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

Dasdubber
Posts: 56
Joined: Sat Jun 20, 2009 4:56 am
Location: Gold Coast, Australia

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

Postby Dasdubber » Fri Apr 15, 2016 4:39 am

Update almost complete! Now the DC is buffed, reassembly can resume inc new rear light housings with LED bulbs
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Smoked lenses front and rear
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Quick roll down to the 'clean shop' (i.e. our parts store - dasrestoparts.com.au)
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Next on the agenda was the flywheel - we enlisted the expertise of Dave Butler who turned this slug of steel into a custom flywheel to mate the Porsche 3.2L engine to the 091 2L VW box:
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Dual ring gears were required - one for the starter and one for the EFI sensor
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AJ fabricated steel door pockets front and rear which will be trimmed in leather
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Finally the JW Speaker headlights were slotted in place
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Trim piece around the vent intake went on after this pic (forgot to install first time around!)
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Alright that's it for now, will try and remember to update again a little sooner than later!
Al
dasrestohaus.com.au

Dasdubber
Posts: 56
Joined: Sat Jun 20, 2009 4:56 am
Location: Gold Coast, Australia

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

Postby Dasdubber » Fri Apr 15, 2016 4:57 am

omr_007 wrote:Ridiculous Al. I'll probably be down in the next week or two to see Dave Butler. Will drop in and say hi when I'm down there


Sounds good mate, will catch you when you swing by ;)

63single
Posts: 188
Joined: Sat Nov 08, 2014 5:42 pm

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

Postby 63single » Sat Jul 16, 2016 8:28 pm

Absolutely amazing........

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K Leake
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Joined: Sun Aug 02, 2015 8:29 am
Location: Bluffdale , Utah

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

Postby K Leake » Sat Jul 16, 2016 10:15 pm

Wow, amazing build.
Kevin

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rustabus
Livin' the retired life
Posts: 6333
Joined: Sat Nov 19, 2005 12:07 am

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

Postby rustabus » Sun Jul 17, 2016 7:22 am

Awesome Build!!!!! =D> =D> =D> =D> =D> Thanks for sharing! Smile

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Franz
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Joined: Sat Feb 12, 2005 1:48 pm

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

Postby Franz » Sun Jul 17, 2016 7:31 am

Looks killer. Almost finished?

Hey Al, do you know anything about SEVEN82MOTORS? I sold Ben a 47 ford coe last year, hat he transported to Australia for a customer build.

Twigman
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Joined: Wed Aug 19, 2015 5:23 pm
Location: Nanaimo B.C.

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

Postby Twigman » Sun Jul 17, 2016 2:06 pm

I am LOVING THIS THREAD. Exceptional work.

Dasdubber
Posts: 56
Joined: Sat Jun 20, 2009 4:56 am
Location: Gold Coast, Australia

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

Postby Dasdubber » Tue Oct 11, 2016 4:33 am

Franz, sorry I missed your post mate.

Yep we know the guys at 782 - they are only like 10mins drive from our shop here on the Gold Coast. They have some very nice cars pass through their shop (they buy and sell mostly)

Dasdubber
Posts: 56
Joined: Sat Jun 20, 2009 4:56 am
Location: Gold Coast, Australia

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

Postby Dasdubber » Tue Oct 11, 2016 4:44 am

Well it was a monumental day today (for me at least) as the owner picked up his DC! As with any major build with so much custom work, it will come back for a few tweaks in a couple of weeks, and also so we can check over everything underneath....but for now it was nice to see the owner so happy. It has been a great collaboration between someone who had a clear vision of what he wanted to create plus the commitment to see the project through...and our team at DAS Resto Haus to put those ideas into reality.

Anyway, I have some catching up to do for the last few months....

Boring pic to start off with just to give an idea of how the central locking is set up:
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After consultation with the dyno tuner, we decided to ditch the factory 1989 Porsche ECU and upgrade to Autronic SM4, plus MSD for some extra 'spark'
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We had an excellent auto electrician jump on board to create a complete plug and play engine harness including auxiliary fuse panel and associated components
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Hydraulic clutch plus EFI fuel filter
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Some subtle advertising with the approval of the owner on the CNC machined number plate housing and laser etched website detail
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Dasdubber
Posts: 56
Joined: Sat Jun 20, 2009 4:56 am
Location: Gold Coast, Australia

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

Postby Dasdubber » Tue Oct 11, 2016 5:05 am

AC lines going through the floor in tank cavity....charcoal canister we made to vent the tank fumes....
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All the wiring is braid wrapped or PVC sleeved....the firewall plug is aircraft spec but makes engine removal (if needed!) a one connection deal (apart from fuel etc)
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Fuse panel distributes power to reverser camera, reverse sensors, and LED reverse lights plus a few other components in the engine bay....earth distribution block avoids having a heap of wires running to body grounds all over the place
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Custom dry sump tank vents to catch can (breather filter not fitted yet in the pic)....obviously this is during fitout before all connections were finalised
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Micro switch under the bus controls the heater booster fan (on the engine fan shroud), operated by the lever on the dash
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Dual optima yellow top batteries
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All engine management electronics were mounted behind the rear seat but had to be up high to clear the sub box
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Oil thermostat (-12 lines), fuel shut off tap (makes fuel system maintenance a lot easier)...and other stuff...
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Two four channel amps power the 8 mid range woofers and 4 tweeters (all controlled via the Alpine processor)
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LED strip light in engine bay helps to see oil level (sight tube on tank) at night...
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Franz
Posts: 20344
Joined: Sat Feb 12, 2005 1:48 pm

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

Postby Franz » Tue Oct 11, 2016 6:11 am

Impressive. It's like a new car. I bet you are glad to be done, and onto other things.

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way2cool
Posts: 366
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Location: Perth, Western Australia
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Re: Project DC - 4 door Dual Cab with 3.2L Porsche engine

Postby way2cool » Tue Oct 11, 2016 6:56 pm

=D> =D> =D> =D> Congrats on a truly wonderful custom car.....
Soooo...will we see this on the streets around Gold Coast/Byron Bay?
I know you told me the owner wanted a cool daily....Man ,you guys have really delivered!!

What's next at Das Resto Haus?
KIM -----------------
" whale oil beef hooked "
http://www.chalkboards.com.au

Dasdubber
Posts: 56
Joined: Sat Jun 20, 2009 4:56 am
Location: Gold Coast, Australia

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

Postby Dasdubber » Thu Oct 13, 2016 1:18 am

Cheers guys, yep it will be on the streets of Byron Bay (already is!).

More splitties on the go at the moment - double door panel barndoor will be killer once done. We are just about done on the metal work, the owner will do the suspension (air) and engine install (Autocraft) all in a pro-street style...this was very early on in the build:
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Also a split beetle with NOS will be fun....bunch of other stuff, some cool, some not that exciting, but always enough to keep us off the streets.
AL

Dasdubber
Posts: 56
Joined: Sat Jun 20, 2009 4:56 am
Location: Gold Coast, Australia

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

Postby Dasdubber » Thu Oct 13, 2016 3:30 am

Few more pics for perusal...

Engine update:
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Engine bay wiring....
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Licence plate backing serves a couple of purposes (other than the obvious)....it also hides the dimple die holes for fan ventilation, and also provides a mount for the reverse camera
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Mid way through rear bumper wiring
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Bit of sunshine through the Webasto electric sun roof
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Dasdubber
Posts: 56
Joined: Sat Jun 20, 2009 4:56 am
Location: Gold Coast, Australia

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

Postby Dasdubber » Thu Oct 13, 2016 3:38 am

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Scissor jack, wheel brace and fire extinguisher tucked up under the back seat out of the way but accessible
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Decided to stick with factory mirrors (painted in gloss and satin black) as everything aftermarket just looked wrong
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Tray was Rhino Lined for protection and longevity
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