Project DC - 4 door dual cab with a couple extra cylinders
- Thread starter Dasdubber
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BO JANGLES
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Enjoying watching this one, if only I could get back to mine :roll:
Ok, back to the DC….and back to the rhinoplasty….
Late bay indicator holes gone and new vent trim mocked up to ensure aperture was the right size/shape
Belly pans (sides only) will help to provide some more torsional rigidity for the DC
Initially we were going to run with splitty rear corners and modify them to fit since no bay DC panels were available repro….but in the end found a pair of NOS rear corners in the UK that we had shipped over instead
Similarly, no complete side panels are available so we used an early bay section and then tabbed the rest to suit….also decided to delete the side vents for a cleaner side (air will be ducted from underneath, more about that later)
New rear tubs
A lot of subtle mods on this DC that will mostly go missed (which is alway the aim) include things like reversing and deleting a lot external seams to keep the sides super smooth
Late bay indicator holes gone and new vent trim mocked up to ensure aperture was the right size/shape
Belly pans (sides only) will help to provide some more torsional rigidity for the DC
Initially we were going to run with splitty rear corners and modify them to fit since no bay DC panels were available repro….but in the end found a pair of NOS rear corners in the UK that we had shipped over instead
Similarly, no complete side panels are available so we used an early bay section and then tabbed the rest to suit….also decided to delete the side vents for a cleaner side (air will be ducted from underneath, more about that later)
New rear tubs
A lot of subtle mods on this DC that will mostly go missed (which is alway the aim) include things like reversing and deleting a lot external seams to keep the sides super smooth
CHILDSEY
Well-known member
Top work guys 
Back to the nitty gritty….time to make this DC a four door - the right side cargo door aperture was opened up and then braced:
The unwanted surrounding metal work was removed in readiness for some new steel to recreate the door aperture as per the left side of the vehicle
Whilst it would have been nice to have a donor LHD DC to provide the door opening cut, that wasn't possible so all the associated metal had to be fabricated
Along with the hinge captive nut plates
The unwanted surrounding metal work was removed in readiness for some new steel to recreate the door aperture as per the left side of the vehicle
Whilst it would have been nice to have a donor LHD DC to provide the door opening cut, that wasn't possible so all the associated metal had to be fabricated
Along with the hinge captive nut plates
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
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
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
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
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
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
skillz 8) 8),but the sunroof is a bit ott :mrgreen:
Few more pics and details….
Since we deleted the vents from the sides, obviously there had to be an alternative way of venting air into the engine bay…..hence the floor vents (scoops will be fabricated to help duct air into the cavity…..and the engine lid will be dimple died behind the number plate for more air flow with the Porsche fan sitting right behind it)..
The floor section (which had some rust in it previously) was replaced first
Then the surround was fabricated to tidy up the edges of the cavity
New tubs were blasted and epoxy primed
To keep the sides straight and maintain the front to back alignment of panels, the tubs had to be modified so the sides didn't get pulled in
Since we deleted the vents from the sides, obviously there had to be an alternative way of venting air into the engine bay…..hence the floor vents (scoops will be fabricated to help duct air into the cavity…..and the engine lid will be dimple died behind the number plate for more air flow with the Porsche fan sitting right behind it)..
The floor section (which had some rust in it previously) was replaced first
Then the surround was fabricated to tidy up the edges of the cavity
New tubs were blasted and epoxy primed
To keep the sides straight and maintain the front to back alignment of panels, the tubs had to be modified so the sides didn't get pulled in
dlscott1974
Well-known member
BLOODY LOVELY BOY U GOT SKILLS :shock:
68_early_bay
Well-known member
Wow :shock: keep it coming awesome work 8)
Resto-raider
Well-known member
Looks good already.
Awesome skills
Awesome skills
Marriedblonde
Well-known member
Good god!!! Looking amazing. I'll be watching this with interest.
J.
J.
Remon T2a
Well-known member
Best type of van and best type off engine getting together here on a high skills level. Great work.
Keep on coming with those pic's....
Keep on coming with those pic's....
VeeDubMan
Well-known member
Should think so too. This is early 'bay' after all ; )
Back onto the DC - been a lot of bodywork going on over recent months….now down to fine tuning stage before paint but before that happens its time to basically mock up everything on the bus to make sure any holes that need to be drilled are drilled, and any welding/brackets that may be required are sorted before the engine and gearbox are sent off for rebuild.
Got some second hand tyres to recheck wheel clearance and finalise ride height
Subtle details like deleting the seams from the front bumper (originally three pieces), as well as the rear bumper bolts will help to maintain the smooth overall look of the DC
Rear seat base was rusty so needed some repair…non factory spec of the profile wasn't a concern giving the custom treatment the rest of the car is getting!
On we go...
Got some second hand tyres to recheck wheel clearance and finalise ride height
Subtle details like deleting the seams from the front bumper (originally three pieces), as well as the rear bumper bolts will help to maintain the smooth overall look of the DC
Rear seat base was rusty so needed some repair…non factory spec of the profile wasn't a concern giving the custom treatment the rest of the car is getting!
On we go...
