorrow I'll start on the headlight mounts but enough for tonight. Day starts early and this old man is šŸ˜“
 
BRUISER said:
did you actually get it and use it.. I tried to order a few and could never find one that bolted to my grinders

if you did what kind of grinder did you use?
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I have on of the amazon ones on a dewalt grinder and have had no problems. Its the best money you can spend if you do much tube work.
 
Front grill mostly done. Waiting on another set of BD S2 amber lights that are supposedly riding around on the UPS truck somewhere. They'll get mounted above the fairlead.

Grill cut, bent, and edges rolled. Not too shabby for a hack job.

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Surface mount bezel made to hold two Baja Designs S2 combo lights. CNC plasma makes stuff easy.

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Final test fit.

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Still debating how to mount the grill. Dzus fasteners, Allen head bolts, or spot welds. Spot welding will make for the best fit and look but obviously not removable. Hmmm...šŸ¤”
 
Joe_U4 said:
Front grill mostly done. Waiting on another set of BD S2 amber lights that are supposedly riding around on the UPS truck somewhere. They'll get mounted above the fairlead.

Grill cut, bent, and edges rolled. Not too shabby for a hack job.

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Surface mount bezel made to hold two Baja Designs S2 combo lights. CNC plasma makes stuff easy.

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Final test fit.

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Still debating how to mount the grill. Dzus fasteners, Allen head bolts, or spot welds. Spot welding will make for the best fit and look but obviously not removable. Hmmm...šŸ¤”
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I donā€™t see anything there that it would block access too. Iā€™d say spot weld would be the cleanest.

Your fab work is a cut (or two) above most, including mine for sure! I would love to see more of how you get to the final product. Iā€™m always looking to learn and to add cool tools (that I can afford :laughing: ) to the shop.
 
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Appreciate it but I ain't going to lie, it's 90% the tools & 10% the man. I've been a hot rodder since I was old enough to know what a car was. One thing I learned a long time ago was having the right tool for the job can make a backyard garage dude look like he's knows what he's doing šŸ˜‚

Kinda like having a badass buggy can make a mediocre driver look good šŸ¤”

Coffee ā˜• break over, time to do something constructive
 
Not being a body man in any sense of the word is going to make straightening the hood a challenge. I'll weld up the cracks and beat the rest into submission šŸ˜… The tubing supporting the passenger side is bent too much to straighten. I'll have to cut out a section where it was hit and replaced it. The plan is to use a matt finish wrap to hide my lack of body work skills :dumbass:

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BRUISER said:
did you actually get it and use it.. I tried to order a few and could never find one that bolted to my grinders

if you did what kind of grinder did you use?
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I bought this one and its a perfect mid range quality. I could never get belts to stay on the retrofit ones (they suck unless you only need to use for about 10 mins)...

 
Made a little progress yesterday. Straightened the hood with a hammer and dollie to get most of the dents out, enough so it fits decently. Once I get everything else done I'll smooth it out with the planishing hammer and roll the edges. Straightened the dzus fastener mounts and replaced all the springs. Several of the mounting holes were torn up too much to use flush mount dzus fasteners. Original plan was to drill out the holes larger and use self ejecting dzus but they present some challenges. I remembered I had some oversized button head dzus fasteners from another project. While I don't like fasteners drawing attention I think this is the route I'm going to go.

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Cut a small section out of the passenger side tubing only to find it double walled. I think the plan will be to make a support tube that connects the hood tubing to the main chassis. This will hold strengthen it and hold it in the correct place while cut out the bent section and replace it.

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Bent section cut out and repaired. Not perfect but acceptable without having to replace the entire bar. New section is sleeved and added a support that IMO should have been done when it was built. Hood half ass fits now and the mounts all line up. Now on to more hood repair :dumbass:
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