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<  You got some projects?  ~  Project DC (and other DAS Resto Haus updates)

Dasdubber
Posted: Tue Apr 01, 2014 7:01 pm Reply with quote
Joined: 06 Jul 2011 Posts: 99 Location: Gold Coast
Hi guys, after catching up with Humpty again in Sydney he reminded me of how I've neglected NOH2O!!

So better get some updates coming along again….before I get into the DC (which will see some pages in VWMA as an ongoing tech/feature article), a quick update of a 55 23 window we have had in the shop for too long (only finishing touches to go)












Cheers
Al
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Rossco WA
Posted: Tue Apr 01, 2014 7:24 pm Reply with quote
Joined: 24 Jul 2011 Posts: 802 Location: Bateman, Perth SOR
Nice one Al, follow your builds on DSK, awesome, gives inspiration for classic builds...keep it up. Cool

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WAY2COOL
Posted: Tue Apr 01, 2014 7:50 pm Reply with quote
Joined: 22 Nov 2008 Posts: 551 Location: sorrento
Hey Al ,It was great to meet you at your new shop.Thanks for the tour.
Sure makes a difference to see your fantastic work 'in the flesh'.
Did you get it to the wedding on time?
Cheers ...Kim

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Dasdubber
Posted: Tue Apr 01, 2014 8:41 pm Reply with quote
Joined: 06 Jul 2011 Posts: 99 Location: Gold Coast
Hey Kim, was nice to meet you mate.

We would have had it ready to go last thursday but the owner pulled the pin wednesday lunch time due to torrential rain prediction….so in the end didn't need to rush Rolling Eyes
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Humpty
Posted: Wed Apr 02, 2014 8:54 am Reply with quote
Otherwise known as Kojak... Joined: 28 May 2008 Posts: 11812 Location: Down Da So'Wessieed!
So much work going through your shop Al.... I get that your flat chat.... Moving part of the business to it's new premises only builds the pressure on.... But it's great to see you and your team going from strength to strength.

Keep it up!

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Dasdubber
Posted: Sun Apr 13, 2014 6:59 pm Reply with quote
Joined: 06 Jul 2011 Posts: 99 Location: Gold Coast
Thanks Humpty Wink

Without rambling on much more here is the DC we started with:



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Dasdubber
Posted: Sun Apr 13, 2014 6:59 pm Reply with quote
Joined: 06 Jul 2011 Posts: 99 Location: Gold Coast
This thing was destined to be torn down to its bare bones given the brief of the project and the importance to get the panels super straight. So off with the nose:



As usual rotten a-pillars and inner valance:


The D-pillar (passenger side) had received a big whack at some stage and rather than fixing it properly, someone decided just to plate over it with a second skin



Both doglegs were to come off and be replaced with Klassic Fab units:


Lower a-pillars needed replacing as well
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Dasdubber
Posted: Sun Apr 13, 2014 7:00 pm Reply with quote
Joined: 06 Jul 2011 Posts: 99 Location: Gold Coast
Rear tubs were knackered so the call was made to remove and replace them as well


The deeper we dig, the more work we find (like all resto's!)


New Klassic Fab cab floor to come


Rear pillars were knackered as well


Off to blasting

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Dasdubber
Posted: Sun Apr 13, 2014 7:01 pm Reply with quote
Joined: 06 Jul 2011 Posts: 99 Location: Gold Coast
Post blasting things always look a little better (but certainly reveals exactly how much work is ahead)






Time to start cutting:


To make way for this:


After lots of research and talking to our gearbox builder, it was decided an 091 bus box would be mated to the 3.2L Porsche engine….it will have full Albins (weddle) internals and super diff. Whilst it will not withstand 3rd gear burnouts or drag race starts, the owner was happy to compromise some sensible driving to save a load of funds on buying/rebuilding/installing a G50 or 915 box.


Cheers
Al
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Humpty
Posted: Mon Apr 14, 2014 12:15 am Reply with quote
Otherwise known as Kojak... Joined: 28 May 2008 Posts: 11812 Location: Down Da So'Wessieed!
The bus trans is highly under valued in these sorts of conversions.... I reckon you will be fine with that setup.... Sure, the bus is a heavy'ish vehicle, but drag racers and off-roaders have been using those transaxles with more hp/torque and sticky/nobly tyres for years with good success... The trans in my drag car is built for 500+hp (with slicks!) and I have been reliably told it will handle it....

The 915 transaxle is supposedly not as strong as a built 091. If this is true, the only advantage I can see with that option is the 5 speed, and the G50 variants are rediculous huge and expensive.

I'm sure you'll have a suitable gifted transaxle builder (DB!) online to build it.

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Dasdubber
Posted: Mon Apr 14, 2014 8:03 pm Reply with quote
Joined: 06 Jul 2011 Posts: 99 Location: Gold Coast
Thats right mate, Dave B will be building this tranny with "all the fruit" according to the man himself Wink
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Dasdubber
Posted: Mon Jun 23, 2014 1:15 pm Reply with quote
Joined: 06 Jul 2011 Posts: 99 Location: Gold Coast
Bit of a big gap from the start of this project to these pics but nothing too exciting (jump on dasrestohaus.com.au and go into the gallery if you are really keen to look through several hundred pics!)

Long time since last update, but here are some more pics:

Klassic Fab early bay front floor going in...


NOS rear corners from the UK:


More side panel fabrication:



Rear tubs:



Bay window engine access hatch opening (will have drain holes for water ingress in the seal aperture):

Tray will be moulded around the opening to look factory
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Dasdubber
Posted: Mon Jun 23, 2014 1:26 pm Reply with quote
Joined: 06 Jul 2011 Posts: 99 Location: Gold Coast
New jacking points and outriggers


Belly pans for both sides will help to stiffen the chassis to a degree given the torque this engine will put out and how hard the owner will want to push it into corners!



Donor chassis front section had to be sourced to replace the poorly repaired and rusty original section




Red9Design front end and brakes will provide the front suspension and braking duties



Hydraulic clutch conversion



Ride height will change a little but this gives you a rough idea


New rear pillars


Tight squeeze but we managed to slip it in


Will be retaining factory heater system, air box, air con etc etc to make life easier with the Porsche engine - learning from experience, the more modifications you make, the more teething problems you have!


17in Fuchs with no dish just didn't look right on the rear
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Dasdubber
Posted: Mon Jun 23, 2014 1:36 pm Reply with quote
Joined: 06 Jul 2011 Posts: 99 Location: Gold Coast
Our customer requested an electric sliding sunroof, Webasto was the largest available so in one went!



Factory style porsche mounts will help support the motor onto the boxed chassis rails

Right side scalloped for engine clearance


Rear valance required some obvious trimming!






Rear tub closing plates


Fast forward a little bit and this is a sneak peek at the wheels the DC will be running. You may love them or hate them, but gotta go out on a limb every now and then to be different. Polished/detailed Fuchs are always a good combo, but they are like belly buttons nowadays Wink
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Humpty
Posted: Mon Jun 23, 2014 3:04 pm Reply with quote
Otherwise known as Kojak... Joined: 28 May 2008 Posts: 11812 Location: Down Da So'Wessieed!
Wow that's come a long way... If I have the time later this year (Im coming to the Warwick races) I'll come by for a visit...

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