Project DC - 4 door Dual Cab with 3.2L Porsche engine

[Lionhart94010]

Nice Work!

Hope when it’s done the owner will give us/let you post some 0-60 and 1/4 mile ET numbers :0)


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Current VWs 71 T2 Westy SO-72/6(Miami), 71 Crew Cab, 2015 GSW TDI
Other owned VW’s 59, 68 1500s, 69 & 71 Bug’s; 72 & 73 S-Bug’s; 67 Westy, 67 Deluxe, Other 71 DC, 72 KG GT that now lives in Australia, 12 JSW TDI, 2015 GSW TDI, 2023 Tiguan
VW technical information sights
thesamba - www.ratwell.com - www.shoptalkforums.com/ - www.vw-resource.com - http://www.type2.com/
http://bobhooversblog.blogspot.com/ - www.aircooled.net/gnrlsite/resource/articles.htm

[zuggbug]

Awesome work
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SOUTHERN INTEGRITY AIRCOOLERS
58 15 window
56 westy

[Dasdubber]

Long time no update - kind of hard to find time sometimes with multiple resto's on the go!

Anyway, a lot of fabrication work has been happening over recent months so rather than rambling on, here is a quick pictorial update. You can find all the pics on my site:
http://dasrestohaus.com.au/gallery2/v/Current+Restorations/Project+DC/?g2_page=68

Porsche 3.2L rear engine brace has been fabbed, and since then the engine has been sent to Brisbane for full rebuild.

The Mercedes van seats will be reshaped during upholstery stage but provide some more comfort than the stock units

Lots of fab work on the runners to centre the seats to the cab and steering column, all the while complying with the engineering/certification requirements

The owner wanted to get rid of the stock plastic 70s styling on the dash so a custom glove box was fabricated with revised hinges so the lid opened downwards

Similarly, a lot of work went into the enclosure for the Dakota Digital gauge pod

[Dasdubber]

The exhaust system also has to comply with noise restriction tests for certification so a baffled primary muffler (non packed to sustain the heat being so close to the heads) in addition to a secondary resonator will keep the noise down - if the owner decides to remove the secondary muffler and just run a straight dump pipe, that will be up to him

Onto the electronics, two four channel amps mounted above the primary Optima Yellow Top battery will power the drivers/tweeters (8 of each!), and then a mono block will power the 2 12in subs. Josh fabricated the custom racks (all of which will be hidden) to maximise the space available

A processor will control the tuning of the system which also includes double din GPS/audio visual unit with reverse camera, and front seat head rest individual DVD players…..plus a dual battery system to control charging duties

A Techsafe rear seat incorporates inertia reel belts (another requirement for the owner who has young kids) and head rests (and is fully complianced)

[Dasdubber]

AJ has been flat out with the centre console fabrication - something a little different that provided some form and function

Electric power steering is another addition to make this thing drive like a new car

Upholsterer will stitch up a boot for the shifter and handbrake lever

There will be a storage compartment/elbow rest up top, but a single cup holder on the angled front face was also a necessity

Part of the briefing sessions with each owner is to find out exactly how they intend to use their car, perfect example was the fact he drinks mostly small red bull cans, plus the occasional coffee and bottle of water, so the cup holder had to be fabricated so that all drink sizes would be accommodated without wobbling around/falling out under brakes….and also have some degree of style and visual interest

Air con evaporators have now been mounted, so next up is ducting (four vents in rear bulkhead, plus two hoses feeding the front which will split to four vents also)….

So the work goes on, and on…..and on :tu:
Al

[Lionhart94010]

nice work :0)

Will the center console have access panels or be easily removable to service the shifter and parking brake if/when needed?
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Current VWs 71 T2 Westy SO-72/6(Miami), 71 Crew Cab, 2015 GSW TDI
Other owned VW’s 59, 68 1500s, 69 & 71 Bug’s; 72 & 73 S-Bug’s; 67 Westy, 67 Deluxe, Other 71 DC, 72 KG GT that now lives in Australia, 12 JSW TDI, 2015 GSW TDI, 2023 Tiguan
VW technical information sights
thesamba - www.ratwell.com - www.shoptalkforums.com/ - www.vw-resource.com - http://www.type2.com/
http://bobhooversblog.blogspot.com/ - www.aircooled.net/gnrlsite/resource/articles.htm

[Brian]

holy hell, that's amazing
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Wash your hands

'69 Bug
'68 Baja Truck
'71 Bug
'68 Camper

Only losers litter

[Dasdubber]

[Bala]

Awesome work!

I'm a bit of a cup holder snob (if that's a thing), so I love seeing this!

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1976 Westy

1966 Beetle

[Dasdubber]

Time for another quick catch up after a couple months more solid work:

AC evaporator cover:

Ducting outlets from rear evap to outer vents in bulkhead (via flex hose)

Console progress:

Inertia reel seat belts mocked up with custom brackets (around the owner requested mandrel bent tube which forms the ducting to the rear AC vents)

Custom plumbing for the heater tube (from sub floor, ducted to foot outlets in nose and up to windscreen)

[Dasdubber]

Start of lower dash mods to house handbrake lever (billet) and central AC vents:

Pimple come dimple for handbrake

Recessed slot above lever is for audio processor controller (like a head unit that controls all the audio)

Custom steel fresh air (one) and heater (one) levers to replicate original and keep to the 'chunky' brief delivered by the owner

More hand fab'ed metal work including this storage box which resides in the centre console - shape is to allow room for custom hinges which enable lid to flip right up and out of the way to access the storage compartment

Rear corner tray rail repairs

[camit34]

That's amazing fab work! Keep the updates coming.
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In search of a Vanagon
1971 Westy (SOLD)
1971 Deluxe (SOLD)
1967 Freedom Camper (SOLD)

[crushie]

That is incredible work there, the console is amazing!
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1974 VW Combi 1800 Auto. Weber 32/36

[deepcflea]

Digging the center console!! Can't wait to see the finished product!!
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1978 Bay Window Double Cab (1600cc) - Marilyn
https://www.thesamba.com/vw/forum/viewtopic.php?t=...005b041ddd

Formerly owned VW's
1983 Westfalia
1956 Oval Ragtop
1967 Bug
1970 Ghia
1969 Buggy

[P.Stratton]

I'm loving all of your work!!!!
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Always looking for a good opportunity !!!

'73 Bus
'67 Beetle

[Dasdubber]

Been a while since the last update but no shortage of work in the interim, here is an abbreviated recap. First up the centre console is complete including the rear centre speaker mounts, plus outer housing that flows through the front console, AC switches recessed and centre AC vent

Buttys Bits splitty accelerator linkage modified to suit the early bay

Central locking was another major undertaking but eventually was sorted with persistence and fair bit of swearing

[Dasdubber]

PS console will be wrapped in leather so rear section won't look so much like 'Bender' once trimmed

Drains for engine access hatch seal aperture directs water away from the recess in the tray to avoid any rust issues down the track

AC hoses were mocked up so retaining brackets and tabs could be welded on the body before the rear trays were welded on

Porsche engine ancillaries were either painted, powder coated, polished or zinc plated for some factory appearance, and slight custom touch

[Dasdubber]

The DC was towed to a company that applies 'Rhino Liner' which is a urethane liner typically used on pickup (ute here in Australia) beds…but this time on the inside of bus for protection from any sand/water that may find its way in!

[Dasdubber]

After the interior floors etc were done, a different company was contracted to apply a similar urethane coating on the underside - had to be a different product as Rhino Liner can't be applied upside down. The owner wants the DC to be very resilient and last a long time, hence the unconventional finishes!

After the urethane dried, it was over coated with the necessary primer then some two pack black gloss paint for resistance to dirt/mud etc

EFI pump, pre and post filters plus tap round out the fuel system

Oil thermostat

[Dasdubber]

Engine lid was dimple died (will be hidden behind number plate backing) to allow the fan to suck fresh air straight in to aid cooling

Body is in its final prime:

Roof bracing was added after the Webasto sunroof was mocked up again

Doors received their final prime as well

Just to be a little different, JW Speaker LED headlights were fitted (after fighting the mounting rings for a while)

That brings us up to date finally….now the last push to paint then off to the upholsterer, still loads of work to do but the light at the end of the tunnel is drawing closer slowly!
Al