| Bond Bug ZZR1400 Project |
My custom Bug back in 1984 at the Burford Micro Car Rally
Later picture of my Bug in 1992, now srayed light grey with added Webster solid doors and spot lights.
I have owned TUF415J since 1983 when I bought her for a princely sum of £100 back then. It was in very poor shape and I spent the whole of the next year completely restoring it from scratch.
The original engine was a 700cc Reliant alloy engine developing 28bhp. I replaced it with an over-bored 850cc Reliant engine with as many performance upgrades I could do. I had a 'Mike the Pipe' extractor manifold and exhaust made,
engine head was skimmed and gas flowed, electronic ignition, twin 28/36 weber carbs fitted etc which after a rolling road test developed 60 bhp. In 1984 I attended the Burford Micro Car rally and won 1st price for concours.
I used the 'suped' up Bug as my daily mode of transport for many years until my gearbox failed and I was in the process of converting an 850 cable operated box to the Bug hydraulic type. Kids came along and the Bug never got put back on the road.
Now I have more time on my hands and more cash to spend I decided to completely restore the Bug but this time bringing it up to more modern performance and getting experts to make most the bits.
The result is a 200bhp Kawasaki ZZR1400 engined beast, into a Quaife reversing gearbox, into a BMW 318i limited slip diff with MGTF independent rear suspension.I have added lots of specialist electronic bits, triple fan cooling with digital controlled water pump.
Baffled sump, foam filled fuel tank, electric actuator canopy lift etc.
Updated 11/8/22
Bonnet repairs finished
Underbody mods completed - new bonnet badge cut out made Body work
Canopy locating mount finished Body work
Engine side covers glassed in - pedal box finished
Body off - fibre glassing underneath
Body work inner detailing Body work
Mocking up reversing gearbox lever position
Canopy locating lug finished - more pictures
Foot pedal box fibre glassed in Pedal box
Canopy rear and dash locating lug mounts finished Body work
Quaife reversing gearbox linkage parts ordered Quaife reversing gearbox
Inner canopy lug positioned
Air box finished - inner dash completed
New air filter box top made
Split mould completed for air box Air filter
Locating lugs being fitted into central dash board unit and canopy so they mesh exactly when canopy is closed.Body work
Custom air filter box being moulded Air filter
New custom sized pedal support frame arrived.Pedal box
New custom made carbon fibre break pipes arrived
Duct box sealed Body work
Inner canopy moulding finished Body work
New Air duct moulded inlet customised to fit the Bentley dashboard vents
Air intake ducts now moulded
Removable side engine covers being mocked up
Pedal box finished
Pedal box gel coated
Revised engine side cover extended
Revised pedal box plywood template fitted
New pedal box plywood template made - new dashboard back plate made Pedal box
Adding engine side cover top ready to take sealing rubber
Dash side now moulded around steering column support - added removable side engine cover
Custom badge rubber made - posted to Body work
Added ABS sensor fittings to LSI page
V3 ABS ring finally fitted on propshaft - time for making the Kawa ABS sensor locating mounts
ABS ring V3 posted - reduced outside diameter and drilled out locating ring
2nd attempt at an ABS ring arrived and fits perefectly over propshaft locating ring. Pictures posted to LSD page.
Added reversing gearbox extension shaft - machine drawing being prepared for new operating lever
ABS ring back to machinist for central prop shaft location ring drilling
New magnetic lock for rear mesh boot lid arrived
Added chrome hinges and Bentley badge to rear mesh boot lid.
Bought the magnetic catch and boot 'poppers'. Added Classic Mini boot straps.
Remote master cylinders changed - added triple triton reservoirs
Dashboard fibre glassed to canopy inner
Bentley centre console fitted
Dash radius wing added and glassed in
Dash now fibre glassed - Bentley grill now recessed
Dash board top being mocked up in bendy plywood
Added 3 new master cylinders and balance bar to foot pedals, chopped out more of the body work to fit new pedal box
Work had come to halt as my fibre glass expert has been ill and I have been working solid for a month.
Work will commence again on the 20th Oct.
New Master cylinder fitted to pedal box
New modified hand brake cables have arrived
New dial mounting plate fitted to steering column
Chopped out body work to fit new pedal box
New pedal box positioning - ordered new custom dial bracket
Wireless paddle and Kawa dial positions mocked up
Final positioning of steering wheel and column
Laser cut ABS new double ring made
Reversing gearbox lever extension tube positioned
Fitted new steering column support - body lowered
Handbrake cables sent off to be modified - drawings added
Body reunited with frame for more trimming
Reversed the Quaife gearbox into correct direction
E-Stopp fitted in final location
Added master cylinder sizes to pedal box
Added top dash side wings - now mocked up in cardboard
Bentley centre dash air ducts converted
Centre console frame and back plate made
Steering wheel and column mock up
E-stopp mounting plates fitted
Rear triple fans and relays wired up
Loads more wiring update pictures posted
Air box final fitting
170amp new alternator now wired up
Added new ABS ring to 318 LSD page
New waterproof box added to protect ECU, fuses etc.
E-Stopp brackets and fittings being made, line drawings added
Canopy - existing lock now filled in. Roof and drainage channel detailed
Added magnetic canopy lock - housing now made
Added Bentley centre console framework mounting
Added E-stopp layout pictures
Canopy door hinge mounting plates finished.
Added Cartek Wireless Control flappy paddles
Flatshifter and steering wheel - paddle operated gears
Canopy air spoiler now bonded to canopy
Bearings fitted to steering shaft and loosely located in position on the Bug
Kawasaki ancillary wiring extended - pictures
Loosely plugged in the Kawa wiring loom to the engine - wiring up ancillary's
Added two new potential 2 pedal brake and clutch balanced bar set ups
MGTF swinging arms and disc brakes- foot pedals
Both of old rusty canopy side tubes have been cut out and replaced
Added Engine connections tab - trying to connect up all the pipes prior to starting
New UTO-VOX V5PRO OEM Mirror Dash cam added to wiring - cables now routed through fibre glass canopy.
Fibre optic head-lining lights power unit recessed into canopy
Alternator housing is now finished - latest pictures of black anodised finish
170 amp new external alternator
Bentley dash board button printed circuit boards sent of for redesign.
Dash board - Bentley Continental GT
New steering column splined shaft conversion made. New 'Oilite' custom made bearings have arrived
The links below that are active and have been uploaded
External air scoop mould made and fibre glassed for finished scoop
Scoop now taken out of mould and now glassed into final position
More shaping pictures added to internal air duct to accommodate canopy rubber seal
Test D profile canopy seal fitted
Added custom made steel boot lid with mesh insert to bodywork page
Send me a mail for comments and any tips you have to chris.meitiner@btinternet.com
Custom triple fan cooling and fuel tank
Dash board - Bentley Continental GT
Engine extractor manifold and exhaust system
E- Stopp electric hand brake - current project
Flatshifter and steering wheel - paddle operated gears
MGTF swinging arms and disc brakes- foot pedals
Quaife to chain converter - Quaiff to BMW propshaft
170 amp new external alternator
Modified to take independent rear suspension through a limited slip differential
Original fixed axle and frame set up before conversion