VW Bug — Custom Chassis & V8 Build

Halethorpe, Maryland · Serving the Baltimore–Washington areaAutomotive repair + custom fabrication

Projects / VW Bug

Custom chassis · V8 power · Complete build

VW Bug.
Familiar shape.
Entirely new possibilities.

A street cruiser and show car with mild off-road capability. We transformed this customer’s Bug with a full custom frame, custom suspension and a 350-cubic-inch small-block Chevrolet V8 producing approximately 425 horsepower—then carried the build through wiring, bodywork and paint.

Completed black V8 VW Bug custom build parked beside the beach

The completed Bug: custom chassis, V8 power and a distinctive stance, finished by Wits End.

Designed in-houseAll CAD by owner Kenny Belt
Custom foundationFull frame, independent front suspension & triangulated four-link rear
Delivered completeFabrication, wiring, bodywork & paint by Wits End

01 / The vision & the challenge

Big plans.
Compact proportions.

The customer wanted a Bug that could cruise the street, stand out at shows and take on mild off-road use. Bringing that combination together meant rethinking what sat beneath the familiar body.

The biggest challenge was placing the V8 while maintaining good weight balance and usable interior space. The engine, chassis and passenger compartment all needed to work together within the Bug’s compact proportions. Kenny handled all CAD work in-house, developing the layout around those requirements.

In-house CAD layout for the Wits End V8 VW Bug custom chassis

The build began with CAD work by owner Kenny Belt, developed in-house at Wits End.

VW Bug body positioned over the custom frame during fabrication

The original body positioned over the new full-frame chassis during fabrication.

02 / A new foundation

A full custom frame.
Suspension built around the vision.

We replaced the original pan-based chassis with a custom full frame, turning the Bug into a full-frame vehicle. The build pairs a custom independent front suspension with a triangulated four-link rear suspension and a Ford 9-inch rear axle.

QA1 coilovers at all four corners complete the suspension package. From the chassis layout to the suspension fabrication, the work was developed around the customer’s intended combination of street cruising, show presence and mild off-road use.

Ford 9-inch rear axle housing fitted beneath the custom VW Bug chassis

Fitting the Ford 9-inch rear axle beneath the Bug’s new frame.

Custom independent front suspension and front bodywork on the V8 VW Bug

The custom independent front suspension and handmade front bodywork during assembly.

03 / Made to fit

Handmade details.
Inside and out.

The fabrication extended well beyond the frame. We built a roll cage, a custom dashboard and handmade front fenders, bringing the body and interior together with the new chassis and drivetrain.

These progress photos show the work beneath the finished surfaces—from shaping the front sheet metal to fitting the interior around the engine and transmission.

Handmade VW Bug front fender and custom chassis during fabrication

Handmade front sheet metal taking shape around the new chassis and component layout.

Custom roll cage, floor panels and transmission tunnel inside the V8 VW Bug

Interior fabrication: the roll cage, floor panels and transmission tunnel taking shape around the drivetrain.

04 / Finished at Wits End

From CAD drawings
to a completed car.

The 350-cubic-inch small-block Chevrolet V8 produces approximately 425 horsepower. We handled the wiring, bodywork and paint as well as the chassis and fabrication, delivering the Bug fully complete.

The finished car brings together the customer’s vision and the work of one shop—from the first layout decisions to the final assembly.

VW Bug rear triangulated four-link suspension and QA1 coilover during final assembly

A closer look at the triangulated four-link rear suspension and QA1 coilover during final assembly.

Bring us the problem.

Have a vision for a custom vehicle? Let’s talk through the build, the challenges and what it will take to bring it to life.

Discuss your project ↗

Proudly powered by WordPress | Theme: Baskerville 2 by Anders Noren.

Up ↑