Black Fastback Build Thread

Brent · Posted: Wed Jan 15, 2014 2:20 am Post subject:

...Ok Vlad...
My big peeve is you troll these threads and consistently point out how you would do something better. Put up or shut up.

-moving on-

Man, you've made some progress! Seeing all those parts that were packed throughout the shop coming together really gets me giddy. Sure looks good. Looking closely at the pics gives little hints of what's to come. Very Happy

Good thinking on welding the boss to the upper torsion arm like that.

So late 944T hub and rotor, right?
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vlad01 · Posted: Wed Jan 15, 2014 5:47 am Post subject:

Bobnotch · Posted: Wed Jan 15, 2014 7:44 am Post subject:

Clatter, you don't post a whole lot, but this thread is really something to see. Very nice job. I like how you're paying attention to the details. That front beam set up looks sweet, and I like how you incorperated the mounts for the extra sway bar. really well thought out. Cool

I also love how you got your kids involved, especially since they're so young. Most kids at that age aren't interested in anything like full size cars, but yours seem to be willing to help. Cool

The expression on their faces is so rewarding. Great job, and I'll keep watching as your pics progress. Very Happy

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W1K1 · Posted: Wed Jan 15, 2014 8:37 am Post subject:

I have always used eastwoods powders, they have been good since i started powder coating at home back in 2001. We have done everything that can fit in the oven, from engine tin to brake drums, even the mailbox has been a color tester for a few different colors. Laughing

good to see the kids helping out, they are the future of the hobby Dancing

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1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

Clatter · Posted: Wed Jan 15, 2014 12:06 pm Post subject:

I started posting up the brake build thread,
And then remembered I did it here already:
Hope I'm not showing some bad netiquette by cross-posting like this.
http://www.germanlook.net/forums/showthread.php?t=11712

Image may have been reduced in size. Click image to view fullscreen.

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Bus Motor Build

What’s That Noise?!?

VWporscheGT3 · Posted: Wed Jan 15, 2014 1:05 pm Post subject:

im not jealous of those calipers and rotors... no ..not..at.. all... Crying or Very sad

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vlad01 · Posted: Wed Jan 15, 2014 9:21 pm Post subject:

nice brakes! Cool

Nate M. · Posted: Wed Jan 15, 2014 9:50 pm Post subject:

Those should haul that car to a stop in no time. Looking good!!

What is the bolt spacing on those calipers??
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Regards,

Nate M.

Squarsche build
Heavy Metal Affliction feature

For heaven's sake, put a type4 and a Porsche 5-speed in there. . . It's the right thing to do!!

Clatter · Posted: Wed Jan 15, 2014 10:30 pm Post subject:

Nate,
The calipers are all from a 1989 S2.
Same as 944T.
The front rotors are the same as 1989 S2,
But the rears are the required 1986-only 944T,
To work with the steel arms.
This all came from the tech articles section on germanlook.net,
And Lanner's site.

The front hubs, and the inside of all the rear (mounting plate, e-brake, etc.) are all from an early N/A 944. Like '82 or so.

Will get you the spacing next time I'm back out there.
Hopefully soon!

Thanks for the kind words, guys.
Have been lurking and patiently saving parts for years and years.
Helps me to keep moving now that some eyes are upon it.

Will get to the whole rear sub-frame adventure soon.
This will be the part that is different than any other....
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Bus Motor Build

What’s That Noise?!?

Nate M. · Posted: Wed Jan 15, 2014 11:51 pm Post subject:

I'm mainly interested in the bolt spacing of the fronts since I'm running 911 front struts with 3.5" spacing (I think). I had better measure mine too. Rolling Eyes

It'll almost be a shame to cover those up with brake dust. . . almost.
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Regards,

Nate M.

Squarsche build
Heavy Metal Affliction feature

For heaven's sake, put a type4 and a Porsche 5-speed in there. . . It's the right thing to do!!

catbox · Posted: Thu Jan 16, 2014 1:26 pm Post subject:

Love the work you are doing to your car.
Keep it going.
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"...these cars were preferred by the racers because the strut front suspension results in far superior handling than the regular torsion bar front end..." - Keith Seume.

suruba · Posted: Thu Jan 16, 2014 2:33 pm Post subject:

Whoa! You made a thread!

Glad to see it. Good to know the board can actually see what you've been scheming on, even though they have no idea how much time and planning has gone into it. It's truly amazing. Nice sway bar btw, never saw that.

Some more sawzall carnage that Clatter got to be a part of.

Dead roach hates rain

Dave

Clatter · Posted: Thu Jan 16, 2014 8:08 pm Post subject:

Aawwww, yeah, baby. Sawzall!!!!
Twisted Evil

Don't think I just cut up squarebacks.
An equal opportunity destroyer!
Twisted Evil

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Bus Motor Build

What’s That Noise?!?

Clatter · Posted: Thu Jan 16, 2014 11:13 pm Post subject:

Alrighty, then...
Here is the part that has consumed, and continues to consume a big chunk of my life:

See, the square does have a couple of redeeming qualities; the rear sub has reinforcements that you can use on a fastback.
This is a reinforcing bar that runs along the bottom of the torsion tube on an early swing-axle square.

The later, IRS square torsion housing has not the bar, but these gussets at the ends. These can be fit to the top of the torsion tube, between the tube and body.

You can use both, and build a stronger torsion tube/housing assembly, but you will need a couple of extra squarebacks to do it. Wink

So, this is where I was going with this; a Bug@5-speed conversion kit...!
This is the 915 transaxle conversion for a bug, modified to work with our beloved type 3s.
Here I am using the IRS sub to go ahead and get the location of the nose-cone for the transaxle in the place it will need to be according to how the kit was built. Because the IRS sub has the factory brackets in the OG location, it was drilled and mounted for measuring. When the IRS weld-on brackets go on the swing sub, everything can be made to line up the same. Make sense?
Also shown here was a set of the aftermarket IRS brackets and just how much they needed modified to clear the type 3 sub.

Then everything was handed off to a master fabricator by the name of Paul McCain. He has been welding since his early teens, and has done Baja-winning buggies and trophy trucks since the 80s. Last time we talked he was doing stainless exhausts for the Yamaha factory V-Max drag racing effort. The guy is super, super gnarly with his fab work, and someone like me couldn't even carry his toolbox... If you want his contact info, PM me. He's in the Reno area now, but comes back and forth to Santa Cruz pretty regularly. I think some of his work is on a website somewhere... I'll ask him.
Anyways, he welded on the IRS brackets, Clearanced the horns for big CVs, boxed in the reinforcing tube, and stitch-welded the entire perimeter of the whole enchilada.

Then the front crossmember had to be moved a bit from it's typical location in a bug application; this was a stupid/scary/sketchy move, and the whole baby Crapsman drill press wants to lift when doing it using only the weight for support. But I went real real easy and got a new set of holes in the right place..

Then this was bugging me... How to get the perfect angle for a right angle to a tangent of a circle? See what I mean? then I was having a beer with another friend. Check this guy out... Gnarly <---- Capital "G" Think you might know a bit about machine tools? dig his home-made RC car..
http://marksmark.net/
Anyhow Mark showed be that you could just tap these blocks instead of trying to dill through and spot-face at this odd (un-findable) angle. Duh. It's so simple once you get thumped up side yo haid...

Using 944 spring plates fouls the side of the sub, to they got faced a bit, and the sub will get clearanced.

And, while this is all dandy, as Nate can attest, the hard part has not even been touched upon... I plan to (currently am) running a tunnel (and shift rod) through the middle of this magic-marker circle here. Learning exactly why nobody has ever gone this way before...

Stay tuned!
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Bus Motor Build

What’s That Noise?!?

t3kg · Posted: Thu Jan 16, 2014 11:33 pm Post subject:

I'm digging the thinking and detail in this build.
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Aaron M265 · Posted: Fri Jan 17, 2014 1:52 am Post subject:

I agree Scott.

While it's too hot to work on my car (46') I am observing others and this is good!
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Yabbadubbadoo · Samba Member Joined: May 21, 2012 Posts: 914

Are they those pivot box jigs that are too short? I think I borrowed similar ones that didn't clear the tower.

Clatter · Posted: Fri Jan 17, 2014 11:15 am Post subject:

Yabbadubba,
If you do a search on the whole IRS bracke subject, you will find a wealth of info.
It comes up quite a bit, actually.
Brent posted a pic of the jigs i had made, and let him borrow.
He powder-coated them for me, cause, well Brent is the MAN!
Cool

It's a whole long story of clearance, gussets, stress relieving, and using an IRS subframe as a jig for the jigs to get them perfect.
I rent them out to people for $40. (Plus a big deposit and shipping on your dime).
They have been to England already, why not Aus?
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Bus Motor Build

What’s That Noise?!?

Yabbadubbadoo · Samba Member Joined: May 21, 2012 Posts: 914

one4house · Posted: Fri Jan 17, 2014 2:58 pm Post subject:

Cat pulling a photo-bomb.

I see you ninja kitty.
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