volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars
Cutting top shaft housing horizontally. This lobe is then cut vertically to be able to slide 2.5 inches down the jig tube.

Volkswagen Van – Building 2.5-inch dropped spindles

 

Dropped spindles are simply spindle castings where the axle (or hub center) is moved up away from the lower ball joint. This lowers your car/truck/van by moving your wheel up in the fender well. There is a limit to how far you can move the axle up (you run out of casting), which is why you see most spindle applications drop about 2 inches. Precision and maintaining the correct factory alignment specifications are important when it comes to making dropped spindles.

One part of this project is remove the original 1958 split screen beam and replace it with a 6-inch narrowed and adjustable beam accompanied with 2.5-inch dropped disc break spindles from a 1971 Volkswagen bay window bus.

For this post, we will concentrate on converting the original bay spindles to 2.5-inch dropped spindles.  The result of this modification will drop the front of the bus down 2.5 inches, creating better road handling since the vehicle is at a lower center of gravity.   The beam can be also adjusted to even further lower the bus.

Building 2.5-inch custom dropped spindles for Volkswagen Van:

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars bay dropped spindles

Original 1971 Volkswagen disc brake spindles.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

1971 VW complete front beam used as donor. Ready for tear down.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

VW bay window spindles after media blasting.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

Another angle of original spindle before surgery.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

Jig made to aid building the 2.5-inch dropped spindles. Built to keep and maintain the original geometry during modification.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

Up close detail of the jig.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

View from the side.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

Cutting top shaft housing horizontally. This lobe is then cut vertically to be able to slide 2.5 inches down the jig tube.

 

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

The arm is cut and the jig structure is unbolted and moved down 2.5 inches creating a gap which will be filled. All original factory geometry is maintained.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

Here is the gap after the arm is dropped 2.5 inches.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

A piece of steel is cut to fill the 2.5-inch void. Steel is also beveled for maximum weld penetration. Steel is then heated to cherry red in preparation for TIG welding.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

Continuing heat concentration throughout laying beads. Stainless filler rod 302 is used.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

For added strength and peace of mind, we added a gusset for a backbone.

 

Dropped Spindles, Custom Spindles For Volkswagen at The Metal Surgeon volkswagen van, dropped spindles, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, restoration, vintage cars

Welding is complete, now the custom dropped spindles are ready for paint, cosmetics, and assembly.

This is not a tutorial – please don’t try this at home!