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Project Stella - Fresh respray, 2110cc Stroker build + Red9 Kit
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Rottie Mad
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Joined: May 11, 2018
Posts: 7
Location: Cambridge - UK
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PostPosted: Mon May 21, 2018 8:17 pm    Post subject: Project Stella - Fresh respray, 2110cc Stroker build + Red9 Kit Reply with quote

Well its been a long time since we have been on here as other priorities in our lives have meant that Stella had to sit in the garage for a few (7yrs) years waiting patiently for this day to come.

For those that dont know, Stella is a 1966 RHD Dormobile with a Devon interior. This was how she looked when we got her home back in 2009 and pretty much how she has looked for the past 9yrs whilst we have had her. She looks pretty solid, however........looks can be deceiving as we have recently found out. But kinda expected!

In the time she sat in the garage, we did the odd bit of tinkering and have fitted a CE IRS kit, slamwerx beam, porsche 944 brakes, rebuilt the original 1500sp engine and tinkered with the rascal power steering rack................. this is where we got to and never actully got her on the road before we had to leave her sit for a bit whilst other things took priority.

So around Oct 2017 we decided 2018 would be the year we got Stella on the road and finally started looking for bodyshops to do the work that was needed.
After a long chat, we decided upon a local small family run firm called Quest Brothers Classic Cars in St Ives Cambridge.
I cannot rate there work, attention to detail, cutomer service and overall enthusiam for the project enough. They were open and told us this would be there first VW Bus they had ever worked.

In total they had Stella for around 16/17 weeks and this shows from the work undertaken and meticulous attention to detail.

During the time she was with them, we got regular weekly phone calls and email updates, we visited probably every other week to check on progress, they took hundred of photos for us at varying stages throughout and were very accomodating to us the entire time.
They explained clearly what was needed when it cropped up and worked with us to get replacement parts/panels needed as we wanted specific panels if any were to be replaced.

So what was needed:

Front panel upper section from just below the windscreens upto the roof line
Both rear corners replaced upto waist line
Cut out and re-weld the long side panel
Cab floor sections N/S & O/S
Replaced engine bay side panels both sides
Pulled out and reshaped passenger wheel arch
Brand New front and rear bumpers
Repairs to gutter section
Reinforced the Dormobile roof hinges/connections
Repaired rotten cab fresh air box
Replaced both cab door top sections
They reinforced some chassis panels to use as jacking points
The underside was coated with Raptor Protective Coating
Fitted brand new deluxe trim
The cab was to be painted to match the extrerior
The rear section was just to be primed as its all going to be hidden.
Engine bay was to be painted to match the exterior lower section

They did much more to her, but thats all I can remember off of the top of my head.

Now the fun work begins as we have lots of plans for her :bounce:

Here is what Stella looked like before....................

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These are a few of the 'During' pictures, we have 100's on a USB stick the bodyshop took for us throughout there work.

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_________________
Project 1966: https://www.thesamba.com/vw/forum/viewtopic.php?t=699952

VW Splitscreen, 1966 RHD, Devon Roof, Dormobile Interior
Creative Engineering IRS Kit


Last edited by Rottie Mad on Thu May 31, 2018 8:13 pm; edited 3 times in total
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Rottie Mad
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Joined: May 11, 2018
Posts: 7
Location: Cambridge - UK
Rottie Mad is offline 

PostPosted: Mon May 21, 2018 8:18 pm    Post subject: Re: Project 1966 RHD Splitty **** Purest's will hate it **** Reply with quote

Heres just a few of the after pictures, more to follow

The afters......... All opinions welcome

Renault Liquid Yellow (Pearl)
VW Schwartz (Metallic)

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_________________
Project 1966: https://www.thesamba.com/vw/forum/viewtopic.php?t=699952

VW Splitscreen, 1966 RHD, Devon Roof, Dormobile Interior
Creative Engineering IRS Kit


Last edited by Rottie Mad on Mon May 21, 2018 8:57 pm; edited 1 time in total
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Rottie Mad
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Joined: May 11, 2018
Posts: 7
Location: Cambridge - UK
Rottie Mad is offline 

PostPosted: Mon May 21, 2018 8:19 pm    Post subject: Re: Project 1966 RHD Splitty **** Purest's will hate it **** Reply with quote

We have made a start on the sound deadening.
After reading up on the different types of sound deadening we decided upon a layer of Silent Coat 2mm everywhere and also doubled up with a closed cell foam in 4mm for the cargo floor area and engine bay cover

For the cargo area.......... 2 x box's @ 40 sheets of Silent coat were needed and 5m2 of the closed cell foam.

We still have a box of the Silent Coat to do the cab area

Plylining kit arrived also, so that will be fitted this weekend hopefully Very Happy

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_________________
Project 1966: https://www.thesamba.com/vw/forum/viewtopic.php?t=699952

VW Splitscreen, 1966 RHD, Devon Roof, Dormobile Interior
Creative Engineering IRS Kit


Last edited by Rottie Mad on Mon May 21, 2018 8:58 pm; edited 1 time in total
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Rottie Mad
Samba Member


Joined: May 11, 2018
Posts: 7
Location: Cambridge - UK
Rottie Mad is offline 

PostPosted: Mon May 21, 2018 8:20 pm    Post subject: Re: Project 1966 RHD Splitty **** Purest's will hate it **** Reply with quote

I have spent the past couple of weeks speccing up an engine for her, and after ditching my initial plan to build and install a 177cc, it will now become a 2110cc Stroker.
I did plan on buying the Lime Bug kit, however after sending them an email asking them to clarify a few things for me before making my purchase, I didnt hear back and its been a week now.

So we bit the bullet and have taken the plunge and gone for a CB Performance 'Builders choice kit' in 2110cc.
The kit has been slightly modified to suit my needs and requirements.

After chatting to CBP I have opted for the CB 044 'Special' heads instead of the Panchito's and settled upon the 2241 Cam shaft (an inbetween of the Engle W100 and W110)

Ordered last night and now have about a 4 week wait Smile

Full Spec:

Autolinear Super Race Case - Alu
CB 044 'Special' heads 40 x 35.5
Mahle Pistons 90.5
CB Super Race Rods - VW rod journal - 5.400" length - set of 4
CB Eagle Racing Camshaft 2241
CB Crankshaft gear assembly kit
CB Inlet manifolds, carb linkage and air filter kit
Wrist Pin Buttons - Teflon Buttons - 90.5mm pistons
Super Race Crank - 82mm Stroke - VW Journals
Cylinder Head Studs - 8mm Chromoly - Dual Port
CB High Performance Case Kit
Barrel Shims (.040") 90.5
Racing Gland Nut with Washer
End Play Shim Kit
Cylinder Head Gaskets - Copperhead - 90.5mm 0.040" thick (set of 4)
Eagle Adjustable Cam Gear
28mm Ultralight Lifters (set of Cool
Chromoly Push Rods - blank end (.035'')
C Channel Valve Covers (set of 2)
Thin Line Oil Sump - 1 1/2 quart
Main Bearings STD
Racing Camshaft Bearing Set
Rod Bearings Type-1 STD
Rear Main Seal
Posi-Seal Cam Plug
Deflector Plates (8mm) fits 13, 15, & 1600cc (set of 2)
Cam-shield™ 4 oz. Brush Top Jar Assembly Lube
LABOR-CFS Clearance Cam For Stroker

Carbs will be Weber 40IDF's

Im yet to decide on exhaust system and ignition setup yet, but I have plenty of time to decide on that
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Project 1966: https://www.thesamba.com/vw/forum/viewtopic.php?t=699952

VW Splitscreen, 1966 RHD, Devon Roof, Dormobile Interior
Creative Engineering IRS Kit
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Skim
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Joined: April 15, 2001
Posts: 16679
Location: GFK 26 Year Vet
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PostPosted: Wed May 23, 2018 9:42 am    Post subject: Re: Project 1966 UK RHD Splitty **** Purest's will hate it **** Reply with quote

Cool. Keep the updates coming
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GFK
Samba since before the towers collapsed. Still here.

1954 Sunroof
1960 Lt Grey Double Cab
1961 Deluxe SWR / BG 15 Window
1963 Deluxe Turkis Walk Thru 15 Window OG Paint
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Rottie Mad
Samba Member


Joined: May 11, 2018
Posts: 7
Location: Cambridge - UK
Rottie Mad is offline 

PostPosted: Thu May 31, 2018 7:27 pm    Post subject: Re: Project 1966 UK RHD Splitty **** Purest's will hate it **** Reply with quote

Thank you Skim :cheers: :cheers:

Lots of deliveries this week and some of the main components have arrived for the engine PLUS another very small addition :bounce: ....... we have been keeping the couriers busy thats for sure lol

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Massive thanks to:

BJs Speedshop - Auto Linear super race case - Alu with 10mm savers, CB 044 'Special' heads, CB Performance carb linkage kit with filters and manifolds, Mahle 90.5 Stroker pots and pistons plus a crankshaft gear assembly kit

Engine case:

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Heads:

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Twin carb linkage kit:

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Alan Schofield - New indicator lenses

Custom & Commercial - Everything needed to build up 2 brand new headlamps minus the hella glass (as our originals are perfect), chrome windscreen wiper arms, chrome windscreen wiper rubbers, Volkswagen rear badge and rear number plate light kit, Empi quick shift kit

Autocraft - Cargo door latch plate, cargo door/floor opening edge finishing strip, chrome exterior cab door handles, foot pedal rubbers, interior door escutcheons, interior light switch plus an indicator stalk knob and 2 cab door retainers

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Red9 - Double wishbone and coilover suspension kit Razz

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That lot should keep me busy this weekend :cheers:

RM
_________________
Project 1966: https://www.thesamba.com/vw/forum/viewtopic.php?t=699952

VW Splitscreen, 1966 RHD, Devon Roof, Dormobile Interior
Creative Engineering IRS Kit
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Rottie Mad
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Joined: May 11, 2018
Posts: 7
Location: Cambridge - UK
Rottie Mad is offline 

PostPosted: Thu May 31, 2018 9:16 pm    Post subject: Re: Project Stella - Fresh respray, 2110cc Stroker build + Red9 Kit Reply with quote

If anyone has any input on brake options with the Red9 kit it would be much appreciated.

We ideally want to use Porsche, Hi-Spec or AP 4 pot calipers. Currently we have tatty 924T 4 pots sat in the garage which are going to be fairly costly to service and powder coat and we will still need to get a bracket fabricated for these so looking into the newer Boxter/Cayman or HiSpec/AP 4 pots instead

Does anyone do an adaptor bracket for any of the above companies which will fit the calipers to the new Red9 hubs or will I need to get something designed and fabricated once ive purchased the calipers?

Also, currently we have 17" Porsche Turbo wheels on but maybe going down to a 16" rim (Fuchs maybe) before the project is complete.
Will this pose a problem with the choices above?

Thank you
_________________
Project 1966: https://www.thesamba.com/vw/forum/viewtopic.php?t=699952

VW Splitscreen, 1966 RHD, Devon Roof, Dormobile Interior
Creative Engineering IRS Kit
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