I got inspired by Gene’s tech thread on First Aid (Thanks Gene). A while back there was a thread on what people take along for parts and tool, but I couldn't readily find it. So I pulled out my parts cases, spread the contents on a poly tarp, and inventoried them, if perchance posting here would help someone with what to take.
These items all fit into the two 50 caliber ammo cans. That works for me because I have multiple buggies and the ammo cans are able to be moved from buggy to buggy. Each can is labeled fluids or parts so I can tell them apart. Small items are stored in plastic containers in the ammo cans. I also carry a tool bag behind the seat with commonly used tools and parts easily available.
Some of the parts are particular for my application so you may need to adjust to suit your buggy.
This list is not exhaustive. For instance I don’t carry a wheel adapter or torque wrench, but do keep them in the RV. My thinking is I want enough parts to get me back to civilization if stranded in the desert. If I have room for other parts that enable me to make a repair and continue on a run that is a bonus. Therefore I include some arbitrary parts that don't require much room. But getting out of trouble is my first priority.
Feel free to post anything you think I have missed. It may help the rest of us.
Can 1: Fluids, Tires repair.
Scissors Jack (I prefer scissors because a bottle jack leaked on me)
Axle Nut Whacker
Compressor (small 12 volt)
Lug wrench (collapsible is nice because it doesn’t take much space)
Tire plugs (to plug tread punctures)
Can of Flat Fix
Oil, 3 quarts (if you spring a pressure leak you may wish you had more than three quarts)
Trans oil (80W 90, 1 quart, squirt type bottle)
Carburetor Cleaner
Brake Cleaner (Brake and carb cleaner are great for cleaning almost anything during a repair)
Brake Fluid (2 pints)
Starter Fluid
25 foot tow strap with ratchet end. (Doubles as a come-a-long)
Can 2, Parts and electrical
Fuel pump and appropriate rod (electric may be better to carry for a spare)
Brake Cylinders (front and rear)
Solid front trans mount
Spark plugs and plug socket
009 distributor (complete), plus extra coil, condenser, points, rotor, cap and assorted plug wires
Fuses
Carburetor Jets (one size over, and two sizes under for altitude)
Bailing wire (They say you can fix anything with bailing wire, chewing gum, and duct tape)
Electrical Connectors, electrical crimping pliers, a length of electrical wire
Electrical Test Light
Headlight bulb (I use H4 inserts. I’ve heard #2002 replacements work for H4 also)
Swing Axle boot
Swing axle bearing seal
Assorted Nuts, Bolts, and Washers
Assorted Hose Clamps
Throttle Return Spring
ebrake cable end (Bugpack)
Valve Cover Gaskets (rubberized)
Shift Rod connector with screws
Timing Light
Push Rod Tube (collapsable spring type which can be placed without removing the head)
Push Rod
Cable clamps (for shortening 1/8 inch cable)
Brake Lines (2 ea, flex type, front and rear. Mine are used but servicable.)
Fuel Filters
½ inch oil line ( two feet)
Fuel line (two feet)
Brake Reservoir Hose (green VW, one foot)
Plastic cinch ties (6 of assorted sizes)
Bare rocker shaft (some carry one complete with rocker arms)
Clutch pedal rod/hook (if you have ever had a clutch hook wear through you know why)
e-brake pin and retainer clip (for attaching the ebrake arm to the brake shoe)
Rear axle nut cotter pin (for 36mm axle nut)
Fan belts (2)
Throttle cable
Clutch cable
Torque Dude
Electrical Switches
Duct Tape (1/2 roll)
Clymer manual for VW
Tool Bag: I’m not going to list every tool I take, just the essentials. Wrenches and sockets are a given and always with me. In addition I try to take mostly generic tools.
Vice Grip
Adjustable pliers
Screw drivers (Phillips and Slot type. I like the four way so I don’t have to carry eight screw drivers)
Feeler gauges (at least .004, .005, .006 for adjusting valves)
Allen wrenches (one buggy uses button-head screws)
Nut drivers (1/4 and 5/16)
Trans oil plug socket
CV joint 12 point socket (for stock IRS)
Various Crescent wrench sizes
Hack Saw blade
Fire Extinguisher
Hammer
Punch (Small for removing clutch hook pin)
JB Weld (5 minute type)
Silicone Sealer (Ultra type)
Spare Tire (I don’t always carry it. No place to put it on one of the buggies. I try to use 3 ply sidewall tires on the rear and carry tire repair items.)
Tire Pressure Gauges (2ea., one 5-50 lb and one 1-5 lb for sand)
In addition, if running a small gas tank we sometimes take a one gallon metal paint-thinner type can full of gas. It fits nicely inside the 50 cal can for backup fuel.
mel
Institute of Fiberglass Narcosis, Mentone Beach, Calif.