I took a different approach to the handling issue. I also felt the solution for better parts would be addressed too. In the front, I cut off the frame horns 8" in front of the firewall and welded in a complete P1800ES crossmember. This provided me with dual system calipers, ball joints, upgradeable shocks, and beefy front sway bar. I had repaired the 544 frame in front under the contact point of the original sway bar and felt this was a weak spot. If you bolt up a beefy sway bar to a weak frame ...it will rip out! I then fabricated the forward portion to accomodate the wider crossmember and installed an 1800 steering column and tie rods etc. all the way into the cabin with the steering wheel (it fits fine). After that the 1800 tunnel was appropriate and since I had gone this far, those pesky rear end connection points were rusting every winter I drove it. So, the doner car (1800ES) had a floor from the rear bumper forward to the front seats that included a much bigger panhard bar, 4 bar link suspension, upgradeable shocks, disc brakes, and a flat floor! I think I can get a sway bar if I wanted too pretty easily. Add in the 108mm bolt pattern Turbo Wheels (6" wide ....195x60)and I have a 544 that goes, stops and handles mostly like a P1800 and has a much easier replacement option list. For the purest, I have paid the price of the pure 544 owner. I drove this car as original with the B16, 3 speed and a single Zenith and 6 volts for many years of winter driving. I've been refered to as "Frankenstein" but I call him Virgil.

I called you Dr. Frankenstein before - but as a compliment!

To paraphrase the old Beasty Boys song..

You gotta fight...

For your right...

To MIG Welllllllld!

Thats a lot of work you've done on your car. You are a braver man than I. I don't think I could get my car back together after it was that far apart. How/where did you cut out the rear floor and how did you weld the new one in? I'm sure this wasn't an easy task, but how well did the differing parts match up?

I have a future organ donor 1800e (rusty, dented, shot interior, fine mechanical shape) waiting for spare time and a nice 122 coupe body to come along. I think most of the parts will just bolt right on to a 122 chassis.

John McRaven

95 Jetta GLX (traded soon on a TDi?)

71 1800 (its time will come)

63 544 (M41/OD awaiting tranny tunnel modifications)

John, Last Saturday I told you all about how and what I did to get the parts married up. Real detil and more than most wanted to read. And Then...... My hand bumped the mouse and it was all gone! I'll do it again soon.

Thanks for the interest. Is anybody going to Watkins Glen for the Volvo meet and Vintage racing June 1-3 ???

I guess it ended up in the cosmic bit bucket in the bilges of the internet. I was interested because I have a beater 1800 with solid rear floors and subframes and a 544 that is rather fragile and has some chunks of subframe just plain missing.

John Mc.