baja bug long travel front suspension

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how to make a baja bug long travel?

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ok well im new to this and i keep seeing sites talk about having 18" of wheel travel or more on a baja. How is this done? Where can i get long travel kits/ how do you fab up some of this stuff. what are good suspension sites?  

To get that kind of travel, you have to make a number of mod's or combination of mod's. longer and wider arms front and rear notch springplates-rear grind the springplate rest down to allow more droop-rear don't run torsion bars-go to coilovers in the rear Those are probably Class 5 unlimited cars, that are getting 15+ inches of travel. Some of the 5/1600 class cars get up to 12-13" in the rear, running torsions.  

thanx for the info. I'm buying my baja soon (the next month or so). I want to find out as much as possible before I buy it. I don't know what year it is so that limits my searching for suspension related stuff. It's going to be all off-road and if it doesnt already have coil overs it will soon. I do know it has an 1835cc dual port/dual carb engine. I hear they have problems over heating but it doesnt get too hot here so I should be ok. I'll be doing as many cooling upgrades as possible. Any suggestions?  

from all that i have seen.... the largest iv seen pulled with a link pin setup.... 13 inches is teh max... un less it is a a-arm front suspension.... im probubly wrong but i thought id just put in my 2 cents.  

So Trackball, it's been a couple years - are you still around? What did you end up doing with this project?  

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WE BUILD IT.

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3231 e. michigan st., tucson,az  85714.

This center mounted a-arm kit, can be a great up-grade from your stock VW beam suspention. Designed to graft on to your stock pan, it can be installed on Baja bug, Manx, or sand rail. Ships raw

A Arm Kit-Dual Shock

Product details.

Kit comes with upper and lower a-arms, bulk head, spindles, tie rods, and install plates, fully welded. Includes all rod ends, hi-misalignment spacers, bushings and grade 8 bolts. Has 19” of wheel travel when using a 10” coil over shock (not included). This kit has a boxed lower a-arm and accepts dual shocks. It is 70-74” over-all width (depending on wheel hub offset). Same width as bug when using 3x3 rear trailing arms. Remote mounted upper shock tower designed to fit under Baja or Manx hood.  Zero bump steer, 4 degrees of camber change, 5 degrees of caster. Laser cut, CAD designed, jig built, double shear suspension pick-ups even steering box for zero bulkhead flex. Simply cut off old beam suspension and graft on this new one or we can do it for you. Instructions included.

SHIPPING INFO

This kit fits in 2 boxes and ships most places for about $120.

Enhance Baja Bug Performance with a Long Travel Kit

Enhance Baja Bug Performance with a Long Travel Kit. If you’re a Baja Bug enthusiast looking to take your off-road adventures to the next level, a long travel kit might just be the upgrade you’ve been searching for. Designed to provide greater suspension travel and improved handling on rugged terrain, these kits have become a popular choice among off-road enthusiasts seeking to transform their Baja Bugs into unstoppable off-road machines. With our extensive expertise in off-road vehicle modifications, we have thoroughly tested and reviewed numerous long travel kits to bring you an unbiased analysis of their performance, durability, and value for money. So, buckle up and get ready to discover how these kits can revolutionize your Baja Bug’s capabilities.

Key Takeaways:

• Baja Bug long travel suspension kits enhance off-road performance by increasing ground clearance and suspension travel.
• Baja Bugs are modified vehicles with cut fenders and aprons, allowing for more ground clearance and suspension travel.
• Baja Bugs have exposed engines and lack mufflers and emissions equipment, making them powerful and attention-grabbing.
• Affordable options for Baja Bug kits and accessories can be found on eBay, offering a wide selection.
• Pacific Customs also offers Baja Bug kits and front suspension kits for off-road enthusiasts.
• Nicholsfab.net provides an A-arm kit with dual shocks and 19″ of wheel travel, boosting the off-road capabilities of Baja Bugs.
• Wicked-creations.com offers a VW A-arm bulkhead kit, serving as a starting point for building Baja Bugs or Manx vehicles.
• Off-road.com and kibbetech.com provide platforms and forums for discussion on building and modifying Baja Bugs for long travel.
• Amazon.com sells a sand rail/Baja Bug front coil suspension kit with 12 inches of travel, improving off-road performance.

Table of Contents

Baja Bug Long Travel Kit

If you’re a fan of off-road adventures and want to enhance the performance of your Baja Bug, a long travel kit is the way to go. These kits are specially designed to improve ground clearance and suspension travel, allowing your Baja Bug to conquer rugged terrains with ease. In this guide, we’ll walk you through everything you need to know about Baja Bug long travel kits, from choosing the right kit to installing it and maximizing its performance.

Choosing the Right Kit:

When it comes to selecting a long travel kit for your Baja Bug, it’s important to consider a few key factors. Firstly, determine your budget and the level of off-road performance you’re aiming for. Keep in mind that higher-end kits tend to offer better durability and performance. Secondly, check out reputable suppliers like eBay, Pacific Customs, Nicholsfab.net, and Wicked-creations.com. These platforms offer a wide range of options at affordable prices, ensuring you’ll find the perfect kit for your needs.

Installing the Long Travel Kit:

Once you’ve chosen the ideal long travel kit for your Baja Bug, it’s time to dive into the installation process. Before you get started, make sure you have all the necessary tools on hand, including a hydraulic jack, jack stands, and a set of basic hand tools. Follow these steps for a successful installation:

Step One: Front Suspension : Start by removing the existing front suspension components, including the stock control arms, springs, and shocks. Take your time and ensure all fasteners are properly loosened before removing them.

Step Two: Installing the Long Travel Kit : Begin by fitting the new long travel control arms onto the Baja Bug frame, using the supplied hardware. Make sure to tighten all the bolts to the manufacturer’s recommended torque specifications. Then, attach the new coilover shocks to the control arms, ensuring they’re securely fastened.

Step Three: Rear Suspension : Similar to the front suspension, remove the stock rear suspension components, including the springs and shocks. Install the new long travel components, such as longer-travel shocks and heavier-duty coil springs, following the manufacturer’s instructions.

Step Four: Final Adjustments : Once the long travel kit is installed, it’s essential to make the necessary adjustments to ensure optimal performance. Check the alignment of the wheels and adjust the camber, toe, and caster settings as needed. Additionally, inspect all connections and fasteners to make sure they’re tight and secure.

Maximizing Performance:

While the installation of a long travel kit can significantly improve your Baja Bug’s off-road capabilities, there are a few additional steps you can take to maximize its performance:

Tire selection : Choosing the right tires for off-road adventures is crucial. Opt for all-terrain or mud-terrain tires with aggressive tread patterns for increased traction and durability.

Suspension tuning : Fine-tuning your suspension setup can greatly enhance handling and control. Experiment with different shock absorber settings to find the perfect balance between comfort and performance.

Regular maintenance : Keep your Baja Bug long travel kit in top shape by performing regular maintenance. This includes checking for any signs of wear or damage, lubricating moving parts, and tightening bolts and fasteners.

Pros and Cons of Baja Bug Long Travel Kits:

To help you make an informed decision, let’s consider the pros and cons of Baja Bug long travel kits:

Pros: – Increased ground clearance and suspension travel for tackling rough terrains. – Improved handling and control on uneven surfaces. – Enhanced off-road performance and capability. – Wide selection of kits available at various price points.

Cons: – Installation process may require advanced mechanical skills or professional assistance. – Cost can be a significant investment, depending on the kit and brand chosen. – Can potentially affect the overall ride comfort on paved surfaces due to the increased stiffness of the suspension system.

In conclusion, a Baja Bug long travel kit is a fantastic investment for off-road enthusiasts looking to enhance the performance of their vehicles. By choosing the right kit, following the installation steps diligently, and maximizing its performance through tire selection, suspension tuning, and regular maintenance, you’ll transform your Baja Bug into a true off-road beast. Get ready for thrilling adventures and conquering challenging terrains with confidence!

Check out the latest offers and deals from Harr Travel. Explore destinations and plan your next adventure with us. Visit our website at ../harr-travel .

Step-by-Step Installation Guide for Baja Bug Long Travel Kit

Off-road enthusiasts seeking to enhance the performance and handling of their Volkswagen Baja bugs can turn to Baja bug long travel suspension kits. These kits offer greater wheel travel, allowing for better absorption of shocks and bumps during off-road adventures. To help you make the most of your Baja bug long travel kit, we have prepared a step-by-step installation guide that combines technical expertise with practical insights and tips.

Step 1: Gather the Necessary Tools and Equipment

Before diving into the installation process, gather all the tools and equipment you’ll need. Some common tools required for installing a Baja bug long travel kit include wrenches, sockets, a torque wrench, pry bars, and a jack and jack stands to raise the vehicle securely.

Step 2: Safety First

Always prioritize safety when working on your vehicle. Ensure it is parked on a level surface and engage the parking brake. Use wheel chocks to prevent any accidental rolling. Additionally, wear safety glasses and gloves to protect yourself during the installation process.

Step 3: Remove Existing Suspension Components

Start by removing the existing suspension components to make way for the new long travel kit. This may involve disconnecting sway bars, shocks, control arms, and other components. Refer to the specific instructions provided by the manufacturer of your Baja bug long travel kit to ensure proper removal of the existing components.

Step 4: Install New Control Arms and Shocks

With the old suspension components removed, it’s time to install the new control arms and shocks included in the Baja bug long travel kit. Follow the manufacturer’s instructions carefully to ensure proper alignment and secure installation. Use the prescribed torque values when tightening bolts and fasteners.

Step 5: Rear Suspension Installation

Depending on the kit, you may also need to install new rear suspension components. This can involve installing new rear shocks, trailing arms, and mounting brackets. Again, follow the manufacturer’s instructions and torque specifications for proper installation.

Step 6: Adjustment and Tuning

After installing the new suspension components, it’s crucial to make necessary adjustments for optimal performance. This may include aligning the wheels, checking and tightening connections and fasteners, and adjusting the suspension settings to suit your driving style and terrain preferences.

Step 7: Select the Right Tires and Perform Regular Maintenance

To maximize the performance of your Baja bug long travel kit, choose the right tires that are suitable for off-road use. Additionally, perform regular maintenance on your suspension components and follow the manufacturer’s recommended service intervals to ensure longevity and reliability.

By following these step-by-step instructions, you will be well on your way to installing and optimizing a Baja bug long travel kit for your off-road adventures. Remember to consult the manufacturer’s specific instructions for your kit and seek professional assistance if needed.

Key Takeaways: – Baja bug long travel kits enhance off-road performance and handling for Volkswagen Baja bugs. – The installation process involves removing existing suspension components, fitting new control arms and shocks, and installing new rear suspension components. – Making necessary adjustments and performing regular maintenance are crucial for optimal performance. – Choosing the right tires and following manufacturer recommendations are key to maximizing the kit’s benefits. – Prioritize safety throughout the installation process.

Sources: – Baja Kits. (n.d.). Installation Instructions – Baja Kits – MotorTrend. (2016, September 27). Installing A Baja Kits Long Travel Prerunner Kit With … – MotorTrend

Tips for Optimizing Performance and Durability

Off-road enthusiasts who want to push the limits of their Baja Bugs know that a reliable long travel suspension kit is essential. These kits not only provide improved ground clearance but also enhance suspension travel, resulting in better performance and durability on rugged terrain. In this guide, we will explore some valuable tips for optimizing the performance and durability of your Baja Bug with a long travel suspension kit.

Choosing the Right Kit

When it comes to selecting a long travel suspension kit for your Baja Bug, it’s crucial to consider a few key factors. First and foremost, determine your budget and desired off-road performance. This will help you narrow down the options and find a kit that aligns with your specific needs. Additionally, it’s important to source your kit from reputable suppliers who have a track record of delivering high-quality products.

One option to consider is the Baja Kits long travel prerunner kits, which provide wider wheelbases and increased wheel travel. Another reputable choice is the long travel A-arm kit offered by NicholsFab, featuring fully welded components and improved suspension geometry. Take the time to research and compare different kits to ensure you make the best choice for your Baja Bug.

CITATIONS: – MotorTrend.com – Installing Baja Kits Long Travel Prerunner Kit with Fox Shox – NicholsFab.net – Long Travel A-Arm Kit

Installation Process

Installing a long travel suspension kit for your Baja Bug may seem like a daunting task at first, but with the right guidance, it can be a satisfying DIY project. Here is a step-by-step guide to help you through the installation process:

• Gather all the necessary tools and equipment before getting started.
• Ensure your Baja Bug is parked on a level surface, engage the parking brake, and use wheel chocks for added safety.
• Follow the manufacturer’s instructions to remove the existing suspension components.
• Install the new control arms and shocks from the long travel kit, carefully following the manufacturer’s instructions and torque specifications.
• Depending on the specific kit, install new rear suspension components such as rear shocks, trailing arms, and mounting brackets.
• Make the necessary adjustments, such as aligning the wheels and adjusting suspension settings, to optimize performance.
• Always refer to the manufacturer’s specific instructions throughout the installation process and seek professional assistance if needed.

Maximizing Performance

To truly optimize the performance and durability of your Baja Bug with a long travel suspension kit, there are a few additional steps you can take:

• Choose suitable off-road tires that match your driving style and the demands of your off-road adventures.
• Regularly maintain your suspension components, including checking connections and fasteners for any signs of wear or damage.
• Consider tuning the suspension to fine-tune the handling characteristics of your Baja Bug.
• Follow a maintenance schedule that includes regular inspections, lubrication, and replacement of worn-out parts.

By implementing these tips, you can ensure that your Baja Bug’s long travel suspension kit performs at its best for years to come.

• Choosing the right long travel suspension kit for your Baja Bug involves considering factors such as budget, desired off-road performance, and reputable suppliers.
• The installation process requires proper preparation, adherence to manufacturer instructions, and, in some cases, professional assistance.
• Maximize performance by selecting suitable off-road tires, regular maintenance, and tuning the suspension to your preferences.
• Prioritize safety throughout the installation process and ongoing maintenance.
• Regularly inspect and replace worn-out suspension components for optimal performance and durability.

Comparative Analysis of Popular Baja Bug Long Travel Kits

• Baja Bug long travel suspension kits improve off-road performance and handling for Volkswagen Baja bugs by enhancing wheel travel and maneuverability on rough terrain.
• There are different types of suspension kits available for Baja Bugs, including front coil suspension kits and A-arm kits, each with its own advantages and considerations.
• Baja Kits and Pacific Customs are reputable brands that offer a wide range of long travel suspension kits for VW Baja Bugs.
• The installation process involves removing existing suspension components, fitting new control arms and shocks, and installing rear suspension components as needed.
• Optimal performance can be achieved by aligning the wheels, making necessary adjustments, and choosing suitable off-road tires.
• Long travel kits provide benefits such as increased ground clearance, improved handling, and enhanced suspension articulation.
• Considerations for selecting a kit include budget, desired off-road performance, and reputable suppliers.
• Installation may require advanced mechanical skills and professional assistance if needed.
• Regular maintenance and inspection of suspension components are crucial for optimal performance and durability.
• Safety should always be prioritized throughout the installation process and ongoing maintenance.

Comparative Analysis of Baja Bug Long Travel Kits

Installing a long travel kit on your Baja Bug can transform it into a powerful off-roading machine, but with so many options available, it’s important to choose the right kit that suits your needs and budget. In this article, we’ll take a close look at some of the popular Baja Bug long travel kits in order to provide you with a comparative analysis and help you make an informed decision.

Baja Kits Long Travel Prerunner Kit

The Baja Kits Long Travel Prerunner kit is designed to add two inches of width per side and increase wheel travel to nearly 12 inches, providing your Baja Bug with improved off-road capabilities. With its robust construction, this kit offers increased ground clearance, improved handling, and enhances suspension articulation. It is considered one of the leading options for Baja Bug enthusiasts looking to enhance their vehicle’s performance.

Pacific Customs Long Travel Suspension Kit

Another popular choice is the long travel suspension kit offered by Pacific Customs. Known for its wide range of options, Pacific Customs provides Baja Bug owners with a variety of kits suitable for different off-road requirements. Their kits offer increased wheel travel and improved maneuverability, ensuring a smoother ride on challenging terrain. Pacific Customs is a reputable brand that provides dependable products for off-road enthusiasts.

Comparing the Kits

When comparing these two popular Baja Bug long travel kits, it’s important to consider factors such as budget, desired off-road performance, and reputable suppliers. Both kits offer increased wheel travel and enhanced handling, delivering a significant improvement in off-road capabilities. However, the Baja Kits Long Travel Prerunner kit stands out with its additional width per side, further improving stability and maneuverability.

Pros and Cons of Baja Bug Long Travel Kits

Before making a decision, it’s important to weigh the pros and cons of Baja Bug long travel kits. Here are some key points to consider:

• Increased ground clearance for tackling challenging terrain with ease.
• Improved handling and maneuverability, providing a smoother driving experience.
• Wide selection of kits available at various price points to suit different budgets.
• Enhanced suspension articulation, allowing for better wheel travel and improved performance off-road.
• The installation process may require advanced mechanical skills and potentially professional assistance.
• Cost can be a consideration depending on the kit and additional components needed.
• Impact on ride comfort on paved surfaces should be taken into account, as long travel kits are primarily designed for off-road use.

Get Ready to Enhance Your Baja Bug’s Performance

Installing a long travel kit on your Baja Bug can significantly improve its off-road performance and handling, allowing you to tackle challenging terrain with confidence. By considering your budget, desired performance, and reputable suppliers like Baja Kits and Pacific Customs, you can choose the perfect long travel kit for your Baja Bug. Remember to prioritize safety throughout the installation process and follow a regular maintenance schedule to ensure optimal performance and durability. Get ready to take your Baja Bug to the next level and enjoy adventurous off-road experiences!

• Baja Kits. Website
• Pacific Customs. Website

Q1: What is a Baja Bug long travel suspension kit?

A1: A Baja Bug long travel suspension kit is a modification package designed to enhance the off-road performance and handling of Volkswagen Baja Bugs. It typically includes components such as front coil suspension, upper and lower A-arms, spindles, tie rods, and installation plates. These kits provide increased wheel travel, allowing for better absorption of shocks and bumps on rugged terrain.

Q2: What are the benefits of installing a Baja Bug long travel suspension kit?

A2: Installing a Baja Bug long travel suspension kit offers several benefits. It can provide smoother rides, improved traction, and increased ground clearance. The greater wheel travel allows the vehicle to navigate challenging off-road conditions more effectively. Additionally, the kit’s modifications and combinations of mods can optimize the Baja Bug’s performance and durability.

Q3: How do I achieve long travel suspension in a Baja Bug?

A3: Achieving long travel suspension in a Baja Bug often involves installing longer and wider arms, notch springplates, and other modifications. By upgrading various components of the suspension system, such as the A-arms and coil springs, the vehicle can achieve greater suspension travel, resulting in improved off-road capabilities.

Q4: Where can I find Baja Bug long travel suspension kits?

A4: Baja Bug long travel suspension kits can be found online on platforms like eBay, Pacific Customs, and NicholsFab. These websites offer a range of kits and accessories specifically designed for off-road enthusiasts. Additionally, brands like Baja Kits, Nicholsfab, and Pacific Customs Unlimited are known for providing quality long travel suspension kits compatible with Baja Bugs.

Q5: Are there any resources available for installing and working with Baja Bug long travel suspension kits?

A5: Yes, there are several resources available for installing and working with Baja Bug long travel suspension kits. Online forums such as TheSamba.com and race-deZert.com provide useful discussions and insights from users who have experience with these kits. Platforms like YouTube also offer video demonstrations showcasing step-by-step installation guides and updates on long travel Baja Bug projects.

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Pacific Customs Sand Rail/Baja Bug Front Coil Suspension Kit 12 Inches Travel

Purchase options and add-ons.

• This kit is a good starting point for a complete front build. We can swap shocks for different stroke shocks, different stroke and width beams, trailing arms and so forth. Please contact us for more information.

Product Description

Complete Kit Comes With The Following: Usa Made 6 Inch Wider Mild Steel King And Link Pin Axle Beam For 10 Inch Stroke Coil Over Shocks Set of Four - Usa Made White Delrin Bushings For Foddrill Trailing Arms In King Pin Axle Beams 1.750 Inch O.D. Set of Four - T.I. Designs Front D.O.M. King And Link Pin Trailing Arms 2.25 Longer X 1 Wider For Thru Rods Pair - T.I. Designs Combo Link Heavy Duty Spindles For 5/8 Heim Joints - Stock Height Made In U.S.A. Pair - Latest Rage Clamp Style Aluminum Spindle Nuts For King And Link Pin, Combo Link, Or King Kong Spindles 4 - Chromoly Material Heavy Duty 5/8 Link Pin Set For Aftermarket Front Trailing Arms 40 - Link Pin Shim For 5/8 Link Pins To Adjust Camber On King And Link Pin Front Beams 2 - 1/2 Inch Replacement Thru Rod Only For 5 Inch Or 6 Inch Wider Axle Beams 4 - Replacement 1/2-20 Thread Pinch Nut For Thru Rods 2 - Fox Racing Shocks Coil Over 2.0 Body 10.5 Stroke With .625 Diameter Shaft With Reservoir 2 - Silver Eibach 10 Inch Long Spring 150 Pounds For A 2 Inch Diameter Coil Over Shock 2 - Silver Eibach 12 Inch Long Spring 200 Pounds For A 2 Inch Diameter Coil Over Shock Does Not Include: Front Wheel Hubs Wheels/Tires Rack And Pinion This kit is a good starting point for a complete front build. We can swap shocks for different stroke shocks, different stroke and width beams, trailing arms and so forth. Please contact us for more information.

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Zen Volkswagen Baja Bug

Volkswagen Front Suspension

VW used double trailing arms mounted in twin front torsion spring housings in the front of their autos.  Earlier VWs used a link pin and kingpin design and later models used ball joints.

www.thesamba.com   Front Suspension

The front torsion arm suspension is equipped with two trailing arm on either side of the front beam.  This allows for a good travel arc that arcs the front wheel up and back (not towards) away from obstacles,  reducing upward strain/shock on the suspension and vehicle particularly at high speeds.  This durable design makes it work very well for off-roading because of its travel shape being an arc.

The basic principle of the Beam - Torsion arm suspension is to have two parallel tubes running a few inches apart. There are four arms, two on either side of the beam which pivot at two ends: one side pivots within the beam which is bolted to the car, and the other side pivots at the spindle around a Linkpin or a Balljoint.

Type 1 Beetles produced in 1965 and earlier came from the factory with a Linkpin pivot torsion arm front suspension.  This setup allows for full cycling of the suspension without the binding limits inherent in ball joints.  This makes the Linkpin setup more ideal for offroad use since you are able to benefit from potentially much greater suspension travel.  This same lack of binding also makes linkpin setups more desirable for those that choose to lower their VWs as far as they can go.  The front beam has two torsion tube which are  4 3/4 inches center to center.

Type 1 Beetles produced between 1966 and 1977, the end of German production of the standard Beetle, were equipped with a Ball-joint pivot torsion arm suspension.  The overall design of the balljoint front end is very similar to the earlier linkpin/kingpin design.  The main difference is that the torsion tubes are further apart from each other and the out end of the torsion bars incorporate more modern ball joints.  These ball-joint have misalignment limits and are the limiting factor in up and down travel of the front suspension.  At their maximum limits, they will bind and potentially become damaged.   The torsion tube separation on Ball-Joint beams is approximately 5 3/4 inches center to center.

Super Beetles incorporated a MacPherson-strut system that is not designed for any off road use.  The Mexican-built Beetles' front-end has additional re-enforcement plates not found on the hammer-head chassis from Germany and are more durable than the European Supers.

Complete Front Beams:

Kustom1 Warehouse

Chircoe Store

AirCooled.net

Mid America Motorworks

Lengthened/Widened Beam

Used to widen your track for increased stability especially when turning.  The most common is going 6" wider than stock. Wide beams can be purchased in a variety of configurations from 10" travel shock towers for coil-overs or no shock towers at all for use with torsion leaves.

thesamba.com Building a Widened BJ Beam

Narrowed Beams

This is commonly done on street rods to allow wider tires to fit under the front fenders.  This decreases overall stability of the VW.

Type 3 Beam

The Type 3 beam is wider than a Type 1, has 2-1/2" longer arms, uses torsion bars instead of leaf springs and has disc brakes.  This is not a bolt on modification and will require a good amount of fabrication to mount the beam further out to allow your tires to still fit in the wheel wells.  The ball joints can be removed in the field without the need for a press.

The most common suspension upgrade for the Ball-Joint front end Type 1 Beetles is to incorporate components from a VW Thing (Type 181) front end.  This has extra reinforcement on the shock tower and attachment points for Thing beam supports.  Thing spindles and trailing arms will provide some lift and can be used on the type 1 ball joint beams.

What makes the Thing spindles stronger aside from any casting differences is that the Ball-joints are pressed in from above (instead of one from above and one from below like the stock Beetle), this prevents knocking a Ball-joint loose on a hard impact. Thing components are a direct swap and will provide approximately 2.5" of front lift.

Ball Joint to King Pin

If you have a Baja or buggy project with a 1969 or later Beetle equipped with Independent Rear Suspension (IRS), you may want to upgrade your car to the earlier Linkpin suspension and abandon the Ball-joint beam originally holding up the front of your vehicle.  This will allow for greater front suspension travel durability, two desirable features in an off road vehicle.  This unfortunately is not a straight forward swap as the separation between the two torsion tubes of the linkpin and ball-joint beams differ by about an inch.  There are however several ways to go about converting a newer VW to use an earlier setup.

You can use an adapter to bolt a complete linkpin front end to a previously ball jointed body.  This is probably the easiest way of going about this conversion but has some drawbacks.  For one, the adapter will push the front beam forward a bit.  This may be desirable if you would like to use longer torsion arms, but also places greater stress on the mounting point of the front beam to the framehead.

Old adapters may be difficult to find, but luckily, newer ones are also available.

http://www.thesamba.com/vw/classifieds/detail.php?id=787535

Grind and Fit Method

Many budget VWer seem to be fine with reshaping the ball-joint framehead with a grinder to fit a linkpin beam.  This doesn't seem like a good idea al all, but again seems to be common practice by many a backyard mechanic.  And with a little bit of reinforcement and quality welding, this should work fine for most applications.

Ball Joint Framehead cut to fit Linkpin Beam (Rack and Pinion also added)

http://www.thesamba.com/vw/forum/viewtopic.php?t=314267

Framehead Replacement

With just the right amount of welding experience, you can weld on a linkpin framehead to a ball-joint body.  You can get a link pin framehead from a donor VW or many aftermarket VW shops.  And done right, this allows for a stock strength clean conversion.

http://www.thesamba.com/vw/forum/viewtopic.php?t=63491

http://fvwa.sitefactory.fi/data/10.pdf

http://www.mamotorworks.com/acvw?frame=1.4627

http://www.volksrods.com/forum/showthread.php?t=27457

Cage Fabrication

If you have or are fabricating a cage for the front of your VW, you can set it up to fit what ever front beam you like and wherever you like it.  A front cage also has fabrication potential for overall strength, shock towers, lights, body mounts, etc.

Hybrid Beam

There are a few ways to create a hybrid linkpin/ball-joint beam that "bolts on" to a VW.

A "combo-beam" is mentioned in the forums.  This is a linkpin outer beam with a ball-joint inner beam welded together.  This allows the center section to bolt to a new framehead, while having a linkpin suspension.  This may also increase the overall width of the front end if the linkpin beam sections aren't trimmed.

Another method is to build a linkpin beam with same torsion tube separation as a ball-joint framehead.  The guy at Bugzyla makes these and swears by them.  They look nice and should bolt right on.  The problem is that if you use an unmodified linkpin spindle with this setup, the torsion arms will not be parallel to each other.  This will cause significant caster changes as the front suspension cycles.

Bugzyla and others state the this hybrid system works well without noticeable steering problems, but the geometry does not seem right by any means.  Their argument for use of conversion arms (see below) is this:

We have conversion arms available now for anyone interested. We have been testing these and the conversion beams for quite a while now. The linkpin beam tubes are actually about 4 3/4" apart cernter to center, while the link pins are actually about 5 3/16" apart center to center at the spindle carrier. The balljoint beam is 5 3/4 center to center on the tubes. So the stock linkpin beam is about 1/2" narrower than the linkpins center to center, and the balljoint beam is about 1/2" wider center to center. So while you are changing the geometry, its no more caster change throughout the travel between the 2, just in the oposite direction. These arms and conversion beams all but eliminate the bump steer issue, and they work great. I have a couple dozen of these beams in various cars from street cars, to weekend warriors, to all out race cars. The arms do the same thing as the beam if you dont want to swap beams. Stop by my shop anytime and have a look.

http://www.thesamba.com/vw/classifieds/detail.php?id=939587

http://www.azbaja.com/ForumsPro/viewtopic/t=5139/

http://www.thesamba.com/vw/forum/viewtopic.php?t=345781

Conversion Arms

Yet another hybrid option is to use conversion torsion arms.  The fit on ball joint beams and allow for use of kingpin spindles and should have the same drawback or advantages of the hybrid beam concept.

http://www.azbaja.com/ForumsPro/viewtopic/t=7007.html

Ball Joint Removal

Removing the ball joints from the trailing arms on a ball joint front end can be a real challenge.  It is generally thought that you need a press and the proper fittings to remove and install new joints.  There are however other options.  One is to use heat on your arms and a big hammer.  This technique is questionable as it may change the temper on your arms.

http://www.harborfreight.com/3-in-1-ball-joint-u-joint-c-frame-press-service-kit-38335.html

http://www.busdepot.com/catalog.jsp?model=3&category=19 Meyle/Germany parts

Another options to replacing ball joints is to just to purchase rebuilt trailing arms with the ball joints already installed.

http://www.aircooled.net/new-bin/viewproductdetail.php?keyword2=SSB0008

High-Angle Ball-Joints

Another solution to Ball-joint suspension issues is high-angle Ball-Joints. These are not used much do to poor quality issues.

Front End Lift

The cheapest way to gain lift with your torsion arm suspension is to pre-load the torsion leaves. You can do this with the "cut and turn" method or by welding in adjusters.

Available through some VW parts shops are Lift Spindles. These lower the mounting point of the wheel in effect raising the front of the car and retaining completely stock suspension geometry for reliability and longevity.

http://www.tweedsdesigns.com/img/pages/spindles/spindles_AS-BJ.html Tweeds Designs - late model lift spindle

Trailing Arms

Another common upgrade is the use of longer/wider trailing arms. These will provide you with more suspension travel for a more comfortable/faster ride off-road. Obviously, the longer the trailing arm is, the more travel you will attain. This can range from about 9" with a maxed out stock setup to about 15" with 4" longer arms and coilover shocks. Stock arms can be modified with a long travel shock mount for better control of the shock throughout the suspension range.

A flaw with the stock beams is that they were designed for the autobahn and not for real off-road abuse. They are mainly tack-welded together and you can increase the strength of the front end by welding the seams with a MIG and gusset where the shock towers meet the upper beam tube.

For Link/Kingpin suspension, you can gussets on the weak points of stock spindles (around the king pin carrier and tie rod arm) and the beam. Another spindle upgrade is combo spindles - much stronger and much more expensive.

For Ball Joint Suspensions, you can also beef up the spindles.

http://www.thesamba.com/vw/forum/viewtopic.php?t=365665&start=33

Limiting Suspension Travel

You can and perhaps should use limiting straps to limit downward travel.  This prevents your shocks from bottoming out, your ball joints from breaking (if you have a ball joint front end) or other suspension damage.

http://www.thesamba.com/vw/forum/viewtopic.php?t=365665&start=62 - welded on bolt for limiting strap

Another novel way to limit travel is to build in hard stops.

http://www.thesamba.com/vw/forum/viewtopic.php?t=365665&start=60

This design allows for suspension control that can allow for good steering and camber control and the potential for long travel, all depending on design.

A-Arm baja roller Mendeola S2-T1 Chassis A-Arm Suspension LLCC Orange county buggy Performance Chassis for T1

5 and 4 Lugs

Most-off road VWs use the early 5-lug wheel because of it's superior strength compared to the 4-lug wheel and because the link/king pin front ends come with 5 lug setups.

If you are running a Ball Joint front end you can use 5-lug 66-67 front drums if you use the 68 and later inner wheel bearing.  If you have a King & Link front end then you are pretty much stuck with a 5-lug drums up front unless you upgrade to an aftermarket conversion.

Torsion Beam Bearings

VWs cam with metal roller bearings in ends of the beams.  Aftermarket replacement bearings are still available, but the original German ones seem to be hard to find.  Many VWers also use polyurethane or derlin as bearing replacements front and rear.  The quality of the available polyurethane bushing seem to be in question and the derlin bushings seem to be a bit firmer and more durable.  Some have even reported that their polyurethane bushing have failed within a year or even as early after a single offroading run.  Both the poly and derlin bushings may need to be reamed out for a proper fit.

http://www.thesamba.com/vw/forum/viewtopic.php?t=402712

http://www.sacoperformance.com/products.php?cat=28

http://www.thesamba.com/vw/forum/viewtopic.php?t=211720

http://www.pacificcustoms.com/AC413115.html

http://airkewld.com

Some VWers have gone as far as modifying their beams to fit other bearings to allow for easy to find quality replacement parts.

http://www.thesamba.com/vw/forum/viewtopic.php?t=402712&start=10

"Local bearing shop, we shrank a steel insert over the arms, and fitted a pair of gold speedi-sleeves to give a bearing surface, and pressed in a stainless sleeve in the beam to bring it down to the closest off-the-shelf size. It's a bit of work, but they've held up damned well, we've had to replace every other bush on the car after this season but they're fine."

Inner Micarta/phenolic Bushing

http://www.thesamba.com/vw/forum/viewtopic.php?t=355617

http://www.thesamba.com/vw/forum/viewtopic.php?t=323551

King Pin Stock Bearings

Inner 111 405 627 Outer 111 405 647 Seal  111 405 641A

Ball Joint Stock Bearings

Outer Upper 46mm Upper Torsion Arm Needle Bearing 111 40 1301 Outer Lower 50mm Lower Torsion Arm Needle Bearing 311 40 1301C Upper Torsion Arm Seal 131 40 5131 Lower Torsion Arm Seal 131 40 5129 Upper Ball Joint 131 40 5361F Lower Ball Joint 131 40 5371G  Ball Joint Replacement Boot Kit with Clips 131 49 8001

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